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What is Scale-Up?. To take a manufacturing process from the laboratory scale to a desired large scale at which it is commercially feasible.3 StagesBench Scale ( 2
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1. Rob Levine Bioreactor Scale-Up and CFD Review 12/3/10
2. What is Scale-Up?
To take a manufacturing process from the laboratory scale to a desired large scale at which it is commercially feasible.
3 Stages
Bench Scale ( 2 20 L)
Pilot Scale (100 500 L)
Plant Scale (500 20,000 L)
3. Scale-Up Parameters Geometry
Height to Diameter Ratio is held constant
Called aspect ratio
4. Scale-Up Parameters
Agitation-based parameters
Mixing time
Power input per Volume (P/V)
Tip Speed
Gassing-based parameters
Vessel Volumes per Minute (VVM)
Superficial Gas Velocity (Vs)
NOTE: Cannot keep all parameters constant during scale up because they scale by different values
5. Agitation Parameters
6. Gassing Parameters
7. Scale-Up Review Overall, scaling up process parameters is tricky
Each scale-up parameter is dependent on another
Cannot keep all constant during scale-up
Not one scale-up process is correct
Technicians determine which parameter is critical to the process and try to find a happy medium between each of the remaining parameter
8. Computational Fluid Dynamics (CFD) The prediction of fluid flow, heat, mass, and momentum transfer, chemical reactions, and related phenomena in a model system.
Utilizes computer power to process the differential equations that have been developed to describe a model of a system
9. CFD Modeling/Meshing Once the model is generated using CAD software, next have to partition into a mesh that will provide the best resolution for the fluid flow
Ensure adequate resolution in the most dynamic regions
Comes at a cost of computing capability
10. CFD Solves Scale-Up Issues Many facilities dont have the space or time to calculate/run experiments for scale-up
Companies model the equations and the CFD results model the systems digitally
11. Pros and Cons of CFD