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Covers enterprise improvement methodologies intended to prevent and eliminate product and process defects.

RC1e Process Safety Workstation

Product Announcement from Mettler-Toledo, Inc.

RC1e Process Safety Workstation -Image

The chemical and pharmaceutical industries often use complex products and processes in which large amounts of energy can be released. Process development is concerned with identifying risks related to scale-up and manufacturing, Knowing and understanding the potential risks of a chemical process are critical and key for safely and sustainably manufacturing products.
The potential risk of a chemical reaction is directly linked to the reactants, intermediates and products, the progress of the reaction and the accumulation of reactants and intermediates. The Reaction Calorimeter RC1su and RC1e provide a comprehensive set of data to investigate the potential safety risk of a reaction. Unlike standard technologies which generally require running a series of experiments to define the ideal dosing profile,

RTCal™ accomplishes this task much faster. Together with iControl RC1™ software the real time heat release measurement RTCal™ permits the dosing rate of a reagent to be continuously adjusted ensuring the accumulation and heat release rate is under control. RTCal™ is a highly sensitive walk-up tool that quickly scans reactions for exotherms. No calibration procedures need to be run before or after the reaction significantly reducing experiment time. The precise reaction data collected during the course of a reaction is subsequently converted into relevant safety information.

As opposed to standard evaluation methods, iC Safety™ provides more advanced safety information and can be applied by expert as well as non-expert users. iC Safety™ computes information, such as thermal accumulation, ΔTadiabatic , the maximum temperature of the synthesis reaction (MTSR) or maximum achievable temperature (MAT) which is the basis for more advanced calculations. Additional threats may also arise due to secondary or undesired reactions. These may accelerate the production of energy resulting in a runaway reaction. Therefore, the data of the desired reaction are combined with additional data of the undesired reaction (e.g. decomposition reaction) determined by either DSC or adiabatic calorimetry. Subsequently, iC Safety™ merges the information into the so-called "Safety Runaway Graph" and the "Criticality Graph". The two graphs present a comprehensive picture and classify the reaction based on their hazardous potential.

By combining RC1 workstation with RTCal™ and iC Safety™ chemists and engineers can judge the hazardous potential early on in the process and reduce failures at scale.