Hazard evaluation for redox system of cumene hydroperoxide mixed with inorganic alkaline solutions

In petrochemistry, dicumyl peroxide (DCPO) is used in various resins for improving physical properties, which was produced by cumene hydroperoxide (CHP) with oxidization reaction, redox reaction, and dehydration reaction. The reactant, CHP, is a typical organic hydroperoxide and has been intrinsically unstable and reactive due to its bivalent -O-O- structure which can be broken readily with bond-dissociation energy. This sequence on sensitive study aimed at the thermal hazard evaluation for the reactive and incompatible characteristics of CHP mixed with various inorganic alkaline solutions. Differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2) were used to analyze the thermal hazards and runaway reaction of redox system, such as decomposition of CHP in cumene solution and CHP react with inorganic alkaline solutions, exothermic onset temperature, peak power, heat of decomposition of dynamic scanning tests, adiabatic self-heating rate, pressure rise rate, maximum temperature, maximum pressure of reaction system, etc. The results of the tests have proven helpful in establishing safe handling, storage, transportation, and disposal guidelines.     

Thermal hazards evaluation of cumene hydroperoxide mixed with its derivatives

Over 90% of the cumene hydroperoxide (CHP) produced in the world is applied in the production of phenol and acetone. The additional applications were used as a catalyst, a curing agent, and as an initiator for polymerization. Many previous studies from open literature have verified and employed various aspects of the thermal decomposition and thermokinetics of CHP reactions. An isothermal microcalorimeter (thermal activity monitor III, TAM III), and a thermal dynamic calorimetry (differential scanning calorimetry, DSC) were used to resolve the exothermic behaviors, such as exothermic onset temperature (T ₀), heat power, heat of decomposition (ΔH _d), self-heating rate, peak temperature of reaction system, time to maximum rate (TMR), etc. Furthermore, Fourier transform infrared (FT-IR) spectrometry was used to analyze the CHP products with its derivatives at 150 °C. This study will assess and validate the thermal hazards of CHP and incompatible reactions of CHP mixed with its derivatives, such as acetonphenone (AP), and dimethylphenyl carbinol (DMPC), that are essential to process safety design.     

Reaction hazard analysis for the thermal decomposition of cumene hydroperoxide in the presence of sodium hydroxide

Organic peroxides have caused many serious explosions and fires that were promoted by thermal instability, chemical pollutants, and even mechanical shock. Cumene hydroperoxide (CHP) has been employed in polymerization and for producing phenol and dicumyl peroxide (DCPO). Differential scanning calorimetry (DSC) has been used to assess the thermal hazards associated with CHP contacting sodium hydroxide (NaOH). Thermokinetic parameters, such as exothermic onset temperature (T ₀), peak temperature (T _max), and enthalpy (ΔH) were obtained. Experimental data were obtained using DSC and curve fitting using thermal safety software (TSS) was employed to obtain the kinetic parameters. Isothermal microcalorimetry (thermal activity monitor, TAM) was used to investigate the thermal hazards associated with storing of CHP and CHP mixed with NaOH under isothermal conditions. TAM showed that in the temperature range from 70 to 90°C an autocatalytic reaction occurs. This was apparent in the thermal curves. Depending on the operating conditions, NaOH may be one of the chemicals or catalysts incompatible with CHP. When CHP was mixed with NaOH, the T ₀ is lower and reactions become more complex than those associated with assessment of the decomposition of the pure peroxide. The data by curve fitting indicated that the activation energy (E _a) for the induced decomposition is smaller than that for decomposition of CHP in the absence of hydroxide.     

