Monitoring Off-Gasses to Guard Against Thermal Runaway Risk with Li-Ion Batteries

 

Lithium-Ion Batteries

Rechargeable lithium-ion (“li-ion”) batteries (comprised of cells in which lithium ions move from a negative electrode through an electrolyte to a positive electrode during discharge—and the other way around when charging) were first described conceptually in the 1970s.

Following initial prototype development in the 1980s, li-ion batteries became commercially viable in subsequent decades, and they are now commonly used in a variety of portable consumer electronic devices, including cell phones, laptops, and tablets.

Li-ion batteries also provide power for a broad array of automotive, aerospace, and commercial energy applications, such as electric vehicles (i.e., cars, trucks, buses, and trains), drones and satellites, and battery energy storage systems (or “BESS”, which enable power system operators and utilities to store energy—including that generated from renewable power sources—for later discharge and distribution as demand necessitates).

Analysts expect that the global size of the lithium-ion battery market will grow from some $40 billion in 2021 to over $115 billion by 2030, as users increasingly appreciate li-ion batteries for their rechargeability, large storage capacity, slow loss of charge when not in use, and high power to weight ratio.

However, those involved with li-ion battery production and usage must live with the inherent safety hazards involved with these batteries, as their electrolytes are flammable by nature, which can, at high temperatures, lead to fires and explosions.

Thermal Runaway Can Impact Lithium-ion Battery Safety

In 2019, a battery failure at an Arizona BESS facility operated by the Arizona Public Service (“APS”) utility resulted in an explosion that caused serious injuries to a number of firefighters. The APS site housed over 10,000 lithium-ion battery cells in 27 battery racks within a relatively small battery storage enclosure.

Authorities believe that the explosion, which they attributed to a chain reaction process knows as “thermal runaway”, was initiated by a failure in just one li-ion battery cell, which leaked explosive gas which, in turn, combusted as soon as the firefighters, responding to an alarm and reports of gas clouds emanating from the structure, opened the door and let oxygen into the storage enclosure.

Described simply, thermal runaway is an exothermic reaction in which li-ion battery cell temperatures rise rapidly in an uncontrollable self-exacerbating fashion. As cell temperatures rise, flammable and/or toxic gasses are vented (that is, “off-gassed”) from the battery.

While the gasses may not ignite immediately, the risk for a potential gas explosion remains. Ultimately, pressure from the buildup of gas can cause the cell to rupture and release toxic or explosive gasses (most commonly, carbon dioxide, carbon monoxide, fluorine, hydrogen, and methane, though there may be others).

An after-incident report commissioned by APS and released in 2020 listed a number of incidents from 2006-2017 involving thermal runaway events in lithium-ion batteries, including one on a tugboat in 2012 and another on a Boeing 787 in 2013.

There have been other such events as well including, memorably, a 2017 fire and explosion in Houston, TX on a train car that was transporting lithium-ion batteries to a recycling facility. The explosion broke windows in nearby buildings and, reportedly, sent a chemical stench throughout downtown Houston.

Off-Gas Monitoring Can Reduce the Risk of Thermal Runaway

Lithium-ion battery off-gassing, and subsequent thermal runaway, can occur due to manufacturing defects, mechanical damage or failures, overvoltage, excessive heat, or improper handling or storage.

Unfortunately, without reliable gas detectors in place, there is no sure way to know, until it is too late (i.e., when thermal runaway has actually started), that battery cells have in fact begun to off-gas.

To detect off-gasses, and protect against thermal runaway, best practices call for manufacturers, researchers, facility operators, storers, transporters, and others working with li-ion batteries to install high-quality gas detection monitors.

The gas detectors should continuously monitor all relevant areas and, if off-gas concentrations are detected, activate alarms and turn on ventilation systems.

PureAire Monitoring Systems

PureAire Monitoring Systems’ ST-48 Gas Detector tracks levels of toxic and/or combustible off-gasses including, but not limited to, carbon dioxide, carbon monoxide, fluorine, hydrogen, and methane. 

