Scalability of pre-packed preparative chromatography columns with different diameters and lengths taking into account extra column effects

Small pre-packed columns are commonly used to estimate the optimum run parameters for pilot and production scale. The question arises if the experiments obtained with these columns are scalable, because there are substantial changes in extra column volume when going from a very small scale to a benchtop column. In this study we demonstrate the scalability of pre-packed disposable and non-disposable columns of volumes in the range of 0.2-20 ml packed with various media using superficial velocities in the range of 30-500 cm/h. We found that the relative contribution of extra column band broadening to total band broadening was not only high for columns with small diameters, but also for columns with a larger volume due to their wider diameter. The extra column band broadening can be more than 50% for columns with volumes larger than 10 ml. An increase in column diameter leads to high additional extra column band broadening in the filter, frits, and adapters of the columns. We found a linear relationship between intra column band broadening and column length, which increased stepwise with increases in column diameter. This effect was also corroborated by CFD simulation. The intra column band broadening was the same for columns packed with different media. An empirical engineering equation and the data gained from the extra column effects allowed us to predict the intra, extra, and total column band broadening just from column length, diameter, and flow rate.