Thermal runaway hazards of <Emphasis Type="Italic">tert</Emphasis>-butyl hydroperoxide by calorimetric studies

Thermal runaway reactions associated with exothermic behaviors of tert-butyl hydroperoxide (TBHP) solutions and TBHP reacting with alkaline contaminants were studied. A differential scanning calorimetry (DSC) was used to characterize these inherent behaviors of TBHP solutions with KOH, NaOH, LiOH and NH₄OH. The exothermic peak in thermal curves of TBHP solutions with different alkali were detected by DSC thermal analysis. By thermal analysis, we compared various heats of decomposition of TBHP solutions with alkaline impurities, and determined the incompatible hazards of various TBHP solutions with alkaline contaminants. Comparing with TBHP in various diluents, the adiabatic runaway reaction via vent sizing package 2 (VSP2) indicated that aqueous TBHP intrinsically possesses the phenomena of thermal explosion with dramatic self-reactive rate and pressure rise under adiabatic conditions. Many commercial organic peroxides may have different hazard behaviors. Therefore, using thermal method to classify the hazards is an important subject.     

Thermal hazard evaluation of lauroyl peroxide mixed with nitric acid

Many thermal runaway incidents have been caused by organic peroxides due to the peroxy group, -O-O-, which is essentially unstable and active. Lauroyl peroxide (LPO) is also sensitive to thermal sources and is incompatible with many materials, such as acids, bases, metals, and ions. From the thermal decomposition reaction of various concentrations of nitric acid (HNO3) (from lower to higher concentrations) with LPO, experimental data were obtained as to its exothermic onset temperature (T0), heat of decomposition (ΔHd), isothermal time to maximum rate (TMRiso), and other safety parameters exclusively for loss prevention of runaway reactions and thermal explosions. As a novel finding, LPO mixed with HNO3 can produce the detonation product of 1-nitrododecane. We used differential scanning calorimetry (DSC), thermal activity monitor III (TAM III), and gas chromatography/mass spectrometer (GC/MS) analyses of the reactivity for LPO and itself mixed with HNO3 to corroborate the decomposition reactions and reaction mechanisms in these investigations.     

Effects of cumene hydroperoxide on phenol and acetone manufacturing by DSC and VSP2

Cumene hydroperoxide (CHP) being catalyzed by acid is one of the crucial processes for producing phenol and acetone globally. However, it is thermally unstable to the runaway reaction readily. In this study, various concentrations of phenol and acetone were added into CHP for determination of thermal hazards. Differential scanning calorimetry (DSC) tests were used to obtain the parameters of exothermic behaviors under dynamic screening. The parameters included exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), and exothermic peak temperature (T _p). Vent sizing package 2 (VSP2) was employed to receive the maximum pressure (P _max), the maximum temperature (T _max), the self-heating rate (dT/dt), maximum pressure rise rate ((dP/dt)_max), and adiabatic time to maximum rate ((TMR)_ad) under the worst case. Finally, a procedure for predicting thermal hazard data was developed. The results revealed that phenol and acetone sharply caused a exothermic reaction of CHP. As a result, phenol and acetone are important indicators that may cause a thermal hazard in the manufacturing process.     

Reaction hazard analysis for cumene hydroperoxide with sodium hydroxide or sulfuric acid

Organic peroxides (OPs) are very susceptible to thermal sources, chemical pollutants or even mechanical shock. Over the years, they have caused many serious explosions. Cumene hydroperoxide (CHP) is widely employed to produce phenol and dicumyl peroxide (DCPO) in the manufacturing process. Differential scanning calorimetry (DSC) and thermal activity monitor (TAM) were employed to determine the potential thermal hazards and thermokinetic parameters (such as exothermic onset temperature (T ₀), maximum temperature (T _max), and enthalpy (ΔH)) of CHP mixed with sodium hydroxide (NaOH) and sulfuric acid (H₂SO₄). High performance liquid chromatography (HPLC) was used to analyze the concentration vs. time of CHP.When CHP is mixed with NaOH, the T ₀ is induced earlier and reactions become more intricate than the pure CHP solution. CHP added to NaOH or H₂SO₄ is more dangerous than pure CHP alone. Depending on the operating conditions, NaOH and H₂SO₄ are the incompatible chemicals for CHP.     

