Catalyst scale-up from a development laboratory to a commercial plant can be difficult. Companies usually decide to conduct a trial run to determine whether the catalyst can be produced on a larger scale. Allowing for the usual manufacturing constraints during catalyst development helps to avoid problems during scale-up, but even so the transfer of a laboratory recipe to commercial equipment can present challenges. It is necessary to consider such issues as (i) heat and mass transfer and equipment selection, (ii) where to source the raw materials and what specification to set, (iii) whether to use a toller or existing in-house equipment, (iv) whether to invest in modifying equipment or rent temporary equipment, (v) existing operating permits, exposure limits and operator safety, (vi) adjusting the recipe to the commercial equipment and (vii) a sampling and analytical program to determine whether the trial has been successful.
Catalyst Intelligence can offer assistance with the scale-up and advice on available alternatives. Not only available capacity, yield, costs and logistics need to be taken into account, but also confidentiality and consistent product quality. Catalyst Intelligence can help develop a fast track plan for commercial production, saving time and minimising costs.
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