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Hazardous Process Technology

High risk chemistry engineering — reactive systems, thermal hazard evaluation, runaway studies, and safe scale up.

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Strategic context

Why hazardous process technology matters

Hazardous Process Technology is the discipline for chemistry that the conventional engineering codebook does not adequately cover — runaway reactions, hydrogenation, nitration, chlorination, oxidation, cryogenic processing, toxic gas handling, and high-hazard storage. The work integrates calorimetric basis (DSC, ARC, VSP2, Stoessel), DIERS vent sizing, reactor engineering (heat removal, mixing intensity), MSIHC / SMPV(U) / Gas Cylinder Rules compliance, and the ISD lens that converts hazardous batch chemistry into inherently safer continuous-flow or intensified routes wherever it is economic to do so.

Hazardous Process Technology
Capabilities

Hazardous Process Technology capabilities

High hazard process conceptualization & BEP developmentView detail page →
Reactive chemistry & thermal hazard engineeringView detail page →
Runaway reaction & calorimetry supportView detail page →
Hydrogenation, Nitration, Chlorination, Oxidation safetyView detail page →
Cryogenic process safety engineeringView detail page →
Toxic gas handling system engineeringView detail page →
Hazardous chemical storage designView detail page →
Safe scale-up & pilot plant safety evaluationView detail page →
Engagement model

How we deliver

A phased, evidence-led delivery model — from discovery through close-out — built around your facility, regulatory context, and lifecycle stage.

Chemistry Hazard Profile
Calorimetric basis from DSC / ARC / VSP2; Stoessel scenario classification (Class 1–5); reactive / thermal hazard register per CCPS Reactive Chemicals.
Reactor & Process Engineering
Heat-removal capability vs adiabatic temperature rise, mixing time, residence time distribution; cooling philosophy (jacket, coil, external HX, vaporisation).
Relief & Emergency Cooling
DIERS-sized emergency relief with two-phase flow regime, kill-system / quench / scrubber design, knock-out and catch-tank specification.
Operating Envelope & BEP
MTSR, IOW per API RP 584, BEP authoring covering normal / abnormal / emergency response; integration with HAZOP and SIL allocation.
Scale-Up & Knowledge Transfer
Pilot-run validation with calorimetric verification, R&D-to-operations handover, ICH Q9 / FDA / GMP-compliant documentation for pharma applications.
Outcomes & value

What this service delivers

  • T2 Labs / Concept Sciences-class runaway pattern engineered out before scale-up
  • Vent-sized to DIERS without over-protection cost burden
  • Cryogenic system meeting BS EN 1473 / API 625 / PESO concurrently
  • MSIHC-defensible toxic gas handling with credible-worst-case scrubbing
  • Pilot-to-commercial scale-up package surviving FDA / EMA inspection
Why Arborion

Our differentiators

  • Embedded calorimetric basis from accredited testing partners
  • DIERS-certified vent-sizing capability with two-phase flow rigour
  • MSIHC / SMPV(U) / PESO India fluency with UN TDG / CEFIC overlay
  • Process intensification evaluation as a default ISD step
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