Reactive Chemical Screening and Reactivity Testing
We run screening test programmes that characterise reactive hazards
Reactive Chemical Screening
and Reactivity Testing
A large share of serious chemical incidents trace back to reactivity that was never recognised, whether an unstable intermediate, an incompatible combination, a water reactive solid or a slow self heating that only matters at drum or reactor scale. Reactive screening is the deliberately inexpensive early gate that surfaces this energy before you encounter it at scale. It uses structured laboratory protocols that probe exothermic onset, decomposition energy, water and air reactivity and binary incompatibility across the materials your process actually handles. We run the screening tier using DSC, Carius tube and mixing cell methods and read it against the Bretherick and Yoshida reactivity literature and CCPS reactive chemicals criteria, so what you receive is not raw thermograms but actionable decisions covering safe handling and storage segregation, where deeper adiabatic testing is warranted and the thermal margins your process design must respect.
How the study is executed
A structured, facilitated process that runs from scope definition through close out and produces defensible, actionable outputs.
Conduct literature screening per CCPS Reactive Chemicals, Bretherick's Handbook, Yoshida structural alerts, NOAA Chemical Reactivity Worksheet, identify reactive functional groups (peroxide, azide, nitro, diazo, acetylide, fulminate).
Apply CHETAH (Chemical Thermodynamic and Energy Hazard) algorithm, calculate maximum decomposition heat (ΔHdec), oxygen balance, and energy release index, align with ASTM CHETAH protocol and CCPS guidance.
Conduct DSC per ASTM E537 / E2046 with controlled atmosphere (N₂ / air / O₂), temperature ramp 5 to 10°C/min, identify exothermic onset, peak, and energy release, align with EFCE / IChemE screening protocol.
Conduct binary compatibility screening for each material pair in intentional contact or credible mixing scenarios, align with OSHA PSM Process Safety Information / CCPS Inherent Safer Reactive Hazard avoidance.
Classify material per Stoessel scenario class (1 to 5) and CCPS Reactive Chemicals hazard tier, risk rank for further testing (calorimetry, RC1 reactor, vent sizing), align with OSHA PSM Reactive Hazard programme.
Compile reactive screening dossier with literature review, CHETAH output, DSC trace, compatibility matrix, integrate with Reactive Hazard Programme, HAZOP / SIL allocation, and OSHA PSM Process Safety Information.
What the study covers in full
Outcomes of Reactive Chemical Screening and Reactivity Testing
- We identify reactive hazards before they cause incidents
- We define safe handling and storage conditions
- We drive management of change for new chemical introductions
- We support incident investigation forensics
- We align with CCPS reactive chemical guidance
- We support OSHA PSM reactive hazard programmes
- We document the UN classification basis
- We produce work that holds up under regulator review
- We harden management of change for chemical introduction
- We improve storage segregation discipline
- We reduce inadvertent mixing incidents
- We support operator training on reactive risk
- We help you avoid catastrophic reactive incidents
- We reduce insurance loadings on reactive inventories
- We target segregation capital where it matters
- We support safer chemical substitution decisions
Codes & standards we work to
Triggers that signal the need
Where Reactive Chemical Screening and Reactivity Testing applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- Reactive screening test report
- Incompatibility matrix
- Water reactivity assessment
- Hazard ranking and recommendations
- Safe storage and handling guidance
- Management of change input data
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.