This paper introduces an efficient scale-up design technology based on mathematical modeling and optimization approach. The target process is a vacuum pressure swing adsorption process which is preferred in purifying unconventional gas such as coalbed methane or landfill gas by sequestering carbon dioxide. The optimization results are validated very well from a pilot scale (10 N m3/h) to a large commercial scale (5000 N m3/h). The simulation and optimization model for the scale up design is established in gPROMS custom modeling tool. Judging from the reasonably very small differences between the optimization results and the vendor suggested data, it can be concluded that the scale-up design is very successful not by depending on the experimental and real plant experiences but by using a mathematical optimization modeling approach.