A global specialty chemical manufacturer requested an assessment of a reactor's integrity and safety when exposed to an external fire. Studying reaction rates, thermodynamics, and heat transfer inside a chemical vessel plays a crucial role in mitigating fire exposure. To prevent catastrophic failures, dynamic modeling is used to calculate emergency relief sizing, optimize cooling systems, and determine safe inventory thresholds for reactive chemicals. Whenever there are processing modifications, expansions, debottlenecking, and other changes, documentation for relief and flare systems must be updated to maintain regulatory compliance. This includes the facility process and instrumentation diagrams, relief device inlet and outlet details, and operating procedures.
The ioKinetic team first performed laboratory testing with an Accelerating Rate Calorimeter instrument, measuring the intended reaction and possible unintended reactions, such as decompositions. This testing is used to identify and quantify thermal hazards, runaway reaction potential, and pressure buildup risks. ioKinetic then developed a kinetic model to match the calorimetry test data. Dynamic modeling is used to calculate emergency relief sizing, optimize cooling systems, and determine safe inventory thresholds for reactive chemicals to prevent catastrophic failures. The modeling took into account external fire and loss of cooling, consistent with Recognized and Generally Accepted Good Engineering Practices (RAGAGEP), API 520, and API 521. All analysis and calculations were performed using Process Safety Office® SuperChems® software from our exclusive partner, ioMosaic Corporation. The ioKinetic team simulated the reaction and flow dynamics within the vessel, incorporating a two-phase dynamics model to accurately represent real-world conditions.
The analysis revealed that their existing vessel relief system was inadequate for a fire-induced runaway reaction. To address this critical safety gap, ioKinetic recommended installing two-inch fire-proof insulation. The enhancement now enables the client to adequately protect their reactor even in the worst-case fire scenarios, significantly improving overall plant safety and minimizing risk. The facility now has increased confidence in the design of its relief valves.
ioKinetic has reduced process safety risk, maintained compliance and substantially increased peace of mind for our clients worldwide. To learn more about how we can help you manage risk, contact us today or call us at 1-844-ioKinetic.