Thermal analysis of RDX with contaminants

Many investigations and researches studied the reaction ability between high explosive RDX and RDX with other chemicals. However, accidents still occur and operating problems exist among the RDX manufacturing process. This study utilized inherent safety concepts and DSC thermal analysis to assess the incompatible reaction hazards of RDX during usage, handling, storage, transporting and manufacturing. This assessment includes thermal curve observations and kinetic evaluations. A decomposition mechanism of the incompatible reaction is proposed. Among all the contaminants evaluated in this study, the existence of ferrous chloride tetrahydrate, ferric chloride hexahydrate and nitric acid shifted the main endothermic and exothermic reactions of RDX. These contaminants further advanced the exothermic temperature onset average by about 53, 46 and 61°C, respectively. The summarized results suggest that ferric oxide, ferrous chloride tetrahydrate, ferric chloride hexahydrate, acetone solution and nitric acid can influence the reaction and thermokinetic properties of RDX. These chemicals could induce potential hazards by causing temperature control instability, heating and cooling systems failure, and produce an unexpected secondary explosion. According to the conclusions of this study, potential incompatible RDX hazards during usage and manufacturing could be avoided.     

Kinetics and thermodynamics of thermal decomposition of synthetic AlPO<Subscript>4</Subscript>·2H<Subscript>2</Subscript>O

Cumene hydroperoxide (CHP) and its derivatives have caused many serious explosions and fires in Taiwan as a consequence of thermal instability, chemical contamination, and even mechanical shock. It has been employed in polymerization for producing phenol and dicumyl peroxide (DCPO). Differential scanning calorimetry (DSC) was used to analyze the thermal hazard of CHP in the presence of sodium hydroxide (NaOH), sulfuric acid (H₂SO₄), and sodium bisulfite (Na₂SO₃). Thermokinetic parameters for decomposition, such as exothermic onset temperature (T ₀ ), maximum temperature (T _max ), and enthalpy (ΔH), were obtained from the thermal curves. Isothermal microcalorimetry (thermal activity monitor, TAM) was employed to investigate the thermal hazards during CHP storage and CHP mixed with NaOH, H₂SO₄, and Na₂SO₃ under isothermal conditions in a reactor or container. Tests by TAM indicated that from 70 to 90 °C an autocatalytic reaction was apparent in the thermal curves. According to the results from the TAM test, high performance liquid chromatography (HPLC) was, in turn, adopted to analyze the result of concentration versus time. By the Arrhenius equation, the activation energy (E _a ) and rate constant (k) were calculated. Depending on the process conditions, NaOH was one of the incompatible chemicals or catalysts for CHP. When CHP is mixed with NaOH, the T ₀ is induced earlier and the reactions become more complex than for pure CHP, and the E _a is lower than for pure CHP.     

Thermal runaway reaction evaluation of two by-products mixed with cumene hydroperoxide in the oxidation tower

Oxygen (O₂) or air is widely used to produce cumene hydroperoxide (CHP) in the cumene oxidation tower. The aim of this study was applied to analyze thermal hazard of two by-products including alpha-methylstyrene (AMS) and acetophenone (AP) in a CHP oxidation tower. Differential scanning calorimetry (DSC) and thermogravimetry (TG) were operated to evaluate thermal runaway reaction of CHP mixed with AMS and AP. Exothermic onset temperature (T ₀), maximum temperature (T _max), activation energy (E _a), etc., that were employed to prevent and protect thermal runaway reaction and explosion in the manufacturing process and storage area. In view of proactive loss prevention, the inherently safer handling procedure and storage situation should be maintained in the chemical industries. The T ₀ of 30 mass% CHP was determined to be 105 °C by DSC. Therefore, the T ₀ of 30 mass% CHP mixed with AMS was determined to be 60–70 °C by DSC. The exothermic reaction of CHP/AP and CHP/AMS by DSC under N₂ reaction gas is thermal decomposition of oxygen–oxygen bond (–O–O–) because of the anaerobic reaction.     