The ST-48 is housed in a NEMA 7 explosion-proof enclosure suitable for Class 1, Divisions 1 and 2, Groups A, B, C, and D, making it ideal for locations (including li-ion storage facilities and electric vehicle manufacturing plants) where toxic and/or combustible gasses may accumulate.

PureAire’s ST-48 Gas Detector offers continuous readings of toxic and/or combustible gasses and features an easy-to-read screen, which displays current gas levels, in either parts per million (ppm) or lower explosive limit (LEL), for at-a-glance observation.

In the event of an accumulation of off-gasses to an unsafe level, the Detector will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area and contact appropriate first responders.

Importantly, the PureAire Gas Detector can be programmed to tie into ventilation systems when off-gas levels reach a user-selectable ppm or LEL, so that the gasses can be flushed before human life is jeopardized.

Toxic and Combustible Gasses – Safety is Paramount

 

On January 31, 2022, a fire at a North Carolina fertilizer manufacturing facility caused officials to urge residents living nearby to stay away from their homes due to an increased risk of a possible explosion at the facility. People with respiratory issues were likewise advised to take precautions to minimize their potential exposure to toxic gasses.

According to Winston-Salem fire chief William Mayo, there were nearly 600 tons of ammonium nitrate and 5,000 tons of finished fertilizer at the site, enough to cause one of the worst explosions in U.S. history.

Ammonium nitrate is widely used to manufacture fertilizers for commercial and residential use. However, when exposed to extreme heat, ammonium nitrate may produce nitric oxide and ammonia (NH₃), which can create not only a toxic environmental situation but also a catastrophic explosion.

What is Nitric Oxide?

Nitric oxide (NO) is a poisonous and highly reactive gas that is colorless at room temperature, with a strong, sweet odor; it can be toxic when inhaled. Although NO is non-flammable, it will react to combustible materials and may increase the risk of fire and explosions if it is exposed to chlorinated hydrocarbons, carbon disulfide, fluorine, alcohol, petroleum, toluene, or ammonia. Nitric oxide can quickly oxidize to form nitrogen dioxide (NO₂).

What is Nitrogen Dioxide?

Nitrogen dioxide is a red-brown gas with an irritating, sharp odor. Like nitric oxide, NO₂ is non-flammable but can accelerate the burning of combustible materials.

What is Ammonia?

Ammonia (NH3) is a colorless gas with a pungent odor. Ammonia is not highly flammable, but it may react violently when exposed to fluorine, chlorine, nitrogen dioxide, or hydrogen bromide, among other gasses. Ammonia can produce poisonous gas during a fire.

Health Hazards

Exposure to nitric oxide, nitrogen dioxide, and ammonia can irritate the eyes, nose, and throat. At higher concentrations, NO, NO₂, and NH₃ can cause pulmonary edema (a build-up of fluid in the lungs). Prolonged exposure to nitric oxide and/or nitrogen dioxide may reduce the blood’s ability to transport oxygen, causing headaches, fatigue, dizziness, nausea, vomiting, unconsciousness, and even death.

Continued exposure to ammonia may cause asthma-like allergy symptoms and, possibly, permanent lung damage.

Workplace Exposure Limits

According to the Occupational Safety and Health Administration (OSHA), the permissible exposure limits (PELs) for nitric oxide, nitrogen dioxide, and ammonia are set forth below:

• Nitric Oxide: 25 parts-per-million (ppm) over an 8-hour work shift; it is immediately dangerous to health at 100 ppm
• Nitrogen Dioxide: 5 ppm, not to be exceeded at any time
• Ammonia: 50 ppm over an 8-hour shift.

Monitoring Hazardous Gasses

Nitric oxide, nitrogen dioxide, and ammonia can all react explosively if they mix with incompatible compounds. Further, exposure to fire may produce additional toxic and corrosive gasses. To help prevent an accidental leak and risk of explosion, gas cylinders should be stored in cool, well-ventilated areas, away from moisture and direct sunlight.

While nitric oxide, nitrogen dioxide, and ammonia all have strong odors, that is not necessarily an adequate warning of their presence, since prolonged exposure to NO₂, NO, and NH₃ can desensitize one’s sense of smell, thereby reducing awareness of the exposure.

