(81bv) Safe Scale up of Chemical Processes: Integration of Safety Testing In Product Life Cycle | AIChE

(81bv) Safe Scale up of Chemical Processes: Integration of Safety Testing In Product Life Cycle

Authors 

Umbrajkar, S. - Presenter, Chilworth Global
Rowe, S. - Presenter, Chilworth Global


Process-safety studies, when conducted just prior to scale-up, can result in the development of processes that may lack inherent safety. The risk associated with scale-up of such processes is high and requires corrective work to mitigate the risk. It is important to understand that process-safety studies do not involve a single reaction calorimetry test or doing a HAZOP or checking the thermal stability of the compounds involved or making sure the reactor has a vent. Safety is the product of all of these activities, and several others, added together. Doing all areas well, and integrating the various outcomes, provides a holistic strategy which is likely to be highly robust.

The key to developing safe processes is in having robust procedures which accompany a process from discovery to large-scale production. Critical safety decisions are made at every stage.

This article/presentation discusses the overall strategy and outlines the tasks that are necessary to ensure the safety of a process, when they should be performed, and, critically, how the outcomes of the individual tasks should be integrated to maximise their benefit. The scale-up of a chemical process is collectively dependent on a variety of individual groups within a company. Ideally, a multi-disciplinary team should be appointed to be responsible for each new process to be scaled-up (from laboratory scale through to full scale). Various tools available to generate, and then evaluate, data on reactivity and stability will be discussed. The use of the Criticality Class concept to help understand the level of intrinsic process hazard is exemplified. Where the hazard level is significant, changes to the process or conditions can be implemented such that the process at the end of development is inherently safer.

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