Process Safety Assessment
All chemical processes are assessed for process hazards (Chemical reaction hazards and Fire & Explosion hazards associated with powders) before scale-up. Chemical reaction hazards are assessed at the Process Hazards Lab at our Goa T&E centre. Fire & explosion hazards associated with powders are currently assessed at an external testing laboratory.
The assessment for chemical reaction hazards starts at the early stage with close coordination between the process chemistry and the process hazards team, where the inherent hazards are identified using literature screening and chemical reactivity worksheets. This helps in identifying any show-stoppers/potential incidents at the lab scale during the very early stage of process development.
This is followed by experimentation with calorimeters.
- Mettler Toledo Differential scanning calorimetry (DSC) with High-Pressure gold plated crucibles and Carius tube testing is used for initial screening for heat and gas generation from thermal instabilities.
- This is followed by Accelerating Rate Calorimetry (ARC) and ambient pressure Dewar calorimetry for studying the sample under low heat loss (adiabatic) conditions. Isothermal measurements are also carried out using the DSC and ARC for assessing auto-catalytic thermal decompositions.
- Reaction calorimeter (RC1e) along with the U-tube gas manometer is used for studying heat of reaction, gas generation and kinetics for synthesis reactions operating from ambient pressure to 6barg pressure.
The lab is managed by a team of chemical engineers and physical chemists who have the necessary expertise. The experience of the team members ranges from 14yrs to 7yrs in Process hazard assessments with previous assignments in global reputed pharmaceutical and agrochemical companies like AstraZeneca and Syngenta. More than 200 assessments have been carried out in the last 7yrs for complex chemistries like nitration, oxidation, grignard, chloro-oxidations, diazotisation etc.
The results from the hazard assessment is used to arrive at the “Basis of Safety” and this is reported in the form of Chemical Reaction Hazard Assessment report. The process is then risk assessed by the Process Risk Assessment team to evaluate the layers of protection before scale-up at pilot and commercial scales.
The process hazards assessment lab also supports the management of change system to assess the risk associated with the proposed process changes.
Maintaining Biodiversity and the Ecological Balance
The facilities was designed and built to co-exist in harmony. It is home to two Lakes -water harvesting (for 40 years)
More than 87 different species of trees, shrubs, herbs, creepers and grasses.
More than 50 species of birds including Cormorants, Herons, Storks, Ibis, Geese, Eagles. The site also is home to a variety of mammals and reptiles living in harmony.