To detect, and protect against, risks emanating from excessive concentrations of nitric oxide, nitrogen dioxide, or ammonia, best practices include placing gas detection monitors (containing visual and audible alarms) in locations where NO, NO₂, and NH₃ may accumulate. The gas detection system should continuously monitor the area and, if gas concentrations exceed the permissible exposure limit, activate an alarm, turn off the gas at the source, and turn on the ventilation system.

PureAire Monitors

PureAire Monitoring System's ST-48 Gas Detector is perfect for tracking levels of toxic and/or combustible gasses including, but not limited to, nitric oxide, nitrogen dioxide, and ammonia.

The ST-48 is housed in a NEMA 7 explosion-proof enclosure suitable for Class 1, Division 1 and 2, Groups A, B, C, and D, making it ideal for locations where toxic and/or combustible gasses are present or may accumulate.

PureAire’s ST-48 offers continuous readings of toxic and/or combustible gasses and features an easy-to-read screen, which displays current gas levels, in either ppm or lower explosive limit (LEL),  for at-a-glance observation. In the event of an accumulation of gasses to an unsafe level, the Detector will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area. The PureAire Gas Detector can likewise be programmed to tie into automatic shut-off valves, and ventilation systems when gas levels reach a user-selectable ppm or LEL.

The ST-48 Gas Detector can connect to multi-channel controllers, a remote display, or into building systems themselves.

Coming Clean on Chlorine Safety

 

What is chlorine?

Chlorine gas (CL₂) is a dense, yellow-green gas that has a distinctive, irritating odor that is similar to bleach and is almost instantly noticeable even at very low concentrations. While CL₂ is not flammable, it may react explosively when exposed to other gases, including acetylene, ether, ammonia, natural gas, and hydrogen, among others. Due to its reactivity, chlorine is rarely used in its pure form but instead is typically combined with other elements.

If you have ever taken a dip in a swimming pool, you are more than likely familiar with chlorine and its distinctive odor, as well as the burning sensation that sometimes affects the eyes. Chlorine is widely used as a disinfectant in swimming pools and in a variety of residential and industrial cleaning solutions, as well as in many everyday products.

Applications and Benefits of Chlorine Use

Chlorine gas is commonly used in water and wastewater treatment facilities to disinfect water and kill contaminants, thereby helping to prevent water-borne diseases such as cholera, typhoid fever, dysentery, and hepatitis A. In the same way, many people use chlorine bleach to disinfect and whiten laundry, as well as on household surfaces to kill germs such as norovirus, E.coli, salmonella, and other pathogens.

In addition to its disinfectant properties, CL₂ is used in a variety of applications by a large number of industries. For instance:

• The automobile industry utilizes chlorine in the manufacture of seat cushions and covers, headlamp lenses, tire cord, bumpers, sealants, paint, fan belts, airbags, brake fluids, and navigation systems.
• Pharmaceutical manufacturers utilize chlorine in the production of medicines such as pain relievers, allergy medications, and drugs to help lower cholesterol.
• Many industrial solvents, dyes, plastics, epoxy resins, and synthetic rubbers (such as neoprene), use chlorine in their manufacturing processes.
• The paper and textile industries use chlorine to bleach paper and textiles.
• Technology firms use chlorine in the production of a diverse array of goods, including microprocessors for smart phones and computers, pc boards, lasers, fiber optic cables, hybrid car batteries, satellite guidance systems, etc.

Chlorine Safety

Well-known to be potentially hazardous to health, chlorine was one of the first poison gases used as a weapon during World War I.

Contact with chlorine can severely irritate and burn the eyes and skin. Exposure can also cause headaches, dizziness, nausea, and vomiting.

At high concentrations, and with prolonged exposure, inhalation of chlorine can cause sore throat, wheezing, coughing, chest tightness, pulmonary edema, permanent lung damage, and even death. While chlorine’s strong odor can provide some warning of its presence, prolonged exposure to chlorine can desensitize one’s sense of smell, thereby reducing awareness of the exposure.

Monitoring Chlorine

According to The Occupational Safety and Health Administration, the permissible exposure level for chlorine is 1 part-per-million (ppm), which should not be exceeded at any time.  Chlorine is considered to be immediately dangerous to life and health when exposure levels reach 10 ppm.

