 While running the production in the larger scaled-up plant, I examined the process and found

out that the jacket heating rate was significantly more for the reaction, which I didn’t face while
carrying out the production in Kilo lab. The overheating of the reaction was creating some
irreversible changes in the reaction, thus, resulting in a low conversion of the reaction. It was my
sole responsibility to provide the well-controlled custom heating process to the Engineering
Technicians by taking everything under consideration which completes the reaction in desire
time without any by-products or disruption. I convoked an internal meeting with the scientist to
develop possible approaches to troubleshoot this issue. After thorough discussion and study on
the subject matter, I developed a controllable interval heating process employing PID
temperature controller around the jacket of the reactor, which helped in completing the
reaction. After the successful installation of a temperature control system, I reran the
production process, and I found out that the temperature was now in the desirable range, and
the preferred output was observed.

 Upon the successful troubleshooting of the heating issue, I reran the production, and after the
successful completion of one batch, I observed that the flow of liquid products from the reactor
into the centrifuge after final cooling was very low which was also not seen in small scale
production, however, it occurred in large scale production where big lumps were developed in
reactors while cooling. After a thorough inspection, I observed that the big lumps that were
developed in the reactor obstructed the output from the reactor into the centrifuge. This issue
slowed down the whole production process at that point. I consulted with my team members
and performed multiple trial and errors in resolving the issue. I finally decided to use a bigger
diameter valve at the bottom of the reactor to save the time of filtration and solvent used for
reactor flushing. I instructed the technicians to install a bigger diameter valve at the reactor
outlet. I reran the production, and the reactor flushing was successfully operated, and the lumps
were no longer developed at the bottom of the reactor that eased the flow of liquid by-product
into the centrifuge.