Live Webinar: Scale-up and Process Safety
Ensure Safe Scale-Up of Chemical Processes
This free online event is for process chemists and engineers who are interested in developing and implementing strategic approaches to ensure product quality via process reproducibility and stability – in a resource-sparing manner. Each presenter will share practical examples and case studies on the use of process analytics to overcome challenges around route selection, reaction understanding and monitoring, heat transfer, and process safety.
Who should attend?
Process chemists and chemical engineers who need to:
- Consider the impact of scaling up delayed or auto-catalyzed reactions, heat or product accumulations, or heat transfer
- Understand reaction mechanisms such as critical reaction parameters, kinetics, reaction intermediates, or limits of heat exchange
- Investigate 'what if' scenarios like cooling failure, mixing failure, heat exchange fouling, or dosing disruptions
- Increase productivity and understanding by eliminating critical data gaps through automated sampling and modeling
- Optimize data quality through representative, reproducible sampling while limiting exposure to hazardous chemistry
Guest Presenters
Model-Aided Scale-Up/Scale-Down of a Problematic Debenzylation
Ted Raymond - Engineer IV in Synthetic Molecule Process Development at Takeda
This study identified the root cause of significant variability in a critical pharmaceutical debenzylation process by combining laboratory experiments, CFD analysis, and kinetic modeling. Researchers found that hydrogen starvation during startup caused catalyst poisoning, making the second reaction step highly sensitive to mixing conditions and extending reaction times. Using these insights, they developed and validated a transport-kinetic model that enabled process redesign, successful scale-up, and implementation at manufacturing scale, improving process consistency and production reliability.
Making Safety Data Count - Practical Approaches to Improving Process Hazard Analysis and Scale-up Outcomes
Dr. Stephen Rowe, Technical Director - Reaction Safety, DEKRA UK Ltd
This webinar explores how organizations can improve process safety and scale-up success by ensuring reaction safety data is not only collected, but effectively used throughout process hazard analysis (PHA). Drawing on real-world industrial incidents and a detailed case study, Stephen Rowe demonstrates how hazard characterization, reaction calorimetry, thermal stability testing, and consequence analysis provide the foundation for identifying risks, evaluating failure scenarios, and implementing appropriate safeguards. The presentation highlights that many major runaway reaction incidents can be traced back to inadequate hazard assessment or poor communication of safety data, and emphasizes the critical partnership between chemists and engineers in translating experimental data into safer, more efficient scale-up decisions and more robust manufacturing processes.
