Although scale-up of a process from the lab to the pilot plant may seem initially straightforward, inherent differences between the two settings require that factors affecting both personal and process safety must be analyzed to establish a high level of safety at the pilot scale.    This analysis should take into account training, procedures, chemical hazards, health hazards, physical hazards, behavioral factors, equipment condition, housekeeping, and emergency preparedness.  A multi-disciplinary approach to this analysis has been found very effective in developing and implementing strategies to ensure safe operation.  Because the appropriate resources are engaged up-front, safety analysis is not a hindrance to project progression and compliments the technical development of the process, ultimately leading to better results and more satisfied stakeholders.

Bridging the gap between the lab and pilot plant:  Safety principles to consider during scale-up

245th National Meeting (2013)

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