Hazard Identification and Risk Analysis
From time to time, plants and facilities in every industry of manufacturing or production will need some sort of testing and engineering consulting services to identify hazards related to the handling or storage of flammable and combustible liquids and gases, combustible dust and reactive chemicals.
When a process is new, moved to a larger scale, or has never been studied, a reaction calorimetry study should be completed on the desired chemistry to understand how it should be properly handled. The过程危害分析（PHA）identifies potential hazards associated with a material. If there are any questions about material behavior, then testing is needed.
丰富的测试经验使一个团队可以识别可能不容易辨别的潜在危险条件。使用一组的好处包括：
Understand and address hazards that pose the highest level of risk to your process facility
确保遵守相关的国家，地方和行业标准
实施最佳工程实践
Reduce overall level of risk
提高生产力和员工士气
Make organization more competitive
降低保险费
A comprehensive engineering testing lab will offer services for safer scaling up of batch, semi-batch and continuous processes. Consultation is available for process development groups involved throughout the development cycle. Areas of expertise include the following topics:
- Onsite or desktop review
- 确定关键过程参数，以避免或减轻不良反应性
- Development of customized scale-up program designed for safer operation at various stages
- Perform calorimetry testing to characterize desired and undesired reactions
- Identify safe operating limits for temperature, pressure and other safety-critical parameters
- Emergency relief design calculations for pilot plant, kilo lab and commercial scale equipment
- Independent safety assessment,
绝热量热仪测试提供了浮雕系统设计的数据，化学过程的安全规模以及处理配方的变化。安全过程设计需要了解化学反应速率，特征和能量释放 - 所有这些都可以从低PHI因素绝热量热量（例如VSP2™（排气尺寸套件2）或ARSST™（高级反应性系统筛选工具）中获得。。
的VSP2™和ARSST™- both developed by Fauske & Associates, LLC (FAI) as the principal research contractor for the Design Institute for Emergency Relief Systems (DIERS) under AIChE - provide thermal data required for safe scaling up of chemical processes and changes to process recipes. A variety of process upset conditions can be tested to quantify hazards identified by a Process Hazards Analysis or HAZOP study. The low phi-factor (or thermal inertia) allows the heat and gas generation rates to be measured and directly applied to the process scale, which leads to appropriately designed emergency relief systems.
Reaction Calorimetry
的关键之一安全地扩大化学公关ocess is managing the energy or heat flux that the intended chemical reaction produces, especially when that chemical transformation is exothermic in nature. When considering process scaling up whether the heat is removed via a jacket, a condenser, or a side loop heat exchanger in the plant reactor or partially allowed to heat up the mass, it is imperative to balance the cooling capacity at scale versus the projected heat flux rate and understand the total energy available due to the desired reaction should that cooling fail. The accepted technique for gathering this type of data in the industry is known as reaction calorimetry.
多年来，已经开发了许多仪器来完成这项任务，而FAI等全面的实验室维护了各种设备，因此我们可以设计最合适的实验，以收集至关重要的热量和安全扩展所需的绝热潜在数据。将此与巨大的经验相结合，可以使用绝热和排气尺寸的量热法表征失控的反应行为，我们提供了安全化学过程的完整图片。
热稳定性
Thermal stability testing aims at collecting reaction rate data and applying that data to assess whether a specified quantity of material can be used in a way such that runaway reactions are avoided. This is important when considering processing, long-term storage, or shipping of a material.
A variety of instruments and tools can be used to characterize the thermal stability of a material:
- 差扫描量热法（DSC）
- Thermogravimetric Analysis (TGA)
- Accelerating Rate Calorimetry (ARC)
- Thermal Activity Monitor (TAM)
- AKTS-Thermokinetics Software
- 高级反应系统筛选工具（ARSST）
- Vent Sizing Package 2 (VSP2)
- C80 Calorimeter manufactured by Setaram
准确确定安全参数：
- 开始温度
- Kinetic Parameters
- Time to Maximum Rate
- Critical Temperature / Temperature of No Return
- 自加速分解温度
Process Hazards Analysis (PHA)
A PHA is a systematic evaluation of the hazards involved in the process. They are required for initiation of a process and at least once every five years after that. It is important to address normal operating conditions as well as start-up, normal shut down and emergency shutdown procedures during the PHA. The team should be multi-disciplinary, including operations, engineering and maintenance. To properly conduct a Process Hazards Analysis, the process safety information (PSI) must be as complete as possible. FAI provides services including auditing / review, revalidating and facilitating.FAI has performed PHAs for compliance to OSHA PSM requirements as well as combustible dust related for compliance per national National Fire Protection Association (NFPA) guidelines: NFPA 654, NFPA 664 and NFPA 484. Using a variety of techniques including, hazard and operability (HAZOP) analysis, what-if, checklists, failure modes and effects analysis (FMEA) as well as quantitative risk assessments such as layer of protection analysis (LOPA), FAI provides a full range of services.
Process Safety Management (PSM) Program Development and Support
A one-stop engineering and lab firm can review or develop process safety programs to support chemical manufacturing facilities or development programs. This can be performed for facilities including a kilo lab, pilot plant, medium scale and commercial scale plants. Services include:
- 审计，报告和介绍
- Gap assessment to identify and prioritize needs
- 流程验证
- 安全扩大指导
- Development report documentation
- Consulting on process safety issues for change control (management of change)
有关安全过程规模规模或过程安全的更多信息，请联系信息@fauske.comor 630-323-8750
