79 – Reactor Design & Scale-Up Challenges (S6E4)

This episode examines the critical role of reactor design in scaling up chemical reactions from small laboratory flasks to large industrial reactors. We'll explore the fundamental differences between various reactor types, including batch reactors and continuous flow reactors. The discussion will focus on how these differences impact key process parameters like heat transfer, mixing, and reaction kinetics.The conversation will center on the challenges that arise when scaling up, such as temperature gradients, inefficient mixing, and runaway reactions. We'll present real-world examples from OPR&D to illustrate how process chemists and engineers troubleshoot these issues. The episode highlights the importance of careful reactor selection and optimization to ensure safe, efficient, and consistent production of pharmaceuticals. Topics covered are, heat transfer, reflux conditions, benzoron derivative, temperature, pressure, mixing, reaction kinetics, hotspots.