Purdue Process Safety & Assurance Center (P2SAC)Overview - Pharma

Ray A. MentzerProfessor of Engineering Practice

Associate Director, P2SAC

Charles D. Davidson School of Chemical EngineeringPurdue University

December 10, 2020

PROCESSSAFETYANDTHEPHARMACEUTICALINDUSTRY

1:00 – 1:15 Ray Mentzer (Professor of Practice ChE, Purdue) Plans for Event & Overview of Recent P2SAC Pharma Related Research

1:15 – 1:45 Ayman Allian (AMGEN) Safe Scale-up of an Exothermic Grignard Reaction Based on Thermal Hazard Understanding and Engineering Control

1:45 – 2:15 Frank Dixon (GSK) Playing with Fire? A Safe and Effective Quench of Raney Cobalt using Aqueous Sodium Nitrate

2:15 – 2:45 Jeff Sperry (Vertex) Assessing Explosive Properties in the Pharmaceutical Industry

2:45 – 3:15 Brett Savoie (Assistant Professor ChE, Purdue) High-Throughput Predictions of Molecular Thermodynamics and Reactivity

3:15 – 3:25 Break

3:25 – 3:55 Bhoja Kandela (Lilly) Safe Operating Space for Handling Hydrogen Evolved During STAB Hydrolysis

3:55 – 4:25 Simon Rea (Mettler-Toledo AutoChem) Utilizing Heat Flow Calorimetry for Understanding Thermal Risks of Chemical Processes During Scale-Up and Safety Studies

4:25 – 4:55 Qiang Yang (Corteva) Explosion Hazards Associated with Using DMSO and DMF in Chemical Reactions

4:55 – 5:25 Rexonni Lagare (PhD Candidate ChE, Purdue) Clearing the Air: Rethinking Dust Safety in Pharmaceutical Manufacturing

5:25 – 5:30 Ray Mentzer (Professor of Practice ChE, Purdue) Closing Comments

P2SAC Formed in 2014

Process Safety a challenging quantitative / technical discipline; scope not widely recognized

Conduct process safety related research focusing on fundamental science

Teach rigorous process safety ChE core course (+172 UG and Grad students enrolled Fall ‘20)

Engage UG & Professional MS students in process safety researchSource of expertise for industry and other stakeholders regarding

process safety related standards & best practices Focus on oil & gas industry, chemicals, pharmaceuticals,

agriculture, consumer products and manufacturing Research projects solicited from industry sponsors, as well as other

stakeholders such as academia & government labs

Process Safety Conferences Held Each SemesterAttendees – December 10, 2020 Fall Conference

SponsorsACC – Am Chem CouncilAcuTechAMGENBPChevronCortevaCountryMarkDowEndress+HauserFauske & AssociatesGSKHoneywellKenexisLillyMarsh RiskPhillips 66PfizerSABIC3M

On-going dialog with other Depts:AAE, ABE, CHEM, IE, IPPH, ME & CV

• Gilead*• Husky*• ICASE• ioMosaic*• Ingredion*• Johnson Matthey• LANGAN*• TX A&M, MKO*• Merck• Mettler Toledo*• MilliporeSigma*• Organix Inc*• PharmaTech*• PI Industries*• Sygene*• Univ CO, Bolder*• Vertex

*denotes 1st meeting

Guests• AB InBev*• ACM Facility Safety*• Aerie Pharma*• aeSolutions• Air Products• AstraZeneca*• Atul Ltd*• Biocon Ltd*• BMS• Cadila*• CatSci Ltd*• CDC - NIOSH• Cummins• DEKRA• Evonik• George Booth, Inc*

Chemical Process Safety - Core Class

Personnel vs. Process Safety & Metrics

Applicable regulations: OSHA PSM, EPA RMP, etc

Source Term ModelingToxicants & Industrial HygieneToxic/Flammable Gas ReleaseDispersion ModelingFire & Explosion ProtectionChemical ReactivityRelief System DesignHazards Identification (HAZOP, ..)Risk Assessment (Matrix, QRA, ..)Accident Investigations