To detect, and protect against, risks emanating from excessive concentrations of chlorine, best practices include placing gas detection monitors (containing visual and audible alarms) in locations where CL₂ may accumulate. The gas detection system should continuously monitor the area and, if chlorine concentrations exceed the permissible exposure limit of 1.0 ppm, activate an alarm, turn off the chlorine at the source, and turn on the ventilation system.

PureAire's Universal Gas Detector

PureAire Monitoring Systems’ Universal Gas Detectors use “smart” sensor cell technology to continuously track levels of chlorine. The sensor cell is programmed to monitor for a specific gas (in this case, chlorine) and measurement range, as required by the user.

PureAire's Universal Gas Detectors allow manufacturers to monitor chlorine levels before employee health is put at risk. In the event that CL₂ is elevated to an unsafe level, the Universal Gas Detector will set off an alarm that includes horns and flashing lights, alerting staff to vacate the affected area. At the same time, the monitor can be programmed to turn on the ventilation system.

The Universal Gas Detector's easy to read screen makes it simple for employees to monitor chlorine gas levels at a glance, giving them peace of mind as they work with this useful but hazardous gas.

Protecting Against Oxygen Deficiency Risk

 

What is Oxygen Deficiency?

The air we breathe is made up of 78% nitrogen, 21% oxygen, and trace amounts of other gases such as carbon dioxide, neon, and hydrogen. The Occupational Safety and Health Administration (OSHA) defines an environment in which oxygen levels fall below 19.5% as an oxygen-deficient atmosphere, which should be treated as immediately dangerous to health or life.

How is Oxygen Deficiency Dangerous?

Oxygen deficiency is often called a silent killer, because there are no warning signs when oxygen concentrations drop to an unsafe level.

Inhaling just a few breaths of oxygen-deficient air can have immediate negative effects, which may include impaired coordination, accelerated respiration, elevated heart rate, nausea, vomiting, loss of consciousness, convulsions, or even suffocation due to a lack of sufficient oxygen.

Where can Oxygen Deficiency Occur?

Oxygen deficiency can occur in any location where compressed oxygen-depleting gases are used, stored, or may accumulate.

Industries that commonly use these types of gases include, but are not limited to, laboratories, MRI, food and beverage, cryogenic facilities, aerospace, pharmaceutical, research and development, alternative fuel, waste management, semiconductor, additive manufacturing, and the oil and gas sectors.

Manufacturers and other organizations utilizing compressed, oxygen-depleting gases in their operations need to successfully navigate complex working environments in which high concentrations of such gases may be critical to production procedures, but where the risks of oxygen deficiency may pose a potential safety hazard for their employees.

Fortunately, by utilizing a top-quality oxygen deficiency monitor, facility managers can maintain stringent processing requirements, as well as protect the health and safety of their personnel.

What is an Oxygen Deficiency Monitor?

An oxygen deficiency monitor is a device that measures oxygen levels in a particular area. By continuously tracking oxygen levels, oxygen deficiency monitors are designed to detect oxygen-depleting gas leaks before employee health is jeopardized.

A number of oxygen-depleting gases, including nitrogen, helium, carbon dioxide, and argon, among others, are both odorless and colorless. As such, unless they are using a reliable oxygen deficiency monitor, personnel working with such gases would likely be unable to detect a gas leak should one occur in a gas cylinder or line, and they could likewise be unaware that they were breathing oxygen-deficient air.

PureAire Oxygen Deficiency Monitors

    

PureAire Monitoring Systems’ line of Oxygen Deficiency Monitors offers thorough air monitoring, with no time-consuming maintenance or calibration required. An easy-to-read screen displays current oxygen levels for at-a-glance reading by employees, who derive peace of mind from the Monitor’s presence and reliable performance.

Our Monitor continuously tracks oxygen levels and, in the event of a gas leak and a drop in oxygen to an OSHA action level, will set off an alarm, complete with horns and flashing lights, alerting employees to evacuate the affected area.

