(494a) Problems of Scale-up of Solids Handling Processes

Scale-up of solids handling processes can be very troublesome, particularly if new equipment or process steps are being incorporated. Unfortunately if scale-up is not handled correctly, commercial operation suffers in terms of the time and expense it takes to correct problems, time to market, and perhaps derating of the equipment or process. If a sound theory has been (or can be) developed that accurately models the process and equipment independent of scale, bench scale tests can be run and the results used as input data in the mathematical model. If such a theory is not available, the only safe and sound approach is usually to model some or all of the critical elements of the system at or close to full scale. Examples of systems that can and cannot be scaled-up are presented, along with scaling rules. In addition, case histories of successful scale-up will be presented.