Guidelines for process safety in batch reaction systems

Preface Acknowledgments Acronyms and Abbreviations 1 Process Safety in Batch Reaction Systems 1.1. Scope 1.2. Special Concerns of Batch Reaction Systems 1.3. Approach Used in Guidelines 2 Chemistry 2.1. Introduction 2.2. Case Study 2.3. Key Issues 2.4. Process Safety Practices Table 2: Chemistry Appendix 2A. Chemical Reactivity Hazards Screening A. 1. Understand the Problem A.2. Conduct Theoretical Screening A.3. Conduct Experimental Screening A.4. Conduct Experimental Analysis 1 2 3 7 8 9 9 11 21 21 21 23 25 vii ... Vlll CONTENTS 3 Equipment Configuration and Layout .IyIILIAIIRIy 3.1. Introduction 3.2. Case Studies Pump Leak Incidents Tank Farm Fire 3.3. Key Issues 3.4. Process Safety Practices Table 3: Equipment Configuration and Layout 4 ~~ Equipment 4.1. Introduction Vessels Including Reactors and Storage Vessels Centrifuges Dryers Batch Distillation Columns and Evaporators Process Vents and Drains Charging and Transferring Equipment Drumming Equipment Milling Equipment Filters Batch Pharmaceutical Reactor Accident Seveso Runaway Reaction Pharmaceutical Powder Dryer Fire and Explosion 4.2. Case Studies 4.3. Key Issues 4.4. Process Safety Practices Table 4.0: General Table 4.1: Reactors and Vessels Table 4.2: Centrifuges Table 4.3: Dryers Table 4.4: Batch Distillation and Evaporation Table 4.5: Process Vents and Drains 27 28 28 28 29 29 30 35 35 36 38 39 40 40 41 41 42 42 43 43 44 44 45 45 48 54 64 70 73 75 Contents ix Table 4.6: Transferring and Charging Equipment Table 4.7: Drumming Equipment Table 4.8: Milling Equipment Table 4.9: Filters Appendix 4A. Storage and Warehousing 5 InstrumentationlControl Systems 5.1. Introtluction 5.2. Case Study 5.3. Key Issues 5.4. Process Safety Practices Table 5: InstrumentatiodControl Systems Operations and Procedures 6.1. Introduction 6.2. Case Studies Initiator Overcharging Incident Reactant Stratification Incident 6.3. Key Issues 6.4. Process Safety Practices Table 6: Operations and Procedures References Glossary 76 90 96 100 105 109 112 113 114 115 125 129 129 130 13 1 131 132 143 159