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Safety by Design
What do we Learn from Reaction Calorimetry?
Ultimately, reducing time and resources as well as speeding the chemical workflow is the
result of acquiring better information earlier.
In a simplified approach, the chemical and process development workflow begins with
Chemical Synthesis in which the chemical and physical information and chemical route
are key. Often a small quantity of the product is made for testing purposes as an integral
part of this step before the development workflow continues.
Contents
1 Screening for Scalability Risks
2 Key Information for Moving a Process from Lab to Plant
3 What is the Value of Reaction Calorimetry?
4 Knowing the True Heat Release Pattern
5 Understanding Maximum Heat Release Rate and
Adiabatic Temperature Increase
6 Conclusions
1 Screening for Scalability Risks
Calorimetry Guide
A thorough understanding of the chemistry, physical properties of the reactants and the
reaction mass is essential. Recently, synthesis workstations have become an increasingly
common tool as they not only ensure accurate and reproducible experiments, but provide a
wealth of information at the same time.
A synthesis workstation, such as EasyMax or OptiMax, provides specifics including start and
end of a reaction and indicates the existence of induction. Information about precipitation
or crystallization during the course of the reaction is provided, along with mechanistic
information.
Looking at the temperature difference Tr - Tj (yellow curve; Figure 1), which is an indicator for
the course of the reaction, a qualitative assessment of the power of a reaction as well as the
possible accumulation of energy can be made. In addition, a wealth of other information can
be derived from the basic trends, such as start/end of a reaction, induction period or duration
of the reaction. It also becomes obvious whether or not reactants have been accumulated.
Although these are estimates and cannot be accurately quantified at this point, a number of
conclusions can be drawn identifying or even eliminating some of the scalability risks.
Broadly speaking, the process can already be separated into not critical, possibly critical
and highly critical. This means that Go/NoGo decisions can be taken early in development
saving time, eliminating waste of precious reagents, and avoiding unnecessary detours.
Reaction Duration
Accumulation
Maximum Temp.
Difference / Maximum
Flow of Engery
Temperature Difference
(Tr - Tj) Heat loss due
to dosing
Dosing (Mr)
Temperature
(Tr)
Time
Figure 1. Information that can be obtained from an experiment looking at basic trends
Tr: Temperature of the reactor content Mr: Total Mass of the Reaction
Tj: Temperature of the jacket
Tr - Tj (T): Temperature difference between
the reactor content and the jacket
2 Safety by Design
2 Key Information for Moving a Process
from Lab to Plant
Meeting the relevant process objectives is critical for manufacturing a product successfully.
However, engineers involved in transferring processes from lab to plant understand the
importance of considering thermal risks and hazardous potential of a chemical process
more precisely.
The costs associated with these problems are far greater than the cost of adequately
evaluating and solving the issues during process development. Applying reaction calorimetry
means that it is possible to obtain the respective information of what is going on faster or
even allows immediate action to be taken.
In other words, examining the chemical process with a reaction calorimeter that provides
accurate and reliable information of non-scalable conditions and potential risks in a
quantitative manner is required in order to characterize the criticality of a chemical process,
and subsequently make it safe at scale.
Safety by Design 3
3 What is the Value of Reaction Calorimetry?
Calorimetry Guide
Reaction calorimetry measures the heat released from a chemical reaction or physical
process under process-like conditions and provides the fundamentals of the thermochemistry
and kinetics of a reaction.
Temperature
enthalpy, conversion) can be
derived. Subsequently, these are
further processed to obtain more
MTT
specific details (i.e. accumulation 80.0 C
of energy, Tad and MTSR) and to
create the Runaway and Criticality Tprocess
Graph (Figures 3 and 4). 40.0 C
4 Safety by Design
Lets assume a process is potentially subject to accumulating unreacted reagent which may
lead to a potentially hazardous situation. If so, control over the reaction may be lost, in case
of a cooling failure, which in the worst case leads to a runaway reaction.
Reaction calorimetry provides the ability to determine the heat flow rate as a function of the
reagent addition rate - enabling the determination of whether the reaction is controlled by
the feed (Figure 5) or if significant reactant accumulation occurs (Figure 6) that results in
increased risk of a runaway.
qr
Mr
Mr
qr
No reactant accumulation, dosing controlled Reactant accumulation
Figure 5: Immediate reaction Figure 6: Delayed reaction
If accumulation is observed and the reaction mass is heterogeneous, the reaction may be
mass transfer limited. If this is the case, increasing the stirring speed may improve mass
transfer which increases the reaction rate and reduces the accumulation.
While information from a synthesis workstation delivers qualitative and simpler information
(which is often sufficient), reaction calorimetry describes a chemical process in detail, and
is quantitative and accurate. As a result, reaction calorimetry is one of the most important
sources of information for scale-up, process safety screening and process safety allowing
scientists and engineers to make the appropriate decisions to create robust processes and
ensure products are manufactured safely according to plant capabilities.
Safety by Design 5
4 Knowing the True Heat Release Pattern
Calorimetry Guide
From a scalability point of view, it is not only a question of how much heat is released,
but also HOW the heat is released. In other words, even when enthalpy, the heat transfer
coefficient, the specific heat of the reaction mass etc. are known, the real heat release pattern
is not necessarily understood at this point.
Example
Reactant A (in excess) is in the reactor at 40 C isothermally whereas Reactant B is added
over a period of 15 minutes (green trend). After dosing was completed, a catalyst was added.
The T (blue trend) shows that only little reaction seems to take place during the addition.
