Chemical Reactivity Hazards

Chemical reactivity hazards still exist even if a plant doesn’t intentionally run chemical reactions. Chemical reactivity hazards can be manifest through: 

  • Materials which become chemically unstable for a variety of reasons,
  • Intended chemical reactions that get out of control for a variety of reasons
  • Unintended chemical reactions that take place due to accidental mixing of chemicals that are normally separate

Read Reactive Material Hazards, What You Need to Know, and explore other resources below.

Update of the Activities of the NOx Safety Task Group

AIChE Spring Meeting and Global Congress on Process Safety
May 1, 2013
The initial AIChE Task Group for NOx Safety was set up following a disclosure of significant accumulations of the NOx compound, N 2 O 3, in an...

Flammable Vapor Explosion At Dupont Yerkes Facility

AIChE Spring Meeting and Global Congress on Process Safety
Apr 30, 2013
This case study examines a November 9, 2010, explosion at an E.I. duPont de Nemours and Co. Inc., Yerkes chemical plant in Buffalo, New York when a...

Troubleshooting a Furnace Emissions Problem

AIChE Spring Meeting and Global Congress on Process Safety
Apr 30, 2013
We had been fighting CO flue gas emissions on our CEMS analyzer for around a year, we had indications that it was a burner problem, fixed the burners...

Near Misses - Private or Public Concern?

AIChE Spring Meeting and Global Congress on Process Safety
Apr 29, 2013
Near miss incidents include those releases and/or fires that do not result in significant employee injury or costs. In many cases there are federal...

Emergency Block Valves

AIChE Spring Meeting and Global Congress on Process Safety
Apr 4, 2012
An Emergency Block Valves (EBV) is used as a means of isolating flammable or toxic substances in the event of a leak or fire. The installation, and...

Prediction of Corrosion in Pipes

Global Congress on Process Safety
Apr 2, 2012
ABSTRACT AIChE Spring 2012 Meeting Prediction of Corrosion in Pipes Sally Nicola, Victor Carreto, Ray A. Mentzer, M. Sam Mannan Mary Kay O'Connor...

The CCPS Reactivity Evaluation Software Tool

Global Congress on Process Safety
Apr 2, 2012
Incidents involving uncontrolled chemical reactions continue to result in injuries, fatalities and economic loss and harm in industry. These...

Flame Flashbacks: Causes and Prevention

AIChE Webinar
Apr 7, 2010
This webinar addresses the principle of flammability of vapor/air mixtures, including flammability limits, ignition temperatures, the effect of...

Assessing the Burning Rate of Solid Oxidizers

Global Congress on Process Safety
Mar 21, 2010
A method for assigning solid oxidizers and products containing oxidizers to an NFPA Class was developed. The method consists of two reaction-to-fire...

Dust Explosions

AIChE Webinar
Jun 24, 2009
Catastrophic dust explosions in 2003 and 2008 have placed an increased emphasis on the prevention and mitigation of dust explosions. In response to...

Explosion Prevention and Mitigation

Global Congress on Process Safety
Apr 30, 2009
The analysis, prevention, protection and mitigation of fire, explosion, and reactivity hazards continue to be important to the loss prevention...

Case Histories and Lessons Learned

Global Congress on Process Safety
Apr 29, 2009
Reviews of process safety incidents and near misses provide valuable learning opportunities. Papers dealing with incidents, near misses, and the...

Fires, Explosions and Reactive Chemicals

Global Congress on Process Safety
Apr 27, 2009
The analysis, prevention, protection and mitigation of fire, explosion, and reactivity hazards continue to be important to the loss prevention...

Introduction to Flammable Materials

AIChE Webinar
Feb 17, 2009
This webinar will provide a basic introduction to flammable materials with the purpose of providing valuable information that a practicing engineer...

Chemical Reactivity Hazards

eLearning (online) Course
Chemical Reactivity Hazards is a web-based SAChE module that shows how uncontrolled chemical reactions can lead to serious harm.