The Monitor will remain accurate at temperatures as low as -40C. PureAire's durable, non-depleting, long-life zirconium oxide sensor will last for 10+ years in a normal environment without needing to be replaced.

To reduce risk to personnel, PureAire's optional Remote Digital Display may be placed well outside of high risk rooms (up to 250 feet from the Monitor itself), where it will safely exhibit oxygen levels inside the room.

Carbon Dioxide Safety – Why It’s Important to Monitor Carbon Dioxide

 

What is Carbon Dioxide?

Carbon dioxide is the fourth most abundant gas in the earth's atmosphere after nitrogen, oxygen, and argon. At room temperature, carbon dioxide (CO₂) is a colorless, odorless, non-flammable gas, but at different temperatures and pressures, carbon dioxide can be a liquid or a solid (i.e., dry ice).

Carbon dioxide is produced when fossil fuels are burned, or as vegetation decays. CO₂is also generated as a by-product in certain manufacturing processes, such as during the fermentation stages when making beer and wine.All living beings exhale carbon dioxide as a normal part of the respiration process, and plants require carbon dioxide for photosynthesis to take place.

Carbon dioxide displaces or depletes oxygen and, at unsafe levels, can cause dizziness, confusion, headache, shortness of breath, unconsciousness, and even death due to asphyxiation. Carbon dioxide may accumulate in confined spaces, causing health and safety hazards.

What is a Carbon Dioxide Monitor?

A carbon dioxide monitor is used to track carbon dioxide levels in targeted areas.Monitors are used to verify that carbon dioxide levels are within a range sufficient to ensure the safety of occupants within the tested areas.  CO₂ monitors are programmed to alert personnel when CO₂ levels reach an unsafe threshold.

Additionally, CO₂ monitors may be used in greenhouses or grows rooms to ensure that appropriate concentrations of carbon dioxide are maintained to yield healthy crops. Increased carbon dioxide levels stimulate the photosynthesis process, resulting in stronger and faster-growing plants, but the levels must be monitored closely, as too much CO₂ can damage plants, as well as present health risks to employees.

The Occupational Safety and Health Administration (OSHA) has established a permissible exposure limit (PEL) for carbon dioxide of 5,000 parts per million (ppm) averaged over an 8-hour workday (time-weighted average or TWA).

The National Fire Protection Association (NFPA) code 13.7.2 stipulates that rooms or areas where CO₂ container systems are filled and used indoors or in enclosed outdoor locations shall be provided with a gas detection and alarm system capable of detecting and notifying the building occupants of a gas release or carbon dioxide levels above the OSHA PEL of 5,000 ppm. Additionally, NFPA specifies that the gas detection system must be capable of initiating an audible alarm within the room or area in which the system is installed.

Industry Applications

Carbon dioxide monitors are designed for use in a wide range of applications, such as the food and beverage industry (breweries, wineries, bottling plants, bars and restaurants, food processing, and frozen food production facilities), laboratories, universities, pharmaceutical manufacturing, agricultural locations, schools, and office buildings.

Bars, restaurants, and fast-food establishments all rely on CO₂ to carbonate beverages such as soda and beer and, as such, all require the use of CO₂ monitors.

Pharmaceutical manufacturers use carbon dioxide to purge oxygen from packaging, not only to maintain a sterile environment but also to protect products during transport, and to prolong the stability and shelf life of the packaged drugs.Additionally, dry ice (the frozen form of carbon dioxide), is used to keep temperature-sensitive medicines at required cold temperatures.

A diverse array of indoor gathering places, including office buildings, schools, and retail locations, monitor carbon dioxide levels to measure indoor air quality and ensure that safe oxygen levels are maintained. Building HVAC systems may be programmed to activate their ventilation systems to recirculate and refresh the air in response to elevated CO₂ levels.

PureAire Carbon Dioxide Monitors

PureAire’s Carbon Dioxide Monitor offers thorough air monitoring, with no time consuming maintenance or calibration required. Air quality measurements are taken every 2 seconds and are visible on the Monitor’s easy-to read backlit display. In the event of a rise in carbon dioxide levels to an OSHA action level, the Monitor will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the affected area.

