CHEMICAL REACTION HAZARDS AND
THE RISK OF THERMAL RUNAWAY
IDENTIFICATION OF HAZARDS AND MITIGATION STRATEGIES
March 31, 2011
Residence Inn Raleigh-Durham Airport
2020 Hospitality Court, Morrisville, NC 27560
November 11, 2011
Residence Inn by Marriott San Diego Downtown
1747 Pacific Highway, San Diego, CA 92101
Chilworth Technology, Inc. has been approved as an Authorized Provider by the International Association for
Continuing Education and Training (IACET), 1760 Old Meadow Road, Suite 500, McLean, VA 22102; (703) 506-3275.
Chemical Reaction Hazards and the Risk of Thermal Runaway
A 1 day seminar for research chemists and process engineers presented by Chilworth Global
Chilworth Global has international consulting bases and laboratory testing facilities in the
USA, UK, France, India, Italy, and Spain with state of the art dust explosion and electrostatic
laboratories (with low humidity facility), and a specialist laboratory for the evaluation of
thermal runaway reactions. Chilworth’s goal is to provide services to business and industry
to help identify, characterize, prevent, and mitigate potential fire, explosion, and thermal
instability (runaway reaction) hazards in their processes by providing expert independent
consulting, specialist laboratory testing and process safety training. Our laboratories are
ISO-IEC 17025 accredited as well as GLP compliant.
Chilworth employs a Doctorate Engineering and Scientific staff along with Graduate
Engineers, Scientists and Technicians. Our senior consultants are internationally recognized
experts in their specialist fields, and many have served on national and international
The client base of Chilworth Technology covers more than 20 countries, and includes
manufacturing companies in the fine chemicals/pharmaceuticals, bulk organics, food stuffs,
paints, resins/plastics, dyestuffs, pigments, agrochemicals, soaps/detergents,
oil/petrochemicals, and the legal and insurance fields.
For further information telephone 1 609 799 4449; or email to email@example.com or visit
Chemical reactions can be extremely hazardous if they are not thoroughly understood and
controlled. When intentional or unintentional reactions get out of control, they can result in
fires, explosion, or release of toxic fumes or gases.
1998 Morton International, explosion and fire – runaway reaction
1999 Concept Sciences, Inc., hydroxylamine explosion, 4 fatalities
2004 MFG Chemical, Inc., toxic gas release, 154 hospitalized
Synthron LLC, chemical explosion, 1 fatality and many injured
Incidents such as these give a grim reminder as to the hazards and risks associated with
manufacturing products that we take for granted. Chemical manufacturing and their
personnel have an obligation to society, let alone any legislative requirement, to design and
develop safe chemical processes. Unfortunately the education system in the US does not
provide sufficient grounding for engineers and scientists to adequately address reaction
hazard assessment at a level necessary to protect our society.
The course presents the ‘current best practice’ in the field making use of extensive case
studies to illustrate the many of key points in the field. Delegates will participate in workshops
emphasizing critical areas of the subject. We will also consider peripheral areas of reactive
chemical hazards such as safe powder drying and the ignition of flammable gases and
vapors, giving a good background and understanding in the subjects.
Dr. Swati Umbrajkar (Ph.D., ASME, AIChE)
Swati Umbrajkar, Ph.D. is the Manager of the Chemical Process Evaluation Group. Dr.
Umbrajkar received her Doctorate from the New Jersey Institute of Technology.
Dr. Umbrajkar consults with clients on a variety of process safety issues including but not
limited to high-pressure DSC cell tests, adiabatic calorimetry (ARC and ADC), reaction
calorimetry (RC-1), all of which allow for the safe scale-up of batch and semi-batch
processes. She has expertise in determining self-acceleration decomposition temperature
(SADT) and time to maximum rate (TMR), which are critical issues associated with the
storage of bulk materials. As the Manager and Consultant in the Chemical Process
Evaluations Laboratory, she is proficient in the interpretation of data for a wide variety of
process safety scenarios. She has authored several articles in the fields of, 'Synthesis and
Analysis of Highly Energetic Materials' and ‘Chemical Process Safety’.
She received the Excellence Award from NASA for her services in NASA’s SHARP student
program in 2005 and Research Experience for Undergraduate (REU) students at the New
Jersey Center for Engineered Particulates (NJCEP) in 2006. She was awarded the Best
Graduate Student Research Overall presented at the Graduate Student Research Day on
November 6, 2006.