5

Process Safety Metrics

Typical 4x4 Risk Matrix

HAZOP

LOPA Frequencies

Multiple Faculty Engaged in Process Safety Related Research – 2019/2020 Program

PhD ResearchSensing dust concentrations by imaging Safer materials and processing design for next-

generation printed electronicsNew directions in prevention by catalyst designOptimal placement of detectors and new

directions driven by systems engineering approaches

Modeling and uncertainty analysis of dust explosions

Battery safety by materials designHigh throughput Predictions of Molecular

Thermodynamics and ReactivityThe role of chemical agents (surfactants) and

electrostatics in coalescence

Pharma Related PMP / UG Projects – 2019 / 20

Survey of heats of reaction for some common reaction types in pharma industry & comparison with predictions – w / Amgen, Corteva, GSK, JP, Lilly, Merck, Vertex

Analysis of 73 global process safety incidents in the pharmaceutical industry - published

Thermal Hazards in the Pharmaceutical Industry – w / Amgen – cont’d

Use of ARSST Calorimeter to Study Reagents Common to the Pharmaceutical Industry

Temperature at Which Time to Maximum Rate is 24 Hours – w / Amgen

Safety in Academic & Industrial Laboratories - w / Corteva

Heat transfer modeling in Accelerating Rate Calorimeter – w / Dow

Analysis of process safety incidents across 14 industries & comparison of root causes –published

Review of Stoessel Classification Methodology and Potential Inclusion of Pressure

Analysis of Root Causes of Process Safety Incidents Across 14 Industries – PMP / UG

• Studied: Refining, Chemicals, Oil & Gas, Storage, Pipeline, Fertilizer, Pharmaceutical, Agriculture, Food, … 3 primary incidents per industry

• Identified14 primary root causes; several per incident• Analyzed significant data set in terms of root causes, fatalities, monetary

damage, impact beyond plant fence, state of operation, and developed / developing country

• Published: Process Safety Progress: e12158 (2020)

Global Process Safety Incidents in the Pharmaceutical Industry – PMP / UG

• Analyzed 73 process safety incidents; 108 fatalities between 1985-19• Identified and summarized trends between the number of incidents, number of

fatalities, location, and contributing factors • Highest reported fatalities occurred in 2018 & 2019, 26 & 16, respectively • 83% of fatalities occurred in China and India • Explosions associated with 71% of incidents, resulting in 89% of fatalities• Published: J Loss Prevention in

Process Industries, 68, Nov (2020)

Number of Fatalities and Corresponding %

Number of Incidents vs. Contributing Factors

Predicting Heats of Reactions Common In Pharma Industry - UG

Companies working on this project provided basic mechanisms and reaction data to compare to calculations with CHETAH and TCIT.

• This research project is using known reaction data from pharmaceutical companies, including Amgen, Corteva, GSK, JM, Lilly, Merck, and Vertex to compare to predictions

• Programs calculate the heat of reaction when given the molecular structures

• Currently have data for 14 reactions

Type of Reaction

NIST [-ΔHrxn(kJ/mol)]

Company Data [-ΔHrxn(kJ/mol)]

TCIT [-ΔHrxn(kJ/mol)]

CHETAH [-ΔHrxn(kJ/mol)]

Cyclopentane Reduction 111 111.7 105.9

Debenzylation 114 80.09 81.98

• One example reaction to test the accuracy of TCIT and CHETAH was the reduction of cyclopentane; Calculations close to the NIST value

• Still resolving calculations for debenzylation reaction, which differs from experimental data

Thermal Hazards in Pharmaceutical Industry (TMRad & TD24 estimation from DSC experiments) - PMP Capstone

• Objective: Utilizing DSC that requires less material and shorter turnaroundto estimate TMRad & TD24 which is important to the pharma industry whenmaterial is scarce especially in the early phase and timelines areaccelerated; comparing the results with results obtained from AKTSsoftware.

