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|---|---|---|---|---|---|
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Summary
Summary
With new and growing interest in dealing with the hazards of reactive chemicals, this book offers guidelines that can significantly reduce the risk or mitigate the severity of accidents associated with storing and handling reactive materials. Necessary elements of a reliable system to prevent equipment or human failures that might lead to a reactive chemical incident are sound and responsible management policies, together with a combination of superior siting, design, fabrication, erection, inspection, monitoring, maintenance, operations and maintenance of facilities. These Guidelines deal with all of these elements with emphasis on design considerations.
Author Notes
The CENTER FOR CHEMICAL PROCESS SAFETY (CCPS), an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has been a world leader in developing and disseminatinginformation on process safety management and technology since 1985. CCPS has published over 80 books in its process safety guidelines and process safety concepts series. For more information, visit www.ccpsonline.org.
Table of Contents
| Preface |
| Acknowledgments |
| Acronyms |
| Introduction |
| 1 Chemical Reactivity Hazards |
| 1.1 Framework for Understanding Reactivity Hazards |
| 1.1.1 Grouping of Reactivity Hazards into General Categories |
| 1.1.2 Key Parameters That Drive Reactions |
| 1.1.3 Types of Runaway Reactions |
| 1.1.4 How Reactive Chemical Storage and Handling Accidents Are Initiated |
| 1.2 Self-Reactive Polymerizing Chemicals |
| 1.2.1 Thermal Instability |
| 1.2.2 Induction Time |
| 1.2.3 Example |
| 1.3 Self-Reactive Decomposing Chemicals |
| 1.3.1 Peroxides |
| 1.3.2 Self-Accelerating Decomposition Temperature |
| 1.3.3 Predicting Instability Potential |
| 1.3.4 Deflagration and Detonation of Pure Material |
| 1.3.5 Slow Gas-Forming Reactions |
| 1.3.6 Heat of Compression |
| 1.3.7 Minimum Pressure for Vapor Decomposition |
| 1.3.8 Shock Sensitivity |
| 1.3.9 Examples of Shock Sensitivity |
| 1.4 Self-Reactive Rearranging Chemicals |
| 1.4.1 Isomerization |
| 1.4.2 Disproportionation |
| 1.5 Reactivity with Oxygen |
| 1.5.1 Spontaneous Ignition and Pyrophoricity |
| 1.5.2 Pyrophoricity versus Hypergolic Properties |
| 1.5.3 Accumulation and Explosion of Pyrophoric Materials |
| 1.5.4 Competition between Air and Atmosphere Moisture |
| 1.5.5 Peroxide Formation |
| 1.6 Reactivity with Water |
| 1.6.1 Water Reactivity: Fast and Slow Reactions |
| 1.6.2 Water-Reactive Structures |
| 1.7 Reactivity with Other Common Substances |
| 1.7.1 Reactions with Metals |
| 1.7.2 Surface Area Effects |
| 1.7.3 Catalyst Deactivation and Surface Passivation |
| 1.8 Reactive with Other Chemicals Incompatibility |
| 1.8.1 Oxidizing and Reducing Properties |
| 1.8.2 Acidic and basic Properties |
| 1.8.3 Formation of Unstable Materials |
| 1.8.4 Thermite-Type Reactions |
| 1.8.5 Incompatibility with Heat Transfer Fluids and Refrigerants |
| 1.8.6 Adsorbents |
| References |
| 2 Chemical Reactivity Classifications |
| 2.1 NFPA Reactivity Hazard Signal |
| 2.1.1 NFPA 704 Rating System for Overall Reactivity |
| 2.1.2 Definitions for Reactivity Signal Ratings |
| 2.1.3 Reactivity Hazards Not Identified by NFPA 704 |
| 2.1.4 NFPA Reactivity Ratings for Specific Chemicals |
| 2.2 NPCA Hazardous Materials Identification System |
| 2.3 Classifications of Organic Peroxides |
| 2.3.1 SPI 19A Classification of Organic Peroxides |
| 2.3.2 NFPA 43B Classification of Organic Peroxides |
| 2.4 Classification of Materials That Form Peroxides |
| 2.5 Classification of Water-Reactive Materials |
| 2.5.1 Materials That React Violently with Water |
| 2.5.2 Materials That React Slowly with Water |
| References |
| 3 Materials Assessment |
| 3.1 Prior Experience Review |
| 3.1.1 Common Knowledge |
| 3.1.2 Analogy |
| 3.1.3 Safety Data and Literature |
| 3.2 Theoretical Evaluations |
| 3.2.1 Unstable Atomic Groups |
| 3.2.2 Oxygen Balance |
| 3.2.3 Thermodynamics: Heat of |
| 3.2.4 Thermodynamics: Heats of Reaction and Self-Reaction |
| 3.2.5 Thermodynamics: Equilibrium Considerations |
| 3.2.6 CHETAH |
| 3.2.7 Example Evaluation |
| 3.3 Expert Determination |
| 3.3.1 Expert Committees |
| 3.3.2 Kinetics Determination Factors |
| 3.4 Reactivity Screening Tests |
| 3.4.1 Thermal Stability Screening Tests |
| 3.4.2 Shock Sensitivity Screening |
| 3.4.3 Pyrophoricity Screening |
| 3.4.4 Water Reactivity Screening |
| 3.4.5 Peroxide Formation Screening |
| 3.4.6 Compatibility Screening |
| References |
| 4 Consequence Analysis |
| 4.1 Identifying Potential Accident Scenarios |
| 4.1.1 Process Hazard Analysis |
| 4.1.2 Checklist of Potentially Hazardous Events |
| 4.1.3 Chemical Interaction Matrix |
| 4.1.4 Industry Experience |
| 4.1.5 Local Size Experience |
| 4.2 Severity Testing |
| 4.2.1 Calorimetric Testing for Consequence Analysis |
| 4.2.2 Self-Accelerating Decomposition Temperature |
| 4.2.3 Isoperibolic Calorimetry |
| 4.2.4 Assessment of Maximum Pr |
