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.     

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).     

Evaluation of adiabatic runaway reaction of methyl ethyl ketone peroxide by DSC and VSP2

Methyl ethyl ketone peroxide (MEKPO) is generally applied to manufacturing in the polymerization processes. Due to thermal instability and high exothermic behaviors of MEKPO, if any operation is undertaken recklessly or some environmental effect is produced suddenly during the processes, fires and explosions may inevitably occur. In this study, thermal analysis was evaluated for MEKPO by differential scanning calorimetry (DSC) test. Vent sizing package 2 (VSP2) was used to analyze the thermal hazard of MEKPO under various stirring rates in a batch reactor. Thermokinetic and safety parameters, including exothermic onset temperature (T ₀), maximum temperature (T _max), maximum pressure (P _max), self-heating rate (dT dt ⁻¹), pressure rise rate (dP dt ⁻¹), and so on, were discovered to identify the safe handling situation. The stirring rates of reactor were confirmed to affect runaway and thermal hazard characteristics in the batch reactor. If the stirring rate was out of control, it could soon cause a thermal hazard in the reactor.     

Self-reactive rating of thermal runaway hazards on 18650 lithium-ion batteries

Vent sizing package 2 (VSP2) was used to measure the thermal hazard and runaway characteristics of 18650 lithium-ion batteries, which were manufactured by Sanyo Electric Co., Ltd. Runaway reaction behaviors of these batteries were obtained: 50% state of charge (SOC), and 100% SOC. The tests evaluated the thermal hazard characteristics, such as initial exothermic temperature (T ₀), self-heating rate (dT?dt ^?1), pressure-rise rate (dP?dt ^?1), pressure temperature profiles, maximum temperature, and pressure which were observed by adiabatic calorimetric methodology via VSP2 using customized test cells. The safety assessment of lithium-ion cells proved to be an important subject. The maximum self-heating rate (dT?dt ^?1)_max and the largest pressure-rise rate (dP?dt ^?1)_max of Sanyo 18650 lithium-ion battery of 100% SOC were measured to be 37,468.8???C?min^?1 and 10,845.6?psi?min^?1, respectively, and the maximum temperature was 733.1???C. Therefore, a runaway reaction is extremely serious when a lithium-ion battery is exothermic at 100% SOC. This result also demonstrated that the thermal VSP2 is an alternative method of thermal hazard assessment for battery safety research. Finally, self-reactive ratings on thermal hazards of 18650 lithium-ion batteries were studied and elucidated to a deeper extent.     

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.     

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.     

Thermal hazard evaluation of tert-butyl peroxide using non-isothermal and adiabatic calorimetric approaches

Tert-butyl peroxide (TBPO), is a typical organic peroxides (OPs),which is widely applied as initiator in poly-glycidyl methacrylate (PGMA) reaction, and is employed to provide a free-radical in frontal polymerization, and which has also caused many thermal runaway reactions and explosions worldwide. To find an unknown and insufficient hazard information for an energetic material, differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2) were employed to detect the fundamental thermokinetic parameters involving the exothermic onset temperature (T ₀), heat of decomposition (??H _d), temperature rise rate (dT · dt ^?1), time to maximum rate under adiabatic situation (TMR_ad), pressure rise rate (dP · dt ^?1), and maximum pressure (P _max), etc. The T ₀ was calculated to be 130?°C using DSC and VSP2. Activation energy (E _a) of TBPO was evaluated to be 136?kJ?mol^?1 by VSP2. In view of the loss prevention, calorimetric applications and model evaluation to integrate thermal hazard development are adequate means for inherently safer design.     

Evaluation of thermal hazard for lauroyl peroxide by VSP2 and TAM III

When above certain temperature limits, lauroyl peroxide is an unstable material. If the thermal source cannot be properly governed during any stage in the preparation, manufacturing process, storage or transport, runaway reactions may inevitably be induced immediately. In this study, the influence of runaway reactions on its basic thermal characteristic was assessed by evaluating thermokinetic parameters, such as activation energy (E _a) and frequency factor (A) by thermal activity monitor III (TAM III). This was achieved under five isothermal conditions of 50, 60, 70, 80, and 90?°C. Vent sizing package 2 (VSP2) was employed to determine the maximum pressure (P _max), maximum temperature (T _max ), maximum self-heating rate ((dT?dt ^?1)_max), maximum pressure rise rate ((dP?dt ^?1)_max), and isothermal time to maximum rate ((TMR)_iso) under the worst case. Results of this study will be provided to relevant plants for adopting best practices in emergency response or accident control.     