Chemical Reactivity Hazard Training CD-ROM

May, 2006
The Chemical Reactivity Hazards CD is a self-paced teaching tool intended to teach people how to recognize and manage reactive chemical hazards. It provides an introduction to the topic and many online links to additional resources. The CD has three main objectives: Introduce reactive chemical...

Guidelines for Safe Handling of Powders and Bulk Solids

November, 2004
Powders and bulk solids, handled widely in the chemical, pharmaceutical, agriculture, smelting, and other industries present unique fire, explosion, and toxicity hazards. Indeed, substances which are practically inert in consolidated form may become quite hazardous when converted to powders and...

Understanding Explosions

July, 2003
There are many different types of explosions, each with its own complex mechanism. Understanding explosions is important in preventing them. This reference provides valuable information on explosions for everyone involved in the operation, design, maintenance, and management of chemical processes,...

Essential Practices for Managing Chemical Reactivity Hazards

March, 2003
In its recent investigation of chemical reactivity accidents, the US Chemical Safety Board noted a gap in technical guidance and regulatory coverage. This volume closes the gap in technical guidance, helping small and large companies alike identify, address, and manage chemical reactivity hazards...

Guidelines for Safe Warehousing of Chemicals

June, 1998
A comprehensive understanding of the potential dangers inherent in warehousing chemicals is the first step in managing the associated risks. Written by industry professionals for warehouse operators, designers, and all who are concerned with the safe warehousing of chemicals, this book offers a...

Guidelines for Safe Storage and Handling of Reactive Materials

September, 1995
With new and growing interest in dealing with the hazards of reactive chemicals, this book offers guidelines that can significantly reduce the risk or mitigate the severity of accidents associated with storing and handling reactive materials. Necessary elements of a reliable system to prevent...

Guidelines for Chemical Reactivity Evaluation and Application to Process Design

April, 1995
Drawn from international sources, this book provides principles and strategies for the evaluation of chemical reactions, and for using this information in process design and management. A useful resource for engineers who design, start-up, operate, and manage chemical and petrochemical plants, the...

Avoid Chemical Reactivity Incidents in Warehouses

J. Wayne Chastain, William W. Doerr, Scott Berger and Peter N. Lodal, Peter Lodal, Scott Berger
Use this approach for the initial evaluation of potential reactivity hazards in storage applications.

Managing Dust Explosion Hazards

Vahid Ebadat
Companies that handle powders or other particulate solids need to be aware of the potential for fire and explosions, and follow industry best practices, codes and standards to manage the risk.

Classifying Reactive Chemicals

M. Sam Mannan, Sanjeev R. Saraf, William J. Rogers
This simple classification scheme can be used to characterize the thermal instability risks posed by reactive chemicals in a process.

Addressing the Hazards of Data Omission from MSDSs

James C. Mulligan
If certain chemicals lack physical hazards data, suppliers must be proactive to keep workers safe. Here’s how to determine dust flammability and reactivity data for inclusion on MSDSs.

Screening Reactive Chemical Hazards

Yen-Shan Liu
Use these tools to identify potentially reactive chemical hazards and avoid the expense of conducting numerous detailed hazard assessments.

Understanding Reactive Chemical Incidents

John F.  Murphy
In order to avoid incidents involving reactive chemical hazards, it is useful to understand the types of chemicals and types of equipment involved, as well as the root causes of the incidents.

Decoding Safety Data Sheets

Ronald J. Willey
A safety data sheet holds a wealth of information that can help you safely and effectively handle chemicals in the lab, at the pilot scale, and on the production floor.

Dow's Chemical Exposure Index Guide, 1st Edition

August, 1998
Dow Chemical developed the Chemical Exposure Index to help its engineers design and operate safer facilities. This seminal guide to rating the relative acute health hazard potential of a chemical release to workers and the neighboring community is available to the chemical process community. The...
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