| Challenge | Description | Solution | |-----------|-------------|----------| | | A reaction works in a flask but fails in a 1000L reactor | Use similarity theory (Reynolds, Damköhler numbers) | | Impurity creep | New byproducts appear at larger scale | Statistical Process Control (SPC) | | Heat management | Exotherms cause temperature spikes | Implement jacketed reactors with cascade control | | Analytical lag | Off-line QC takes hours, delaying decisions | Install inline PAT (Process Analytical Technology) |
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