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 hazard evaluations of 18650 lithium-ion batteries by an adiabatic calorimeter

In this study, the thermal hazard features of various lithium-ion batteries, such as LiCoO₂ and LiFePO₄, were assessed properly by calorimetric techniques. Vent sizing package 2 (VSP2), an adiabatic calorimeter, was used to measure the thermal hazards and runaway characteristics of the 18650 lithium-ion batteries under an adiabatic condition. The thermal behaviors of the lithium-ion batteries were obtained at normal and abnormal conditions in this study. The critical parameters for thermal hazardous behavior of lithium-ion batteries were obtained including the exothermic onset temperature (T ₀), heat of decomposition (ΔH), maximum temperature (T _max), maximum pressure (P _max), self-heating rate (dT/dt), and pressure rise rate (dP/dt). Therefore, the result indicates the thermal runaway situation of the lithium-ion battery with different materials and voltages in view the of TNT-equivalent method by VSP2. The hazard gets greater with higher voltage. Without the consideration of other anti-pressure measurements, different voltages involving 3.3, 3.6, 3.7, and 4.2 V are evaluated to 0.11, 0.23, 0.88, and 1.77 g of TNT. Further estimation of thermal runaway reaction and decomposition reaction of lithium-ion battery can also be confirmed by VSP2. It shows that the battery of a fully charged state is more dangerous than that of a storage state. The technique results showed that VSP2 can be used to strictly evaluate thermal runaway reaction and thermal decomposition behaviors of lithium-ion batteries. The loss prevention and thermal hazard assessment are very important for development of electric vehicles as well as other appliances in the future. Therefore, our results could be applied to define important safety indices of lithium-ion batteries for safety concerns.     

Study on thermal hazards for isoprene monomer (IPM) mixed with aluminum oxide

Isoprene monomer (IPM) is a colorless, volatile liquid obtained from petroleum or coal tar that occurs naturally in many process plants. It is used chiefly to make synthetic rubber. Our study used calorimetric approaches to conduct thermal analysis and hazard assessment of aluminum oxide (Al₂O₃) and IPM relevant studies. Differential scanning calorimetry, thermal activity monitor III, thermogravimetry, and vent sizing package 2 were used to discuss thermal instability reaction of Al₂O₃, which adsorbed IPM, and find every possible reason for cases of fire to prevent any future recurrence of the package store and transport related hazards. By means of calorimetric analysis technology, we can observe thermal decomposition or mass loss for different adsorbed concentrations of IPM and Al₂O₃ to discuss the related thermal stability parameters, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), self-accelerating exothermic rate (dT dt ^?1), pressure rise rate, and maximum reaction temperature (T _max). Then, we can understand the potential hazard factors that contribute to disasters related to processing, transport, and storage of security controls and reaction process design.     

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.     

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 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.     

Elevated pressure and temperature effects on flammability hazard assessment for acetone and water solutions

Flammable chemicals are frequently encountered in industrial processes. Under the safe operation basis and for fire/explosion danger prevention, it is imperative to recognize the flammability characteristics of these processes, especially under the working scenarios for elevated pressure and temperature. This study was conducted to investigate fire and explosion properties, including the explosion limits (LEL and UEL), maximum explosion overpressure (P _max), maximum rate of explosion pressure rise (dP/dt)_max, gas or vapor deflagration index (K _g) and explosion class (St) of various acetone/water solutions (100, 75, 50 and 25 vol.%) at higher initial pressure/temperature up to 2 atm and 200°C via a 20-L-Apparatus. We further discussed the safety-related parameters and fire/explosion damage degree variations in the above aqueous acetone within 1 atm and 150°C. The results offered a successful solution for evaluating the flammability hazard effect in such a relevant crucial process with elevated pressure and temperature.     

Thermal hazard evaluation for methyl ethyl ketone peroxide mixedwith inorganic acids

Methyl ethyl ketone peroxide (MEKPO) possesses complex structures which have caused many incidents involving fires or explosions by mixing with incompatible substances, external fires, and others. In this study, reactivities or incompatibilities of MEKPO with inorganic acids (HCl, HNO₃, H₃PO₄ and H₂SO₄) were assessed by differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2). Parameters obtained by the above-mentioned devices could be readily employed to discuss the runaway reaction, such as onset temperature (T ₀), heat of reaction (ΔH _d), time to maximum rate (TMR), maximum self heat rate (dT/dt)_max, adiabatic temperature rise (ΔT _ad), maximum pressure of decomposition (P _max) and so on. Mixing MEKPO with hydrochloric acid resulted in the lowest T ₀ among inorganic acids. Nitric acid not only lowered the T ₀ but also delivered the highest heat releasing rate or self heat rate (dT/dt), which was concluded to be the worst case in terms of contamination hazards during storage or transportation of MEKPO.     

