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Successful Liquid Mixing Scale-up Methods

May 20 - 22, 2025

$2195

Team enrollment (2 or more) = $1995 per person

In Person in Chicago, IL

21 hours


This course is designed specifically for engineers and scientists who develop and scale-up liquid mixing processes from the lab to the pilot plant to production. This course moves on from The Art and Science of Industrial Mixing, covering development activities that impact scale-up and options for successful non-geometric scale-up.



During this course, you will:

  • Gain an understanding of the methods to scale up liquid mixing processes from the lab to pilot plant to production
  • Examine geometric and non-geometric scale-up
  • Learn to develop and evaluate successful scale-up procedures and objectives for your specific processes
  • Learn how to apply the Mixing Index
  • Determine optimum designs and processing conditions for both scale-up and scale-down
  • Learn to judge the results of an experimental study for success and completeness 


Instructor: David Dickey

Course Hours

You Will Earn

You Will Earn

All hours listed are in Central time

May 20:     8:00 am – 4:30 pm

May 21:     8:00 am – 4:30 pm

May 22:     8:00 am – 12:00 pm


You Will Earn

You Will Earn

You Will Earn

2.0 Continuing Education Units

20 Professional Development Hours 

Please bring a scientific calculator for use during the course.

Hotel Information

The course will be held at the Hilton Garden Inn O’Hare, conveniently located in western Chicago (Illinois) by O’Hare Airport, at 2930 S River Road, Des Plaines, IL. An extended continental breakfast, and morning and afternoon breaks will be provided daily. Lunch will be provided each day. These will be provided as part of your enrollment fee along with a printed course notebook that contains copies of the course materials. Hotel accommodation is not covered within the enrollment fee. We have reserved a block of sleeping rooms at the Hilton Garden Inn, however you are not required to stay at the Hilton Garden Inn. The block will be available until April 21, 2025, with a rate starting at $125.00 per night. Please make your reservation by calling the hotel at +1 847-296-8900 or by using the link below.

(If you elect to call the hotel, please reference the course name, Successful Liquid Mixing Scale-up Methods, and the group code 917 to ensure that you receive the group rate. If you choose to book a room online, simply click the "Book a Room" button below.)


Book a Room

Course Details

Scale-up Objectives

  • New Products and operations
  • Existing processes 

Scale-up Concepts

  • Objectives of scale-up
  • Scale-up and scale-down
  • Concept models   
    • Physical models
    • Mathematical models
  • Dimensional analysis
  • Similarity
  • Scale-up

Principles of Liquid Mixing

  • Fluid properties
    • Density
    • Viscosity
    • Rheology
    • Viscosity measurement
    • Reynolds Number

Mixer Power and Pumping

  • Mixer power
    • Rotating impellers
    • Fluid motion
    • Energy dissipation
  • Power Number correlations
  • Mixing regimes
    • Turbulent
    • Laminar
    • Transition
  • How impeller type affects power
    • Impeller flow patterns
    • Types of impellers
    • Flow patterns and CFD
  • Pumping Number correlations
    • Pumping capacity
  • Flow and shear
  • Blend time correlations
  • Mixing Index
    • Practice measure of intensity for process analysis
  • Affect of baffles

Mixing Scale-up

  • Geometric scale-up
    • Making geometry changes
    • Scale-up ratios
    • Fixed ratios, variable results
    • Inherent changes
  • Non-geometric scale-up
    • Tank geometry changes
    • Mixer geometry changes
    • Mixer speed changes
    • Applying the Mixing Index
  • Class exercise

Mixer Evaluation and Design Spreadsheet

  • Calculate Mixing Index
  • Calculate mixer power and torque
  • Evaluate Reynolds number and tip speed
  • Compare calculations for scale-up

Mixing Processes

  • Mixing terminology
  • Liquid-liquid dispersion
  • Solid suspension
  • Gas dispersion
  • Heat transfer
  • Mass transfer
  • Dry solids addition

Process Specific Scale-up

  • Liquid blending
  • Surface motion
  • Liquid-liquid dispersion
  • Solid-liquid processes
  • Gas dispersion

Scale-Up of Static Mixers

  • Types and applications
  • Scale-up

Mixing Equipment

  • Basic components
  • Elements of design
  • Practical limitations

Process Development

  • What to study
  • How to study
  • Mixing procedures
    • Batch processes
    • Continuous processes
  • Value of visual observation
  • Dealing with failures
  • Improving on success
  • Pre-processing
  • Post-processing

Laboratory and Pilot Plant Equipment

  • Available equipment
  • Reactor vessels
  • Special features
  • Impeller selection
  • Mixer drives and motors
  • Peripheral equipment
  • Basic measurements

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