PROVIDING PROCESS SAFETY SOLUTIONS

Chemical

Reaction Hazards and Thermal Runaway

Exothermic chemical reactions are performed the world over by companies as part of the normal manufacture of their products and intermediates. These reactions carry with them an inherent risk of loss of control, with potentially devastating effects on life and the environment.

HOW CHILWORTH CAN HELP

With a wealth of experience, technical expertise and specialist equipment we produce a range of solutions combining laboratory test data with expert Consultancy advice for the following services:

Identification and Assessment of Process Hazards
  • Thermal stability screening tests and thermochemical calculations
  • Reaction calorimetry including elevated pressure and reflux work using Mettler RC1TM
  • Adiabatic calorimetry and runaway simulation
  • Environmental discharge studies.
Engineering Solutions
  • Safety measure selection and specification
  • Emergency vent design (DIERS methodology)
  • Knock out and quench vessel sizing
  • Reaction inhibition work
CHEMICAL PROCESS DEVELOPMENT AND OPTIMISATION

Many existing chemical processes could be run much more efficiently with improved yield, better quality and greater speed. Our experience has shown that it is possible to accomplish these results without compromising safety or increasing environmental impact. Companies can take advantage of this opportunity to achieve financial gain and an increased competitive edge.

HOW CHILWORTH CAN HELP
  • Review existing processes and develop new ones
  • Conduct automated laboratory reaction studies
  • Test under reflux and at elevated pressures
  • Perform factorial experimental designs
  • Assess safety and environmental implications of process change
  • Make practical and economical recommendations
SPECIALIST CAPABILITIES
  • Adiabatic Dewar calorimetry
  • Accelerating Rate Calorimetry (ARC)
  • Reaction calorimetry using Mettler RC1TM
  • Carius tube screening
  • Differential scanning calorimetry (DSC)
  • Gas evolution rate measurements
  • Mass spectroscopy
  • Evaluation of highly energetic materials
  • Experimental blast chamber facility
  • Handling of toxic and highly active materials



Publications

ADIABATIC CALORIMETRY DATASHEET
The assessment of runaway reactions and thermal decompositions is a critical part of the safe operation of a chemical process or drying operation. Obtaining laboratory data that can be directly scaled-up to the production size of most plant operations requires that both the heat losses and thermal inertia (phi factor) of the plant is replicated. Adiabatic calorimetry is designed to provide data which can be used for consequence assessment, emergency relief system design (using DIERS methods) and accurate thermal stability assessment.

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CHEMICAL PROCESS EVALUATION SERVICES BROCHURE
Detailing our services for chemical reaction hazard assessment, thermal runway studies, emergency relief design and vent sizing, optimisation of existing chemical processes and development of new processes.

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CHEMICAL REACTION HAZARDS UPDATE
A round-up of new services and events from the Chilworth chemical process section during 2005. Information on our PreVent launch at Old Trafford, Manchester and a case study of how even simple processes can go wrong.

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PREVENT
A structured procedure to reduce the need for an extensive reaction hazard assessment of a process. This technique permits a faster and more cost-effective mechanism for ensuring an effective basis of reaction safety using valid and proven engineering solutions - particularly if pressure relief is to be employed.

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REACTION CALORIMETRY DATASHEET
Do you understand the thermochemistry and kinetics of your reactions? Many companies don’t and some have suffered major incidents as a result of scale-up or process modification without a basic appreciation of the reaction thermochemistry. This datasheet explains some of the benefits of Reaction Calorimetry data for process safety and scale-up.

Available for download to Subscribers
 
 
THERMAL STABILITY TESTING DATASHEET
Do you know the thermal limits of your materials? Almost all materials will undergo some form of thermal oxidation, decomposition or self-reaction at elevated temperatures. It is therefore a prerequisite of safe chemical manufacture and processing that the thermal stability limits of the materials are understood when working at elevated temperatures.

Available for download to Subscribers
 
 
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Process Safety issues? Call +44 (0)23 8076 0722 or email info@chilworth.co.uk