Utilization of microcalorimetry for an assessment of the potential for a runaway decomposition of cumene hydroperoxide at low temperatures

The exothermic decomposition of cumene hydroperoxide (CHP) in cumene liquid was characterized by isothermal microcalorimetry, involving the thermal activity monitor (TAM). Unlike the exothermic behaviors previously determined from an adiabatic calorimeter, such as the vent sizing package 2 (VSP2), or differential scanning calorimetry (DSC), thermal curves revealed that CHP undergoes an autocatalytic decomposition detectable between 75 and 90°C. Previous studies have shown that the CHP in a temperature range higher than 100°C conformed to an n ^th order reaction rate model. CHP heat of decomposition and autocatalytic kinetics behavior were measured and compared with previous reports, and the methodology and the advantages of using the TAM to obtain an autocatalytic model by curve fitting are reported. With various autocatalytic models, such as the Prout-Tompkins equation and the Avrami-Erofeev rate law, the best curve fit among models was also investigated and proposed.     

Identificaiton of potential thermal runaways using small scale thermal analytical techniques

With industry's focus on the early identification of potential thermal runaways in chemical processes, it is important that these potential thermal hazards be identified early in a process' development. Thermal runaways can be initiated in several ways: through an uncontrolled heat of reaction, the initiation of an exothermic decomposition/oxidation, or a combination of these two. It is therefore critical that information on exothermic decomposition/oxidation and heat of reaction be easily obtainable using small scale laboratory reactions.A small scale thermal hazards identification program, using process samples from a 200 ml reaction and small scale thermal analytical techniques, identifies potential thermal runaways rapidly. The small scale thermal hazards identification program utilizes three small scale thermal analytical techniques developed at the Merck Research Laboratories. These include the use of specially designed DSC reusable metal crucibles to identify closed system exothermic activity in process samples, the Small Scale Isothermal Age Technique to accurately determine exothermic onset temperatures and Syringe Injection calorimetry to determine heat of reactions which occur at room temperature.     

Thermal runaway analyses for two organic peroxides with H2O and dry fire-extinguishing chemicals by DSC and VSP2

In recent years, organic peroxides, including methyl ethyl ketone peroxide (MEKPO) and cumene hydroperoxide (CHP), have often caused thermal runaway reactions, fires, and thermal explosions worldwide. Under normal circumstances, H₂O and dry fire-extinguishing chemicals are often employed to eliminate fire situations. We evaluated the thermal runaway reaction for MEKPO and CHP mixed with H₂O and dry fire-extinguishing chemicals by differential scanning calorimetry, and thermal runaway reaction for CHP mixed with dry fire-extinguishing chemicals by vent sizing package 2. The results showed that ABC dry chemical, BC dry chemical, and XBC dry chemical all caused the decomposition of MEKPO to occur at lower onset temperature and H₂O caused the ΔH _d of MEKPO to become higher. On the other hand, H₂O and XBC dry chemical induced the decomposition of CHP to occur at lower onset temperature as well as lower thermal explosion temperature. The maximum of self-heating rate ((dT/dt)_max) and the maximum pressure-rise rate ((dP/dt)_max) of CHP mixed with dry fire-extinguishing chemicals were measured lower than CHP alone. The results indicated that MEKPO and CHP are highly hazardous when mixed with H₂O and some dry fire-extinguishing chemicals. In view of loss prevention, the results can be useful references for fire fighters dealing with thermal upsets in chemical plants.     