In certain applications, including inside greenhouses and grow rooms, the carbon dioxide alarm can be set to maintain desired CO₂ levels, and can be programmed to go off when CO2 levels change.

PureAire’s Monitor can be linked to a Programmable Logic Controller (PLC), a multi-channel controller, a remote display, or tied into building HVAC systems themselves.

Our Carbon Dioxide Monitor includes an NDIR sensor cell to reliably measure CO₂ levels. The monitor will remain accurate over a wide range of temperatures (0-50°Celsius) and humidity levels (0-95%RH), as well as changes in barometric pressure.

Where Should Carbon Dioxide Monitors Be Installed?

The specific application will determine where best to install a PureAire CO₂ Monitor. For example, bars and restaurants serving carbonated beverages should install a Monitor 12-18 inches off the floor in areas where compressed CO₂ is stored or used.

For applications that require high concentrations of carbon dioxide, such as inside greenhouses and grow rooms, the Monitor may be mounted inside the room, with employees utilizing a remote display located on the outside for at-a-glance visibility.

To ensure safety, PureAire generally recommends that one monitor be installed for approximately every 400 square feet of your facility’s space. However, since airflow can be unpredictable, we encourage you to contact PureAire for additional guidance specific to your needs.

The Hidden Dangers Inside Boiler Rooms - Why You Need a Boiler Room Gas Monitor

 

In an effort to prevent boiler room accidents due to elevated levels of carbon monoxide, the Texas Department of Licensing and Regulation (TDLR) has adopted new regulations (16 Tex. Admin. Code § 65.206) regarding carbon monoxide (CO) gas detection equipment that is used in boiler rooms built on or after September 1, 2020.

Carbon monoxide

Carbon monoxide gas is produced from the incomplete burning of natural gas, wood, coal, oil, propane gas, or anything else that contains carbon. In enclosed spaces such as boiler rooms, where fuels such as natural gas, oil, coal, or propane may be used,  CO levels can rise quickly creating a dangerous health and safety risk. Carbon monoxide is an odorless, colorless, tasteless, and flammable gas that can be deadly within minutes without warning.

Exposure to CO can cause chest tightness, headache, fatigue, dizziness, nausea, confusion, loss of consciousness, and even death.

Additionally, carbon monoxide gas is highly flammable and can ignite easily when exposed to oxygen and/or source of ignition such as a spark or excessive heat.

Methane

Methane (CH₄), a primary component of natural gas, produces carbon monoxide if incompletely burned. Methane, like CO, is colorless, highly flammable, and odorless unless an additive is used to give it an odor . High levels of methane can deplete oxygen causing headaches, dizziness, weakness, loss of coordination, and asphyxiation.

Keeping Boiler Rooms Safe with a Dual CO/CH₄ Combustible Gas Detector

Carbon monoxide is often referred to as a silent killer because it has no warning properties. Absent appropriate gas detection equipment, people working in and around boiler rooms, would be unable to detect an accumulation of carbon monoxide.To detect, and protect against, risks emanating from excessive concentrations of CO or CH₄, best practices include placing gas detection monitors, containing visual and audible alarms, in boiler rooms where carbon monoxide or methane may accumulate.

PureAire Gas Detectors

PureAire Monitoring Systems’ Dual Carbon Monoxide/Methane Combustible Gas Detector offers continuous readings of CO and CH₄. The gas detector features an easy to read screen, which displays current carbon monoxide and methane levels for at-a-glance observation by employees servicing boiler rooms, who derive peace of mind from the detector’s presence and reliable performance. In the event of an accumulation of carbon monoxide or methane to an unsafe level, the detector will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area. At the same time, the PureAire gas detector can be programmed to disable the burners when CO levels reach a user selectable ppm level.

The monitor is housed in a NEMA 7 explosion proof enclosure suitable for Class 1, Division 1 and  2, Group B, C,  and D.

Solvent Safety in Pharmaceutical Manufacturing

 

The manufacture of pharmaceutical products is a complex and multi-stage operation that can include processes such as blending, wet and dry granulation, milling, hot-melt extrusion, coating, andtablet pressing. Producing the exact formulation, release rate, consistency, and dosage form requires many chemical compounds and substances.

