A global manufacturer of specialty and intermediate industrial chemicals needed a comprehensive evaluation of the pressure relief system on a chemical reactor to confirm its capacity to safely manage overpressure scenarios. This reactor was specifically engineered for the synthesis and production of quaternary ammonium compounds. These are high-value surfactants utilized globally for their antimicrobial, antistatic, and fabric softening properties. This assessment would analyze two scenarios: (1) external fire case and (2) abnormal heat input.
Using data from ARC® testing conducted by our exclusive partner, ioKinetic, the ioMosaic team began with the development of a precise kinetic model of the reactor's specific chemical reaction, simulating a fire-induced runaway reaction scenario. They worked to determine precisely whether the existing pressure relief device could adequately handle such a critical event, providing a robust assessment of its performance and safety capabilities.
During the analysis, ioMosaic identified that additional products were being produced in the reactor. The client then requested that we apply the Gibbs Free Energy Minimization approach to the nine additional representative mixture compositions to screen and identify any potential worst-case mixture compositions. When one formulation warranted further analysis, additional ARC® testing and dynamic simulation were completed at no charge.
ioMosaic used our ERS and dynamic simulation software, Process Safety Office® SuperChems®, for this process technology evaluation and assessment. The team collected data on the client's existing pressure relief devices and delivered detailed electronic pressure relief valve reports, ensuring their compliance with process safety information requirements.
The client received crucial reassurance from the team's thorough analysis of the adequacy of their existing pressure relief system to handle an external fire scenario. This finding offered significant peace of mind, validating the current safety measures in place.
ioMosaic then went a step further and conducted kinetic models for external fire and loss of cooling scenarios on nine more chemical products that had not previously been assessed for risk. The ioMosaic team advised the client on mitigation options for the chemical reactor to improve the facility’s operational resilience and, most importantly, ensure the continued safety of its workers. Ultimately, these proactive recommendations empowered the client to go beyond baseline adequacy and make informed decisions.