Thermal runaway features of 18650 lithium-ion batteries for LiFePO4 cathode material by DSC and VSP2

In view of availability, accountability, and applicability, LiFePO₄ cathode material has been confirmed to be better than LiCoO₂ cathode material. Nevertheless, few related researches were conducted for thermal runaway reaction of the LiFePO₄ batteries. In this study, vent sizing package 2 (VSP2) and differential scanning calorimetry were employed to observe the thermal hazard of 18650 lithium-ion batteries and their content??LiFePO₄ cathode material, which were manufactured by Commercial Battery, Inc. Two states of the batteries were investigated, which was charged to 3.6?V (fully charged) and 4.2?V (overcharged), respectively, and important parameters were obtained, such as self-heating rate (dT?dt ^?1), pressure-rise rate (dP?dt ^?1), and exothermic onset temperature (T ₀). The results showed that T ₀ for fully charged is about 199.94?°C and T _max is about 243.23?°C. The entire battery for LiFePO₄ cathode material is more stable than other lithium-ion batteries, and an entire battery is more dangerous than a single cathode material. For process loss prevention, the data of battery of VSP2 test were applied as reference for design of safer devices.     

Thermal decomposition of hydrogen peroxide in the presence of sulfuric acid

Hydrogen peroxide (H₂O₂) is popularly employed as a reaction reagent in cleaning processes for the chemical industry and semiconductor plants. By using differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2), this study focused on the thermal decomposition reaction of H₂O₂ mixed with sulfuric acid (H₂SO₄) with low (0.1, 0.5 and 1.0 N), and high concentrations of 96 mass%, respectively. Thermokinetic data, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), pressure rise rate (dP/dt), and self-heating rate (dT/dt), were obtained and assessed by the DSC and VSP2 experiments. From the thermal decomposition reaction on various concentrations of H₂SO₄, the experimental data of T ₀, ΔH, dP/dt, and dT/dt were obtained. Comparisons of the reactivity for H₂O₂ and H₂O₂ mixed with H₂SO₄ (lower and higher concentrations) were evaluated to corroborate the decomposition reaction in these systems.     

Effects of flammability characteristics of steam inerting to solution of acetone in water

Preventing accidental explosions of flammable liquid/gas mixtures is very important. As far as flammability characteristics are concerned, we simulated the effects of inert liquid/gas, which was filled with reactors, vessels, or closed space, employed in the chemical process industries. The inert liquid/gas (H₂O) weakened the oxygen concentration and reduced solvent vapor concentration in a 20-L-Apparatus. This study investigated the flammability characteristics of acetone/water solutions (100/0, 75/25, 50/50, and 25/75 vol.%) that are controlled at a temperature of 150°C and pressures of 101/202 kPa, respectively. The flammability parameters included flammability limits (LEL and UEL), maximum explosion pressure (P _max), maximum explosion pressure rise ((dP dt ⁻¹)_max), and vapor deflagration index (K _g). The results of a series of experimental tests showed that UEL, P _max, and K _g all decreased with steam rising under the experimental conditions. The results can be applied to process safety design/operation for identifying whether the inert liquid/gas (H₂O) content has any substantial effects in reducing the fire and explosion hazard of the solution of interest.     

Isothermal versus non-isothermal calorimetric technique to evaluate thermokinetic parameters and thermal hazard of tert-butyl peroxy-2-ethyl hexanoate

Liquid organic peroxides have been broadly employed in the process industries such as tert-butyl peroxy-2-ethyl hexanoate (TBPO). This study investigated the thermokinetic parameters of TBPO, a typical liquid organic peroxide, by isothermal kinetic algorithms and non-isothermal kinetic algorithms with thermal activity monitor III, and differential scanning calorimetry, respectively. An attempt has been made to determine the thermokinetic parameters by simulation software, such as exothermic onset temperature (T ₀), maximum temperature (T _max), decomposition (?H _d), activation energy (E _a), self-accelerating decomposition temperature, and isothermal time to maximum rate (TMR_iso). A liquid thermal explosion model was established for a reactor containing liquid organic peroxide of interest. From experimental results, liquid organic peroxides?? optimal conditions for avoiding a violent runaway reaction of storage and transportation were created.