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Home > Your application > Process Safety
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Process Safety |
What problems are encountered in process safety?
The thermal stability of substances and reaction masses used in a chemical process must be guaranteed at all times. Engineers have to ensure that all the heat produced by a reactive system can be removed from the process quickly.
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Process safety engineers on chemicals sites must:
- assess the risks(explosion, fire, etc.)associated with the conditions of storage, transport and/or transfer of each reagent involved in the process;
- select the safest operating conditions (choice of reactants; reaction temperature; batch, semi-batch, continuous type reactor; etc.) while at the same time ensuring that the process remains economically viable.
Operating within this framework makes it necessary to study the intrinsic thermal stability and decomposition properties of the reactants used; the risks associated with a process in normal conditions (heat production and removal, gas releases); and the risks associated with a process in off-normal conditions (runaway scenarios). | X |
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Calorimetry is the solution! |
Calorimetry is the choice technique because it allows measurement of the parameters required to determine a heat balance. In addition, calorimeters simulate the temperature, pressure, and operational conditions (stirring, mixing, etc…) encountered in industrial applications.
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Several types of calorimeter are used:
Differential scanning calorimeters (DSC)
DSCs are used to measure the heat flux difference between a reactive system and an inert ‘reference’ system, the two systems being subjected to the same temperature programme. The DSC technique requires just a few milligrams of material, is fast and inexpensive. It also has a temperature and pressure range such that all thermal effects associated with both the desired reaction and any secondary reactions or decomposition are detected and quantified.
Isothermal calorimeters
Isothermal calorimeters are used to measure the heat of reactions and their kinetic parameters with just a few grams of sample material. Since this requires long-duration tests, the isothermal calorimeter signal must remain very stable over time.
As sample quantities are generally larger than with DSC, the isothermal calorimeter can be used to study heterogeneous mixtures with even higher resolution.
Adiabatic calorimeters
Adiabatic calorimetry allows thermal runaway phenomena to be reproduced. This is the preferred approach for simulation of poor conditions of heat transfer at the core of an industrial reactor—for instance, when it suffers a cooling system failure. In this case, all of the heat produced by the reaction builds up and fuels its own auto acceleration (runaway).
The adiabatic mode is therefore considered as the most critical for process safety.
Reaction calorimeters
This term is used when the calorimeter in question, whatever its temperature programming mode (scanning, isothermal or adiabatic), allows the simulation of a chemical process under conditions of stirring, mixing (batch or semi batch), reflux, etc. that are close to those of industry.This method, which generally uses cells with a capacity of 10 ml to 500 ml, makes it possible to work with material quantities that are more representative of the industrial reaction masses. | X |
Some references
| Some references | X |
Sanofi-Aventis (France)
Diosynth (Netherlands)
Organon (Netherlands)
Astra Zeneca (Sweden)
Akzo Nobel (Netherlands)
Oril Industrie, Groupe Servier (France)
Astra Zeneca (United Kingdom)
Syngenta (United Kingdom)
Firmenich Inc (USA)
Nestec (Switzerland)
INERIS (France)
Pfizer (USA)
Institute of Safety and Security (Switzerland)
Novartis (Switzerland)
Synkem (France) Bayer (Germany)
The Dow Chemical Company (USA)
Boehringer (Germany)
Zambon (Italy)
Akzo Nobel (Netherlands)
Wacker Chemie (Germany)
BASF (Germany)
Merck (USA)
Stazione Sperim. per li combustili (Italy) Centre d’études de Gramat (France)
Ashland Chemical Company (USA)
Mitsubishi Chemicals (Japan)
LG Chem (South Korea)
KOSHA (South Korea)
National Research Institute of Fire & Disaster (Japan)
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Calorimeter for screening synthesis reactions |
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DRC EvolutionDifferential Reaction Calorimeters (DRC) are used in laboratories working on the optimization of industrial processes and the screening of chemical reactions.
The DRC Evolution was developed jointly with the process safety laboratory of Sanofi-Aventis in Neuville-sur-Saône (France).
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