(263c) Scale-Down Considerations for Optimization & Troubleshooting of Operating Processes

Dow Consumer Solutions Process R&D (DCS-PR&D) leads the design and implementation of new process schemes, as well as the optimization and troubleshooting of existing operations that may deviate from designed behavior.

Scale-down is the idea of taking an existing manufacturing process (>1000 KG scale) and reproducing it in the lab scale (1 – 30 KG). This approach allows PR&D to troubleshoot and test hypotheses in the lab, knowing that the learnings will be applicable in manufacturing. This is essential to optimize reaction times, validate simulations with experimental data, and perform root cause investigation of reactors that are generating out-of-spec material. Scaling down processes, however, is not always straight forward.

In this presentation, a variety of scale-down considerations will be reviewed, ranging from technical aspects such as thermodynamics and fluid mixing, to effective idea generation between R&D and manufacturing, in order to formulate hypotheses and define research deliverables.