Industrial Safety Series - 4: Thermal Hazards of Chemical Reactions

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Exothermic reactions in chemical production can be hazardous if uncontrolled, potentially leading to catastrophic events such as reactor blow-offs and gas explosions. Similar destructive outcomes can arise from undesired reactions during production, purification, or storage due to excessive temperatures or other factors. While the dangers of exothermic reactions have been acknowledged since the chemical industry's inception, systematic knowledge of their effects has emerged only in the past 25 years, largely due to investigations of various incidents by expert groups. The author, with over 20 years of experience in investigating plant incidents and testing experimental methods, emphasizes the importance of sharing knowledge about these hazards with younger colleagues focused on chemical plant safety. This work aims to provide foundational understanding of the risks associated with exothermic reactions, highlighting the necessity of knowing relevant properties for safe processing of products and mixtures. It also critically reviews extensive experimental techniques developed alongside the growing understanding of reaction hazards, offering valuable insights for safety in the chemical industry.