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SAFETY IN AN INDUSTRIAL LABORATORY
Jordan Reddel and Matt BelowichThe Dow Chemical Company
October 22, 2019Chemical Safety
Michigan State University
Acknowledgments
• MSU Chemistry Department
• Our colleagues and leadership at Dow
• Lori Seiler, Associate Director for Global R&D EH&S Delivery
MRosen & MBelowich, 11/29/2018 Page 2
Outline
1. Introductions
2. Hazards of Laboratory Research
3. Approaching Research in Industry: How Does Dow Do Research Safely?
4. Q&A
MRosen & MBelowich, 11/29/2018 Page 3
• 2007 – 2011: University of New Hampshire – Undergraduate Research
• 2011 – 2016 : Northwestern University – Ph.D. (Regan Thomson)– Total synthesis of lignan natural products and method development
• 2016 – present: The Dow Chemical Company – Chemical Science (Core R&D)
– Organic Synthesis– Homogeneous catalysis, new catalyst development
Jordan’s Background
Page 4JReddel & MBelowich, 10/22/2018
– Bioinorganic chemistry: Design and synthesis of copper (II) ligands for ratiometric metal-ion sensors
Matt’s Background
MRosen & MBelowich, 11/29/2018 Page 5
• 2011: Northwestern University – Ph.D. (Fraser Stoddart)– Supramolecular chemistry– Mechanically-interlocked molecules– Organic synthesis
• 2012: Princeton University – Post-doc (David MacMillan)– Synthetic methodology– α-Arylation of carbonyls
• 2012: The Dow Chemical Company – Coating Materials– Polymer chemistry– Emulsion polymerization
• 2016: The Dow Chemical Company – Chemical Science (Core R&D)– Organic synthesis– Polymer chemistry– Organometallic chemistry
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MRosen & MBelowich, 11/29/2018 Page 6
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Positioned to Capitalize on Global Growth Trends
High-Throughput Research
Polymer Science
Material Science
Formulation Sciences
Process Engineering
Target MarketsBuilding Blocks Product Development
Tech
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High-PerformanceComputer Modeling
Solu
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Mat
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Catalyst Discovery & Ligand Synthesis
Application Development
Packaging
Infrastructure
Consumer
Urbanization Digitalization SustainabilityGlobalization
Cellulosics
Acrylics
Olefin Building Blocks
Ethylene Oxide
Propylene Oxide
Silicones
Various Others
Chemical Science Core Capability
MRosen & MBelowich, 11/29/2018 Page 7
POLYMERCHEMISTRY
Controlled architecture synthesisPolymer modification
Novel polymer additives
Electronic structure methodsMolecular dynamicsStructure-activity relationships
COMPUTATIONALCHEMISTRY
PROCESSCHEMISTRY
Atom economyRoute optimizationMaterials processingScale-up troubleshooting
ORGANIC & INORGANIC SYNTHESIS
HTR enabledCatalytic coupling chemistriesLigand design and inorganic
materials synthesis
Structure-property relationshipsHTR screening
Synthesis of homogeneous &heterogeneous catalysts
PHYSICAL CHEMISTRY
Reaction kineticsReaction thermodynamics
Phase behavior analysis
SKILL SETSORGANOMETALLIC CHEMISTRY
Hazards of Laboratory Research
Overview of Process Hazards
MRosen & MBelowich, 11/29/2018 Page 9
• Chemical Hazards Examples– Toxicity– Flammability– Shock sensitivity– Reaction exothermicity
• Physical Hazard Examples– Mechanical– Thermal– Pressure– Electrical– Ergonomics
• Work Area Hazard Examples– General housekeeping– Location and amount of
flammable materials
Engineering controls, administrative controls, and personal protective equipment (PPE) can keep you safe!
Rupture disc: Pressure Relief Device
Sign to Warn Others of Thermal Hazard
Sign and Physical Shield to Mitigate
Mechanical Hazards
Hidden Hazards of “Common” Reactions
• Hazards– Toxicity of NaN3: equivalent to NaCN– NaN3 can be explosive – even using a metal spatula can cause decomposition!– Changing the solvent from DMF can to dichloromethane (CH2Cl2) can lead to an explosive
chemical incompatibility!MRosen & MBelowich, 11/29/2018 Page 10
Macromolecules, 2018, 51, 2969
• Azide-Alkyne ‘Click Chemistry’is commonly used to makevarious polymer architectures.