She is also the recipient of the ‘best presenter’ award at the AIAA (American Institute of
Aeronautics and Astronautics) Young Professionals in Science and Engineering Conference
(Northeast Section) in November 2006. She is a member of the American Institute of
Who should attend?
This course is designed for the following personnel:
Scientists and engineers working in chemical processing and manufacture with the
necessary tools to develop robust risk assessment techniques, and enable the
industry to improve its safety record.
Technical personnel from Engineering, Operations, Maintenance, and Safety who are
responsible for developing and implementing the Chemical Processing Elements.
What You Will Gain
UNDERSTAND the various concepts of Chemical Reaction Hazards
OBSERVE the most significant process safety related disasters that illustrate the
need to understand CRH
LEARN the key elements of CRH for efficient implementation and effective
DISCOVER the best practices of industry in CRH implementation
PREVENT potential disasters with CRH management techniques
REVIEW some of the selected advanced topics of CRH
Chemical Reaction Hazards and the Risk of Thermal Runaway
COURSE DESIGN AND OBJECTIVES
The risk analysis of reactive systems is an essential tool to ensure safety prior to process operations.
Reaction study provides an insight into the complex interaction of a wide range of factors that influence the
probability and consequences of undesired safety incidents involving chemical reaction, energies, equipment,
personnel and productivity. This course will benefit attendees from a broad spectrum of backgrounds and job
responsibilities including chemical engineers, process engineers/scientists, plant/process safety/risk
managers, facilities managers and all others who need to be aware of the risks and hazards that can lead to
accidents, injuries, property damage and business interruptions to the plant.
The course will help the attendees assess chemical reactivity by
Use of Chemical Engineering Principles to study the potential runaway reactions for storage and
reactor risk assessments
Performing risk analysis of chemical processes
Development of inherently safer processes
In general this course is designed to identify and recognize the thermal and chemical reactivity hazards
associated with a chemical process based on the principles of scale-up and development. The participants
will be able to decipher the results of the preliminary screening tests by using the chemical engineering
concepts relating to safe plant operation and will be well-versed with the latest techniques for the optimization
of the processes.
Seminar Outline – Slide Presentation
Where hazards arise
– A review of reported incidents involving runaway reactions and current legislation
Chemical hazards assessment strategy
-Integration of a testing and assessment strategy into the development lifecycle of a chemical
Fundamental principles of scale-up and reaction runaway
- Thermal inertia and scale up
-Kinetics, heat loss and reagent accumulation
Identification of highly energetic materials
-Strategy for assessing Explosivity:
Experimental techniques and their analysis
Small scale screening tests for liquids, mixtures and powders
-Experimental protocols and analytical techniques including
-Specific methods for drying
-Storage Stability Testing
Reaction characterization through calorimetry
-Characterization of a process when it is running under control
What happens when control is lost
-Characterization of Thermal Runaway Reaction through Adiabatic Calorimetry
-Runaway kinetics and generation of thermal data for vent sizing
Putting it into practice – Data Interpretation
-A workshop designed to enable delegates to interpret the data derived from the experimental
Course Evaluation Feedback Form
*You will need to bring a scientific calculator to this course.
2011 - DATES & LOCATIONS
Please choose which location you will be attending.
March 31, 2011 November 11, 2011
Residence Inn Raleigh-Durham Airport Residence Inn by Marriott San Diego
2020 Hospitality Court, 1747 Pacific Highway
Morrisville, NC 27560 San Diego, CA 92101
City: State: Zip:
All course fees must be received before course commences. We accept Visa, Mastercard, Amex or company
checks. Course fees including continental breakfast, lunch and course notes.
Fax or email this registration form to:
Chilworth Technology, Inc.
250 Plainsboro Rd, Bldg #7
Plainsboro, NJ 08536
ATTN: Victoria R. Jones
Absolutely NO refunds will be made if cancellations are made within 30 days prior to the course date; a possible credit may be arranged.
Chilworth reserves the right to make last minute changes and/or cancellations.
Hotel Reservations must be made directly with each hotel. The cost of accommodations is NOT included in the course fee. Hotel parking fees may apply. We
strongly recommend making reservations as early as possible since the Hotels will only keep the Chilworth Group Block of rooms until 30 days prior to the course start date;
after 30 days our group rates no longer apply and reservations are on a first come, first serve basis.