Hazardous Process Technology

It is the discipline for chemistry that the conventional engineering codebook does not adequately cover, including runaway reactions, hydrogenation, nitration, chlorination, oxidation, cryogenic processing, toxic gas handling and high hazard storage. We work through your reactive systems, thermal hazards and the physics of scale up so you can take demanding processes from concept to commercial production with the hazards properly controlled.

We establish a calorimetric basis from DSC, ARC and VSP2, classify the scenarios after Stoessel across Classes 1 to 5 and build a reactive and thermal hazard register to the CCPS Reactive Chemicals Guidelines. We then compare the reactor heat removal capability against the adiabatic temperature rise, define the cooling philosophy and design the DIERS sized emergency relief, kill system, quench and scrubber for the two phase flow regime.

We work to the AIChE DIERS Project methodology, Stoessel reaction hazard classification, the CCPS Reactive Chemicals Guidelines, and BS EN 1473, NFPA 59A and API 625 for cryogenic systems. For India we apply the MSIHC Rules 1989, the SMPV(U) Rules 2016 and the Gas Cylinder Rules 2016 alongside the PESO certification regime and the UN Manual of Tests and Criteria.

You receive a chemistry hazard profile and reactive hazard register, a reactor and cooling design engineered against the adiabatic temperature rise, DIERS sized relief without an over protection cost burden, a defined operating envelope with integrity operating windows, and a basic engineering package integrated with HAZOP and SIL allocation. For pharma applications the scale up documentation is prepared to ICH Q9, FDA and GMP expectations.

It applies to specialty and fine chemicals, pharmaceuticals and API, energetic and explosive materials, hydrogen production and fuelling, LNG and cryogenic gas storage, and polymer and resin manufacturing. Wherever it is economic we evaluate process intensification to convert hazardous batch chemistry into inherently safer continuous flow or intensified routes.