R LG
LG = -Cl, -Br -OMs
NaN3+ Solvent
R N3
Sodium Azide CH2Cl2
HIGHLY EXPLOSIVE!
R LG NaN3+ R N3
DMF
+ N3
H2C N3
Diazidomethane
R N3
Hazards of Literature Prep Modification
• Modifications to literature procedures, and the procedures themselves need to be considered carefully
• In Dec. 2010, a reaction mixture detonated in a lab in the chemistry department at Northwestern University and a researcher was seriously injured
– Deviations to literature procedures were made:• Higher H2O2/iodobenzene ratio (25 instead of 2.8)• 35 wt% freshly opened H2O2 instead of 30 wt% H2O2
– Cause of explosion is unknown, but it is thought that the modified reaction conditions may allow the formation of diacetyl peroxide, a shock-sensitive explosive
MRosen & MBelowich, 11/29/2018 Page 11
1) H2O2/Ac2O
2) NaOH
ISO2
IOSO2
2-(t-butylsulfonyl)iodosylbenzene
C&EN News, Jan 10, 2011 Letters
OO
O
ODiacetyl peroxide
Work Area Hazards
MRosen & MBelowich, 11/29/2018 Page 12
• Poor housekeeping can lead to hazardous situations!– Ex: One student put a 1-L bottle of HCl on a high shelf, and later that day a different
student put a 1-L bottle of KCN on the same shelf hazardous situation!• Numerous hazards in messy hoods
Example from academia
Approaching Research in Industry: How Does Dow Do Research Safely?
Two Types of Chemistry Environments
1. Plant-Scale Reactors– Large reactor vessels (hundreds to thousands of gallons)– Materials transferred from large holding tanks– Chemistry is well-established and reaction process/products are fully
characterized and understood
2. The Research Laboratory– Small scale glassware and reactors– Material synthesis usually gram-scale– Exploratory chemistry and reactions
MRosen & MBelowich, 11/29/2018 Page 14
Safety in this environment will be the focus of our talk today!
The Move to Industry
• Disclaimer: The approach to safety that we take at Dow works well for us. However, each program and organization is unique, and the techniques that work for us may not work for your organization. Your organization should ensure that the safety program you use matches your needs!
Safety is the foundation for everything we do
Safety is collaborative Proactive about safety Safety is equally as important as generating results (scientific success)
MRosen & MBelowich, 11/29/2018 Page 15
Collaboration: The Cornerstone of Safety
• The key to our safety program is that we actively work with each other to share information and have lots of eyes on our chemistry!
• We have different communication options and tools to emphasize safety
– CHAT (Continuous Hazard Awareness Tool) Meetings: informal discussion about tasks planned for the day and the hazard control steps to be used
– WAG (Work Area Group) Meetings: discussion of chemistry occurring in the hoods in our immediate work area
– Safe-Operation Cards (SOC): reactions and processes we plan to perform are reviewed by a colleague for potential hazards
– Safety Moments: start a meeting with a “lesson learned”, may be work-related or even personal examples
MRosen & MBelowich, 11/29/2018 Page 16
Preparing to be safe: The SOC card• Before we do ANY process, we prepare an “SOC Card”
– SOC card posted on the hood or outside the area where process is being conducted– Consider worst-case scenarios: “If this happens, am I still safe?”– Provides others with quick reference to ongoing processes– In case of emergency, others can rapidly identify components/hazards of process
• Key components of a Safe Operation Card (SOC)– Process owner and contact info– Experimental section
• Description of chemistry• Reagent hazards (use SDS!) • Procedure for experiment
– Order of addition, reaction time, workup, and purification
• Acceptable operating parameters– Temperature, pressure, etc.
– Emergency procedures• Proper PPE for Chemistry• Emergency shutdown• Spill cleanup procedures
MRosen & MBelowich, 11/29/2018 Page 17
Preparing to be safe: The SOC card
MRosen & MBelowich, 11/29/2018 Page 18
(SLOW DOWN!)