Among the mare active pharmaceutical ingredients (API), the primary and biologically active medicinal component of the drug; excipients, the non-active components, including lipids,which serve as carriers, solubilizers, or emulsifiers of the active ingredients; and plastics or polymers used in production to create the dispensing form of the finished pharmaceutical product.

Lipids and Polymers

Lipids and polymers are vitally important to the drug production process. They are used for the fabrication of most dosage forms, release rate modifiers, enhanced drug absorption, stabilizers, solubilizers, and more.

Lipids, which are soluble in organic solvents such as ethanol, isopropyl alcohol, acetone, and benzene, are purified and refined to be used as fillers, binders, lubricants, solubilizers, emulsifiers, and emollients in a variety of delivery forms, including tablets, capsules, suppositories, emulsions, ointments, creams, and lotions.

Polymers are used in a wide variety of applications that can include everything from film coatings on medicines, to controlling the release rate of drug formulations.They are also used as a taste masking agent, stabilizer, thickener,and as a protective agent in oral drug delivery.

Solvents such as acetate, methanol, isopropanol, and ethyl acetate are used dissolve or disperse the polymer materials and apply them to the surface of the tablets and capsules.

Solvents

Solvents can be solid, liquid,or gas and are often used to dissolve, disperse, suspend, or extract other materials during pharmaceutical manufacturing. They can also be used as the medium in which the chemical reaction takes place to make APIs. To maintain a sterile environment and adhere to strict quality control standards, solvents such as isopropyl alcohol may be used to clean and disinfect surface areas and equipment.

Depending upon the manufacturing stage, the solvent being used can be either organic ( i.e., carbon-based), such as hexane, alcohols (including isopropyl, ethanol, and methanol), toluene, and acetone, among others; or inorganic solvents ( i.e., non-carbon-based), including water (the simplest and most abundant), ammonia, hydrogen fluoride, and sulfur dioxide.

Potential Safety Risks Involved with Solvent Use

While solvents are necessary components of the medicine formulation process, exposure to solvents is one of the most common hazards in the pharmaceutical production industry. Solvents can irritate the eyes and respiratory tract, cause damage to the liver, kidneys, heart, blood vessels, bone marrow, and the nervous system. Inhalation of some solvents may have a narcotic effect, causing fatigue, dizziness, unconsciousness, and even death.

Moreover, many of the organic solvents used in pharmaceutical manufacturing, such as hexane, acetone, methanol, isopropyl alcohol, ethanol, and toluene,are highly volatile, as well as flammable or combustible.

Combustible Gas Monitors Can Reduce Risk in Pharmaceutical Facilities Utilizing Solvents

Solvent vapors are very often flammable and, depending on the solvent, even explosive. It is critically important to understand the lower explosive limits (LEL) of the solvents being used, because LEL reflects the lowest concentration of gases or vapors in the air that could cause combustion in the presence of an ignition source, such as static electricity , heat, or flame.

Best practices call for combustible gas detectors to be installed in any area where flammable or combustible solvents are used or stored. In the event of a leak, and an accumulation of solvent vapors, an LEL gas detection monitor should activate visual and audible alarms, and turn on the ventilation system.

PureAire Monitors

PureAire Monitoring Systems’ line of LEL Combustible Gas Monitors is designed to meet the safety needs of pharmaceutical manufactures utilizing solvents. The Monitor is housed in a NEMA 4 explosion-proof enclosure suitable for Class 1, Groups B, C, and D, and Class 2, Groups E, F, and G. The enclosure is specifically designed to prevent an explosion. The Monitor’s durable, long-life LEL catalytic sensor will last 5+ years without needing to be replaced.

PureAire Monitors feature an easy to read screen, which displays current gas levels, for at-a-glance observation by employees, who derive peace of mind from the Monitor’s presence and reliable performance. In the event of a solvent leak, PureAire’s Monitors will set off alarms, complete with horns and flashing lights, alerting personnel to evacuate the area. Alarm signals can tie into automatic shut-off valves and ventilation systems when solvent levels reach an unsafe threshold.

Our LEL Combustible Gas monitor can connect to multi-channel controllers, a remote display, or into building systems themselves.