2000 1400
After the catalyst is added, the 200 500
Catalyst Added 1200
reaction picks up and becomes
1000
quite strong (visualized by the 150
1500
400
800
T trend in blue). As the heat
Tr-Ta (K)
600
production becomes larger it
Mr (g)
300
qr_hf (W)
100
Tr (C)
1000 400
exceeds the heat removal capacity
200
of the cooling system and the 50 200
0
excessive heat gets accumulated 500
T -200
in the reaction mass. Hence, the 0
Mr 100
Once, the reaction becomes less powerful the heat release slows down and the heat removal
capacity becomes dominant over the heat production. Subsequently, the accumulated heat
is released into the jacket which causes the temperature to go back to its target value of 40
C. However, all of the above is qualitative information indicating possible issues or threats.
For more accurate, quantitative conclusions heat flow, with all its side effects, needs to be
understood (Figure 8).
100
Mr (g)
Tr (C)
1000 400
Integrating the curve between 50 qow 200 200
the start and end of the reaction
0
provides us with the reaction 500
T
0 -200
enthalpy (Hr = -123.1 kJ/mol). Mr 100
Tr -400
Figure 8 shows the way the energy 100
was flowing across the reactor 03:20:00 03:30:00 03:40:00 03:50:00 04:00:00
Time (hh:mm:ss)
wall with a maximum of over 400 Figure 8: Heat flow across reactor wall
W. Following the heat flow trend
(orange) it also becomes clear that the catalyst addition didnt impact the reaction at all, but
the reaction itself has a significant induction time and a huge accumulation.
6 Safety by Design
Figure 8 provides insight into how the energy was removed by the cooling jacket and
what the overall turnover of energy is. But is this also identical to the heat evolution by the
chemical reaction?
To better understand the heat evolution of the chemical reaction, the temperature change of
the reaction mass - caused by the accumulation of heat (not identical to the accumulation of
reactants, though!) needs to be analyzed.
Tr-Ta (K)
300
trend qaccu (orange). Once heat 100
Mr (g)
qr_hf (W)
Tr (C)
1000 400
removal becomes larger than the
qaccu decreasing
heat production, accumulation 50
qaccu 200 200
100 300
of over 87 % 1 Induction Flow Prole
Mr (g)
qr_hf (W)
Tr (C)
1000 400
4 True heat release pattern repre-
senting the chemical reaction 50
qr 200 200
profile 500
0
Safety by Design 7
5 Understanding Maximum Heat Release Rate and
Calorimetry Guide
Adiabatic Temperature Increase
The best way to control a reaction Heat Transfer Coefcient (U) 46.188 kJ
qr (W)
substrate. At large scale, the best 50
Heat Flow (qr) 2.4
300
Tr (C)
Mr (g)
solution is usually starting a solid
cpr (K)
600 2.3
suspension and subsequent dis-
U (W)
40 Enthalpy (46.2 kJ) 2.2
200
pensing of the substrate.
500 2.1
Tr
In this example methyl-isonicotinate 30 2.0 100
Mr
was reduced with NaBH4 in the 400 1.9
presence of ethanol as solvent. By 03:20:00 03:30:00 03:40:00 03:50:00 04:00:00
Time (hh:mm:ss)
adding solid NaBH4, the reaction
immediately starts vigorously and Figure 11: Heat flow pattern of reduction reaction
In general, batch reactions are Therefore, the Maximum With a reaction time of almost
typically more prone to issues Temperature of the Synthesis three hours the batch time is
than semi-batch or continuous Reaction (MTSR) would result in quite long and may become a
processes about 83 C which is just above cost issue
Adding solids raises the concern the boiling point of the solvent.
of mixing issues occurring With a maximum of In other words, changing from a
Because the reaction is run in approximately 119 W/L the batch to a semi-batch reaction,
batch mode a large accumula- reaction is clearly more powerful reducing the maximum heat out-
tion of more than 90 % is seen than a typical production vessel put, the accumulation of reagents
indicating a potential safety is- can handle (approximately 30 and the batch time are identified
sue W/L) targets to improve making the
Assuming a cooling failure at Heat transfer coefficient (as indi- process safe at scale.
exactly the time when all the cated in blue) changes by about
NaBH4 is added, the adiabatic 5 % and is, therefore, not very
temperature increase would significant
amount to around 53 K.
8 Safety by Design
6 Conclusions
EasyMax HFCal is typically used for calorimetric screening and to identify scalability issues
while OptiMax HFCal is ideal for scale-up and safety investigations.
The industry standard RC1e is suitable for comprehensive investigation in process safety and
is characterized by an unmatched accuracy and precision.
Safety by Design 9
Sources and References
[1] F. Stoessel, Thermal Safety of Chemical Processes, Wiley-VCH, Weinheim, (2008)
[2] H. Fierz, P. Finck, G. Giger, R. Gygax, The Chemical Engineer 400, 9, (1984)
[3] F. Brogli, P. Grimm, M. Meyer, H. Zubler, Prep. 3rd Int. Symp. Safety Promotion and Loss
Prevention, Basle, 665, (1980)
[4] P. Hugo, J. Steinbach, F. Stoessel, Chemical Engineering Science, 43, 2147, (1988)
Additional Resources
Webinars
- Francis Stoessel: Avoiding Incidents at Scale-up: Is Your Process Resistant
Towards Maloperation?
- Stephen Rowe: Safe Scale-up of Chemical Processes: Holistic Strategies Supported
by Modern Tools
For a complete listing of webinars, please visit: www.mt.com/ac-webinars
Brochures
- Process Safety Brochure
To download brochures or datasheets, please visit: www.mt.com/process-safety
Websites
- Process Safety Application Website (www.mt.com/process-safety)
- Calorimetry Product Page (www.mt.com/hfcal)