Screen Reactive Chemical Hazards Early in Process Development

(CPI), by their very nature, involve chemical reactions and the handling of reactive chemicals. As such, there are inherent dangers involved in the CPI that can lead to catastrophic consequences. Much activity is directed towards avoiding these types of events. Safety is not the only driver in process development. Chemical processes are developed to earn a positive return on investment. The overall cost of developing, starting up, and running the process at the projected volume needs to be minimized. This places a wide variety of demands on a chemical process development program. The reaction must be optimized for both yield and purity, a manufacturing site must be chosen or designed, and raw materials sources must be found. Additionally, the entire process development should be done as quickly as possible. Safety concerns are addressed within the context of this broader picture of process development. Developing the knowledge to prevent reactive chemical incidents should not be done independently from, and later than, the other aspects of process development. Using the tools of hazard analysis early in process development can lead to a more rapid understanding of the reaction chemistry, aiding in process optimization studies, as well as appreciation of safety issues. Exploiting this synergistic effect will foster greater efficiency in process development, both in terms of safety and economic concerns.