HAZARD: A condition or action that has the potential for an unplanned release of, or unwanted contact with, a chemical

or energy source that may result in harm or injury to people, property, or the environment. Identify hazards at your workplace, analyzing each energy source with the Hazard Identification Tool. Gravity: The force caused by the attraction of all other masses to the mass of the earth. Examples: a falling object, a collapsing roof, a body tripping or falling Motion: The change in position of objects or substances. Examples: vehicle, vessel or equipment movement, flowing water, wind, body positioning: lifting, straining, or bending Mechanical: The energy of the components of a mechanical system, i.e. rotation, vibration, motion, etc. within otherwise stationary piece of equipment/machinery. Examples: rotating equipment, compressed springs, drive belts, conveyors, motors Electrical: The presence and flow of an electric charge. Examples: power line, transformers, static charge, lightning, energized equipment, wiring, batteries. Pressure: Energy applied by a liquid or gas which has been compressed or is under a vacuum. Examples: pressure piping, compressed gas cylinders, control lines, vessels, tanks, hoses, pneumatic and hydraulic equipment Temperature: The measurement of differences in the thermal energy of objects or the environment, which the human body senses as either heat or cold. Examples: open flame and ignition sources, hot or cold surface, liquids or gases, hot work, friction, general environmental conditions, steam, extreme and changing weather conditions Chemical: The energy present in chemicals that inherently, or through reaction, has the potential to create a physical or health hazards to people, equipment, or the environment. Examples: flammable vapors, reactive hazards, carcinogens or other toxic compounds, corrosives, pyrophorics, combustibles, inert gas, welding fumes, dusts Biological: Living organisms that can present a hazard. Examples: animals, bacteria, viruses, insects, blood-borne pathogens, improperly handled food, contaminated water Radiation: The energy emitted from radioactive elements, or sources, and naturally occurring radioactive materials. Sound: Sound is produced when a force causes an object or substance to vibratethe energy is transferred through the substance in waves Controls/Barriers * Remove energy source Prevent release Protect from release Stop Work Authority + Interactions * Chemical & Gravity Temperature and Chemical Sound and Motion Gravity and Motion] Inherently Safer Processes: A chemical manufacturing process is INHERENTLY SAFER if it reduces or eliminates the hazards associated with materials and operations used in the process, and this reduction or elimination is permanent and inseparable. The Four Elements of Inherent Safety are:[ 1. Intensification / Minimization 2. Substitution / Elimination 3. Attenuation / Moderation (Limitation of Effects) 4. Simplification / Error Tolerance] Where possible, you should first eliminate or reduce hazards by inherently safer design. For example: replace hazardous materials with safer ones: - have less unreacted material in the reactor, eg using a continuous process instead of a batch reactor: use a semi -batch method (in which one of the raw materials is added over time) instead of a batch process; and/or.- use a heating medium which has a maximum temperature that is too low for the reaction mixture to decompose. Runaway Reaction: Thermal runaway can occur because, as the temperature increases, the rate at which heat is removed increases linearly but the rate at which heat is produced increases exponentially. Once control of the reaction is lost, temperature can rise rapidly leaving little time for correction. The reaction vessel may be at risk from overpressurization due to violent boiling or rapid gas generation. The elevated temperatures may initiate secondary, more hazardous runaways or decompositions. The scale on which you carry out a reaction can have a significant effect on the likelihood of runaway. The heat produced increases with the volume of the reaction mixture, whereas the heat removed depends on the surface area available for heat transfer. As it scales, the ratio of volume to surface area, increases, cooling may become inadequate. Additional reaction mechanism can be initiated due to increase in temperature. Improper mixing or impr oper order of chemical addition can increase rate of reaction Requires a thorough understanding of the chemistry and energy pr oduction. What Causes Runaway Reaction inadequate understanding of the process chemistry and thermochemistry; inadequate design for heat removal; inadequate control systems and safety systems; and inadequate operational procedures, including training. Assessment of Reactive Hazards understand the possibility of thermal decomposition of raw materials, intermediates, products and by-products; Determine whether exothermic runaway can occur Evaluate the rate and quantity of heat and gas produced by t he reaction Consider the margins of operation that could initiate a runaway chem rxn. Determining Proper Scale: It is not safe to test unknown reactions in a full-size reactor, various techniques and tests have been developed to provide predictive data. The main methods are: literature data and calculation, to give preliminary information; basic screening tests, such as differential scanning calorimetry or carius tube; isothermal calorimetry (mai nly to measure reaction kinetics and heats of reaction); adiabatic calorimetry (mainly to examine runaways); and relief vent sizing tests. 90% of reactive hazard ac cidents have been covered in existing literature and reports