Guidance on Safety/Health for Process Intensification including MS Design; Part II: Explosion Hazards

Abstract

The implementation of process intensification by multiscale equipment will have a profound impact on the way chemicals are produced. The shift to higher space‐time yields for partial oxidation processes using micro‐designed reactors comprises the risk of having a permanent explosive atmosphere in the reaction section. In Part I, it was concluded that spontaneous reaction with hot spots can be presumed if highly exothermic reactions were performed and may cause ignition of an explosive atmosphere. The risk analysis of the situation, based on public information in the literature, leads to the conclusion that microreactors are inherently safe regarding the initiation and propagation of an explosion inside a microchannel by an uncontrolled reaction. The situation is the opposite when a propagating explosion enters the same micro‐designed reactor from one of the outside openings. The external explosion may enter the micro‐designed equipment and destroy it when the same starting conditions are present.

Guidance on Safety/Health for Process Intensification Including MS Design. Part III: Risk Analysis

“…Part II on explosion hazards [4] concludes: The shift to higher space-time-yields for partial oxidation processes with gaseous oxidizers creates the risk of a permanent explosive atmosphere in the mixing section and the reaction section. Higher reaction temperatures, higher pressure and more active catalysts to obtain the same conversion rates at a reduced residence time are other challenges of the new technology.…”

“…reaction mixtures of oxidizing substances and organic substances that may detonate or are prone to explode in close to stoichiometric mixing ratios The hazard of an external explosion originating in adjoining apparatus entering the micro-designed equipment is not considered in this study. In this case, major damage of equipment is highly probable so that all efforts should be focused on identifying potential ignition sources and ignition prevention (see Part II [4]). …”

“…Table 1. Overview on structure of the "guidance on safety/health for process intensification including MS design" (IMPULSE [2], Parts I and II [3,4]). MS technology in general reduces risks of major accidents due to the reduction in mass in critical process steps (e.g.…”

“…In Part II: "Explosion Hazards" of the "Guidance on Safety/ Health for Process Intensification Including MS Design" [4], the consequences of the shift to higher space-time-yields for partial oxidation processes by the use of micro-structured reactors were analyzed.…”

Beyond Organometallic Flow Chemistry: The Principles Behind the Use of Continuous-Flow Reactors for Synthesis

“…in catalyst beds, 147 which can serve as an ignition source. [148][149][150][151] Surface effects are also important as they can initiate the decomposition of compounds, e.g. steel reactors can initiate radical formation.…”