• TMRad: Defined as the time between the onset of a runaway reaction andthe point at which heat release rate is at its peak. It helps to determine theprobability of a runaway reaction.

• TD24: Defined as the temperature at which TMRad is equal to 24 hours.Depends on the onset temperature (Tonset).

• Borchardt and Daniels approach was used as the basis for estimatingparameters required to calculate TMRad & TD24, namely Activation Energy(Ea). Borchardt-Daniels assumes that the reaction under considerationfollows nth order kinetics and exhibits Arrhenius behavior.

• Results: The proposed model was able to predict TD24 values for 4commercial chemicals which was corroborated with the TD24 predicted byAKTS software.

• Limitations: Model assumes zero order kinetics; Model seems to bedependent on DSC heating rates (best results obtained at heating ratesbetween 2-5 °C/min).

• Future Work: More samples to be analyzed for the proposed model;corroboration of results using Fauske’s method for estimating TD24 usingARSST data.

References

1) Stoessel, F. Thermal Safety of Chemical Processes: Risk Assessment and Process Design, 2nd ed.; Wiley-VCH: Switzerland, 2020; pp 38-76

2) Borchardt, H.J.; Daniels F., J. Am. Chem. Soc.1956, 79, 41

3) Keller, A.; Stark, D.; Fierz, H.; Heinzle, E.; Hungerbuhler, K.; J. Loss Prev. Process Ind. 1997, 10, 31-41

Advanced Reactive System Screening Tool (ARSST) Project

• Used to study the decomposition of Dimethyl Sulfoxide (DMSO)• The ARSST records temperature and pressure data over time• Calculated the ΔHR, Ea, and the Pre-Exponential Factor from the

DMSO Decomposition reaction• Compared the thermochemical properties of the DMSO

decomposition under acidic conditions by mixing DMSO with acids of varying pKa’s

• Obtained a Linear Free Energy Relationship between the onset T of the DMSO decomposition reaction and the pKa of acid added to the system

• Analyzed the change in this Linear Free Energy Relationship under different concentrations of acid with DMSO

Figure 3: Plots illustrating the change in Tonsetwith different acid strengths

Figure 2: Slope of linear portion on the right is proportional to

Ea

Figure 1: Plots illustrating pressure generation over time

Joint P2SAC / CISTAR projects funded by NSFLab Safety – Academic & IndustrialFocused on:• Surveys of academic & industrial labs;

establishing / sharing best practices• Development of software tool for hazard

analysis, toxicity, flammability

RHEACT Features: • PDF parser for chemical SDS • Generation of hazard matrix • Calculation of adiabatic T & P change• Compatibility matrix

Cybersecurity Best PracticesAddress cybersecurity implications of proposed CISTAR facilities: remote sites, unmanned well-site facilities or regional/centralized processing facilities

300% increase in energy sector cyber-attacks since ‘12

Computer & Informational Technology, y MS student – 2018 / 19- Survey of companies in three subject areas: demographics, cybersecurity & physical security - 80% of cos employ 4+ cyber professionals; 93% of cos use a layered cyber defense- Best practices: Password requirements; scheduled software patch cycles; antivirus software; two-factor authentication; cloud-based services

Assessment of cyber vulnerability of specific facilities and steps to mitigate – w / AcuTech -2020 / 21

2020 P2SAC Closing

• Two new Sponsors• Progressed 10 PhD / 9 PMP / 6 UG research projects• Active engagement of multiple companies in student research via

WebEx, teleconferences, etc• Created ‘P2SAC Pharma Trainee’ position • COVID implications:

• resulted in no face-to-face conferences • laboratory with ARSST calorimeter to reopen in spring• nearly all research progressed as planned • fewer international PMP students will reduce number of students

with summer Capstone projects• ALWAYS interested in your process safety research ideas & projects

P2SAC Sponsors