S S
Br
x yS S
N3
x y
NaN3
THF
The alkyl bromide is dissolved in anhydrous THF under an atmosphere of nitrogen behind ablast shield. NaN3 is added in one portion and the solution is heated to 70 C for 16 hr. Thereaction mixture is then poured into methanol to precipitate the polymer and filtered.
CAS #’s: Sodium Azide (26628-22-8), Tetrahydrofuran (109-99-9), Methanol (67-56-1)
In the event of a chemical exposure immediately enter safety shower and havesomeone call emergency services.
• Goggles• Fire-retardant lab coat• 2 layers of nitrile gloves• polyethylene sleeves for wrist protection
Sweep up and dispose of material in appropriate waste stream. Do NOT use water asit may generate toxic gas.
Sodium Azide: H310 Fatal if in contact with skin H373 May cause damage to organs (brain)H410 Very toxic to aquatic life with long lasting effectsTetrahydrofuran: H225 Highly flammable liquid H302 Harmful if swallowed H319 Causesserious eye irritation H335 May cause respiratory irritation H351 Suspected of causing cancerMethanol: H225 Highly flammable liquid H301/H311/H331 Toxic if swallowed, in contact withskin, or inhaled H370 Causes damage to organs
Marie Curie, (917) 123-7654Irene Joliot-Curie, (917) 456-0987
Taking Your Safety Personally• Levels of Control
– Engineering Controls• Fume Hoods (ventilation and fume hood sash)• Blast Shields
– Administrative Controls• Training• Procedures
– Personal Protective Equipment• Gloves, Goggles, Lab Coat, etc.• Should be treated as a LAST LINE OF DEFENSE
MRosen & MBelowich, 11/29/2018 Page 19
Most Effective
Least Effective
Example from academia
PPE should never be used in place of engineering controls
• Trends at Dow:– Relatively few injuries involve reactive/toxic chemistry issues– Routine tasks/ergonomics lead to most injuries!
• Examples of Low Risk, High Frequency Tasks:– Glassware handling: NMR tube insertion into spinner, washing dishes, etc– Walking– Driving– Ergonomic
• SOC cards force one to think about thehazards of chemistry and anticipatepotentially dangerous scenarios.
“Sleeper” Hazards
MRosen & MBelowich, 11/29/2018 Page 20
High Risk, Low Frequency Tasks
High Risk, High Frequency Tasks
Low Risk, Low Frequency Tasks
Low Risk, High Frequency
Tasks
62%
Frequency
Perc
eive
d R
isk
Reaction Example
• Olefin Polymerization in a 2-L Semi-Batch Parr Reactor
• Some chemistry and process hazards:– Ethylene polymerization is a highly exothermic reaction (ΔH = -22 kcal/mol)
• Is the reactor properly equipped to dissipate the heat of reaction?– Variables: temperature, pressure, scale, catalyst loading
• Low temperatures: more ethylene is in solution, high temperatures: more active catalyst• High pressures and larger scales: more ethylene in the reactor• High catalyst loading: potential exotherm is higher
– Flammability of ethylene, 1-octene, and reaction solvent• Is the reactor free of leaks?
MRosen & MBelowich, 11/29/2018 Page 21
H2C CH2 CH2 CH2 n CH CH2
C6H13
CH CH2
C6H13
m+ catalyst
1-OcteneLiquid (bp = 121 °C)
EthyleneGas (bp = -104 °C)
PolyethyleneSolid (mp > 120 °C)
Summary
Safety is the foundation for everything we do
Safety is collaborative Proactive about safety Safety is equally as important as generating results (scientific success)
No experiment is worth pursuing without understanding the hazards
• At Dow, safety is our primary focus whenever we consider doing work– The activities that we use to ensure a safe work environment vary from process
to process or reaction to reaction but it is always a priority.
MRosen & MBelowich, 11/29/2018 Page 22
Dow Lab Safety Academy
http://safety.dow.com/en
LaunchedMay 2013
Earned the 2013 Safety Investment Award from ChemInnovations
MRosen & MBelowich, 11/29/2018 Page 23
Earned the 2018 Howard Fawcett Chemical Health & Safety Award from ACS
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