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SAFER TECHNOLOGIES AND EQUIPMENT

SAFER TECHNOLOGIES AND EQUIPMENT. By T.S.Sudhir. TYPE OF CHEMICAL HAZARD. FLAMABLE - SOLVENTS TOXIC – CARCINOGENIC…. HAZARDOUS – LIKE Na metal. CORROSIVE – Chlorine/ Thionyl chloride. REASON FOR HAZARD. STORAGE REACTIONS HANDLING FAILURES OF EQUIPMENTS

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SAFER TECHNOLOGIES AND EQUIPMENT

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  1. SAFER TECHNOLOGIES AND EQUIPMENT By T.S.Sudhir

  2. TYPE OF CHEMICAL HAZARD • FLAMABLE - SOLVENTS • TOXIC – CARCINOGENIC…. • HAZARDOUS – LIKE Na metal. • CORROSIVE – Chlorine/ Thionyl chloride

  3. REASON FOR HAZARD • STORAGE • REACTIONS • HANDLING • FAILURES OF EQUIPMENTS • PIPES/PUMPS/STORAGE TANKS - LEAKAGES

  4. HOW TO AVOID/REDUCE? • MINIMIZATION • Reducing hazardous inventories • Reactor sizes • Pipe diameters. Can lessen the consequences of potential mishaps • CHANGE MANUFACTURING TECHNOLOGY – TO ELIMINATE HAZARDS The result will be a safer and a cost-effective plant design

  5. PRINCIPLES OF GREEN CHEMISTRY • P Prevents wastes • R Renewable materials • O Omit derivatization steps • D Degradable chemical products • U Use safe synthetic methods • C Catalytic reagents • T Temperature & pressure ambient • I In-process monitoring • V Very few auxiliary substances • I I-factor, maximize feed input product • T Toxicity- low of chemical products • Y Yes then it is safe • Y Yes it's safe

  6. SAFER TECHNOLOGIES STEPS • Possible replacement of solvents. • Alternate green chemistry • Short reaction steps or combined reactions. • Recycle and reduce ingredients-solvents • Reduce storage of hazardous chemicals • Gas vs. Liquid transport – e.g.. Chlorine gas

  7. PRINCIPLES OF GREEN ENGINEERING • I Inherently non-hazardous and safe • M Minimize material diversity • P Prevention instead of treatment • R Renewable material and energy inputs • O Output-led design • V Very simple • E Efficiently use mass, energy, space & time • M Meet the need • E Easy to separate by design • N Networks for exchange of local mass & energy • T Test the life-cycle of the design • S Sustainability throughout the produce life-cycle

  8. INHERENT SAFETY • “Inherent" as "existing in something as a permanent and inseparable element, quality, or attribute. • " A chemical process is described as inherently safer if it reduces or eliminates one or more process hazards, • This is accomplished through changes that are permanent and inseparable from the basic process technology. • We cannot change hazards. • We can alter the materials or their conditions to reduce or eliminate them. • Reducing the quantity of a hazardous material or energy through process intensification is one important way of increasing the inherent safety of a CPI process.

  9. STRATEGIES - INHERENTLY SAFER PROCESS DESIGN • Minimize the size of process equipment. • Substitute a less-hazardous substance • Less hazardous process step. • Moderate storage or processing conditions. • Simplify process and plant design. • Alternate equipments. • Plant area segregation and separation.

  10. SAFER PLANT EQUIPMENT DESIGN • Intense mixing & mass transfer- e.g. Nitration • Rapid heat transfer – Exothermic reactions • Proper designed equipments.- safety/Rupture disc/scrubbing etc. • Reduce storage and handling. • In situ generation of small quantities of reactants than storage and transfer. • Multiple operation in single equipment – reduces all other paraphernalia's like pumps/pipes/storage etc. • Innovative energy sources Energy sources such as lasers, ultraviolet light, microwaves, or ultrasound can be used in a controlled fashion in a chemical reaction or physical unit operation to increase efficiency.

  11. GUIDE FOR RISK ASSESSMENT • International Conference on Harmonization Q 9 guidelines. • Tools for use of Risk assessment The Risk assessment is carried out by a Team using the format SOP drafted for the purpose in line with ICHQ9 guide lines. The cGMP compliance, process flow, Equipment, services in use and the personnel involved are verified. The assessment is based on Failure Mode and Effect Analysis (FMEA).

  12. Initiate Quality Risk Management Process Risk Assessment Risk Identification Risk Analysis Risk Evaluation unacceptable R n i s o k i t a M c Risk Control a i n n u a g m Risk Reduction e m m o e C n t k t s Risk Acceptance o i o R l s Output / Result of the Quality Risk Management Process Risk Review Review Events GUIDE FOR RISK ASSESSMENT

  13. GUIDE FOR RISK ASSESSMENT Potential threat - chemical reaction - manufacturing issues - facilities and equipment hazard Failure System defect - technical breakdown - not detected - human breakdown - insufficiently prevented - extrinsic effect - emerges by degree Anything that has the potential to harm patients, product quality or the business (loss, interruption, image)

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