柠檬酸镧催化双基推进剂的非等温热分解反应动力学

采用TG-DTG和DSC技术研究了含二缩三乙二醇二硝酸酯(TEGDN)和硝化甘油(NG)的混合酯、硝化棉(NC)和用作燃烧催化剂的柠檬酸镧组成的双基推进剂在常压和流动态氮气气氛下的非等温热分解反应动力学. 结果表明, 该双基推进剂的热分解过程存在2个失重阶段: 第I失重阶段为混合酯的挥发分解过程; 第II失重阶段为主放热分解反应, 机理服从三级化学反应, 减速型α-t曲线, 动力学参数: Ea=231.14 kJ·mol-1, A=10^23.29 s-1, 动力学方程为dα/dt=10^22.99(1-α)³ e^-2.78×104/T. 由外推起始点温度(Te)和峰顶温度(Tp)计算得出该双基推进剂的热爆炸临界温度值分别为Tbe=463.62 K, Tbp=477.88 K. 反应的活化熵(⊿S^≠)、活化焓(⊿H^≠)和活化能(⊿G^≠)分别为219.75 J·mol-1·K-1, 239.23 kJ·mol-1和135.96 kJ·mol-1.     

Reactivity in the solid-state between ZnWO<Subscript>4</Subscript> and some rare-earth metal molybdates RE<Subscript>2</Subscript>MoO<Subscript>6</Subscript> (<Emphasis Type="Italic">RE</Emphasis>=Y,Sm, Eu,Gd, Dy,Ho, Er and Lu)

Organic peroxides (OPs) have caused many momentous explosions and runaway reactions, resulting from thermal instability, chemical pollutants, and even mechanical shock. In Taiwan, dicumyl peroxide (DCPO), due to its unstable reactive nature, has caused two thermal explosions and runaway reaction incidents in the manufacturing process. To evaluate thermal hazards of DCPO in a batch reactor, we studied thermokinetic parameters, such as heat of decomposition (†H _d), exothermic onset temperature (T ₀), maximum temperature rise ((dT/dt)_max), maximum pressure rise ((dP/dt)_max), self-heating rate (dT/dt), etc., via differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2).     

Novel validation on pressure as a determination of onset point for exothermic decomposition of DTBP

Exothermic decomposition of di-tert-butyl peroxide (DTBP) was measured and assessed for determination of onset or threshold point which is essential for hazard evaluation or early detection of runaway reaction. Thermal decomposition of DTBP was conducted by differential scanning calorimeter and thermal scanning unit. Criteria of onset points are determined by and compared by the deflection curve of exothermic behavior (or heat flow), selected pressure, self-heat rate, or pressure-rising rate, respectively. Exothermic onset temperature of DTBP can be determined as low as 73.5 °C by pressure selected at 1.5 bar. Onset point determined by selected pressure is more sensitive and superior to the onset temperature traditionally measured by thermal analysis, adiabatic calorimetry using heat-wait-search methodology or theoretical approaches.     

Explosion evaluation and safety storage analyses of cumene hydroperoxide using various calorimeters

Plenty of thermal explosions and runaway reactions of cumene hydroperoxide (CHP) were described from 1981 to 2010 in Taiwan. Therefore, a thermal explosion accident of CHP in oxidation tower in 2010 in Taiwan was investigated because of piping breakage. In general, high concentration of CHP for thermal analysis using the calorimeter is dangerous. Therefore, a simulation method and a kinetic parameter were used to simulate thermal hazard of high concentrations of CHP only by the researcher. This study was applied to evaluate thermal hazard and to analyze storage parameters of 80 and 88 mass% CHP using three calorimeters for the oxidation tower, transportation, and 50-gallon drum. Differential scanning calorimetry (DSC) (a non-isothermal calorimeter), thermal activity monitor III (TAM III) (an isothermal calorimeter), and vent sizing package 2 (VSP2) (an adiabatic calorimeter) were employed to detect the exothermic behavior and runaway reaction model of 80 and 88 mass% CHP. Exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), maximum temperature (T _max), time to maximum rate under isothermal condition (TMR_iso) (as an emergency response time), maximum pressure (P _max), maximum of self-heating rate ((dT/dt)_max), maximum of pressure rise rate ((dP/dt)_max), half-life time (t _1/2), reaction order (n), activation energy (E _a), frequency factor (A), etc., of 80 and 88 mass% CHP were applied to prevent thermal explosion and runaway reaction accident and to calculate the critical temperature (T _c). Experimental results displayed that the n of 80 and 88 mass% CHP was determined to be 0.5 and the E _a of 80 and 88 mass% CHP were evaluated to be 132 and 134 kJ mol^?1, respectively.     

Thermal behaviors of electrolytes in lithium-ion batteries determined by differential scanning calorimeter

Lithium-ion batteries have been widely used in daily electric appliance, but abusive accidents occurred from time to time. Lithium-ion batteries composed of various electrolytes (containing organic solvents, inorganic salts), binder, and electrode materials, which may be unstable under some abnormal conditions. The formulation or components of electrolytes played a crucial factor in affecting reactive hazards within the cell. In order to meet safety requirements of the lithium-ion batteries on electronic device, reseachers and scholars are continuing to do further studies on the important issues in relation to the lithium-ion batteries. This study aims to apply the differential scanning calorimeter for measuring the thermal or reactive hazards of the organic solvents related to the formulation of the electrolytes. Besides, thermal instabilities of lithiated graphite or deposited lithium with electrolytes were simulated by the reactions between metallic lithium (Li) and organic carbonates of linear and cyclic structures. Exothermic onset temperatures and enthalpy changes were measured and analyzed. Results showed that the thermal behaviors of these organic carbonates themselves or with lithium hexafluorophosphate liberated less enthalpy changes. However, violent exothermic reactions were detected between the linear or cyclic carbonates and lithium metal with larger enthalpy change larger than 1,000 J g^?1 of lithium. This can be observed by Li reacted with diethyl carbonate at surprisingly lower onset temperature about 46.6 °C.     

Reactive incompatibility of DTBP mixed with two acid solutions

Organic peroxides are commonly employed as an initiator for polymerization, a source of free radicals, a hardener, and a linking agent. Due to its relatively weak oxygen-oxygen bond, di-tert butyl peroxide (DTBP) has been categorized as flammable type or Class III by the National Fire Protection Association (NFPA). The transport of dangerous goods (TDG) has published a warning against DTBP that it could potentially induce violent heat, explosion, fire and self-ignition under certain circumstances. DTBP has been recommended as an international standard sample for estimating the performance of several calorimeters, such as glass tube tests, differential scanning calorimetry (DSC), and vent sizing package 2 (VSP2). In this study, we measured the precise temperature changes and heat flow with the above-mentioned testing instruments. However, some runaway incidents caused by DTBP have demonstrated the reaction temperature could be as low as ambient temperature. The reactivity and the hazardous incompatibility with sulfuric acid (H₂SO₄) and hydrochloric acid (HCl) of DTBP have not been evident, and the runaway hazards involved in different processing conditions were clarified in this study by implementing the two calorimeters. Acid-catalyzed characteristics and reaction hazards of DTBP could be acquired, such as heat of decomposition (ΔH _d) and exothermic onset temperature (T ₀).     

Effects of mixing metal ions for the thermal runaway reaction of TMCH

1,1-bis(tert-Butylperoxy)-3,3,5-trimethylcyclohexane (TMCH) is commonly used as a crosslinking agent or an initiator of the heat-curing agent for polybutadiene rubber. Metal ions that remain in the pipelines or containers of manufacturing processes may affect the thermal stability of the organic peroxides. Moreover, pipelines or metal containers may contain some metal ions because of inner corrosive chemicals or surface deterioration, which may induce a chemical reaction, while TMCH is mixed with them. To avoid these unexpected chemical reactions, we focused on the thermal hazard analysis of TMCH mixed with metal ions, such as nickel(II) bromide or copper(II) bromide. The experiments can determine thermokinetic parameters, including exothermic onset temperature (T ₀), maximum temperature (T _max), and heat of decomposition (ΔH _d), under non-isothermal conditions by differential scanning calorimetry. Non-isothermal experimental results combined with isoconversional kinetic analysis can acquire further safety parameters, such as apparent activation energy (E _a) and time to maximum heating rate. The results of this study could be used as a proactive case for the storage of TMCH mixed with metal ions.