Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Gas and Vapor

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Classification of hazardous materials subject to shipping and storage regulations
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Thermal Stability

Safe storage or processing requires an understanding of the possible hazards associated with sensitivity to variations in temperature

Adiabatic Calorimetry
Data demonstrate the consequences of process upsets, such as failed equipment or improper procedures, and guide mitigation strategies including Emergency Relief System (ERS) design
Reaction Calorimetry
Data yield heat and gas removal requirements to control the desired process chemistry
Battery Safety

Testing to support safe design of batteries and electrical power backup facilities particularly to satisfy UL9540a ed.4

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Cable Testing
Evaluate electrical cables to demonstrate reliability and identify defects or degradation
Equipment Qualification (EQ)
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Water Hammer
Analysis and testing to identify and prevent unwanted hydraulic pressure transients in process piping
Acoustic Vibration
Identify and eliminate potential sources of unwanted vibration in piping and structural systems
Gas & Air Intrusion
Analysis and testing to identify and prevent intrusion of gas or air in piping systems
ISO/IEC 17025:2017

Fauske & Associates fulfills the requirements of ISO/IEC 17025:2017 in the field of Testing

ISO 9001:2015
Fauske & Associates fulfills the requirements of ISO 9001:2015
Dust Hazards Analysis
Evaluate your process to identify combustible dust hazards and perform dust explosion testing
On-Site Risk Management
On-site safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up
DIERS Methodology
Design emergency pressure relief systems to mitigate the consequences of unwanted chemical reactivity and account for two-phase flow using the right tools and methods
Deflagrations (Dust/Vapor/Gas)

Properly size pressure relief vents to protect your processes from dust, vapor, and gas explosions

Effluent Handling

Pressure relief sizing is just the first step and it is critical to safely handle the effluent discharge from an overpressure event

FATE™ & Facility Modeling

FATE (Facility Flow, Aerosol, Thermal, and Explosion) is a flexible, fast-running code developed and maintained by Fauske and Associates under an ASME NQA-1 compliant QA program.

Mechanical, Piping, and Electrical
Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid, flow, and electric power systems
Hydrogen Safety
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Thermal Hydraulics
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Nuclear Safety
Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant
Radioactive Waste
Safety analysis to underpin decomissioning process at facilities which have produced or used radioactive nuclear materials
Adiabatic Safety Calorimeters (ARSST and VSP2)

Low thermal inertial adiabatic calorimeters specially designed to provide directly scalable data that are critical to safe process design

Other Lab Equipment and Parts for the DSC/ARC/ARSST/VSP2 Calorimeters

Products and equipment for the process safety or process development laboratory


Software for emergency relief system design to ensure safe processing of reactive chemicals, including consideration of two-phase flow and runaway chemical reactions


Facility modeling software mechanistically tracks transport of heat, gasses, vapors, and aerosols for safety analysis of multi-room facilities


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With over 40 years of industry expertise, we have a wealth of process safety knowledge to share.

Recent Posts

3 Reaction Calorimetry Instruments for Chemical Reaction Safety

Posted by Fauske & Associates on 08.07.13

Our company has long been known for characterizing outcomes our customers would rather not encounter but have to be ready for nonetheless. That would be sizing vents to safely handle runaway reactions, preventing and mitigating combustible dust explosion hazards, assessing the flammability potential of combustible gases and vapors or determining the thermal stability of reactive monomers and other chemical reagents. Understanding what you don’t want to do is a vital part of a process safety plan. So, too, is characterizing what you do want to do, and knowing what it takes to keep it that way.

In the case of a desired (exothermic) chemical reaction, we are talking about knowing the rate of heat production, how it scales and how it is affected by deviations, and whether said upsets can lead to any unwanted events. In process development, we are concerned with the ramifications of scaling this heat production rate, where and how it is to be removed and does the initial concept of the process jive with the projected performance at scale (addition times, addition orders, batch versus semi-batch operation). And, all of this must be studied under conditions where the effects of mass and heat transfer are well understood and controlled.

The accepted technique for gathering this type of data in the industry is known as reaction calorimetry. There have been many instruments developed over the years to accomplish such tasks and Fauske & Associates (FAI) maintains a variety of devices so we can be flexible and design the most appropriate experiment to gather the vital heat rate and adiabatic potential data you need for a safe scale up. Couple this with our vast experience in characterizing runaway reaction behavior using adiabatic and vent sizing calorimetry and we can deliver you a complete picture of a safe chemical process.

FAI currently has three reaction calorimeters of varying size and capability:

1. THT- RC THT uRC Chemical Risk Management and Nuclear Plant Safety
This device is reaction calorimetry in a vial. The reactor is simply a GC vial
or a metal pressure (SS or HC) cell, volume ~1.5 ml. Agitation is via magnetic stir bar. Temperature range is -5°C to 150 °C and pressures up to 10 bar are possible with the pressure cells. The instrument has a 5 W sensitivity and roughly ±110 mW heat flow limit. Modes of operation include isothermal with steps, titration with an integrated syringe pump, scan and hold (2°C/min max) and heat capacity determination. FAI is also developing this device for measuring binary compatibilities.

2. Mettler-Toledo RC1 Mettler Toledo RC1 AP00 Nuclear Plant Safety and Chemical Process Safety
The RC1 is a heat flow calorimeter. As such, the heat leaving or entering the jacketed reaction vessel is characterized by UA(Tr-Tj) where U is the overall heat transfer coefficient, A is the area of heat transfer and Tr and Tj are the temperature of the reactor and jacket, respectively. The temperatures are measured, A is known by geometry (stirred volume) and the heat transfer coefficient, U, is calibrated for by an immersed calibration heater before and after the reaction. Available temperature range is -73°C to +230°C, pressure ambient to 2 bar. Reactors are borosilicate glass, 500 ml or 1 liter. Agitation via overhead stirrer with a conventional Teflon® bearing or magnetic drive, glass or Hastelloy stirrers and baffles, the latter for difficult to stir systems. Automated reagent additions can be performed with integrated balances using positive displacement Teflon® diaphragm pumps or solenoid valves. With an inserted probe, pH monitoring and/or control is also possible. The RC1 is not just for batch or semi-batch operation. It has been used by the author to demonstrate continuous processing too.

3. ChemiSens CPA Chemisens Reactor Accident Management and Chemical Risk Management
The ChemiSens is a heat flux calorimeter that provides a true heat flow signal without requiring any calibration.

The heat transfer surface is entirely through the bottom of the reactor making use of Peltier technology and is independent of the heat transfer coefficient as defined above. FAI is the North American Distributor for the ChemiSens. The temperature range is -50°C to 200°C and the combination 316 stainless steel glass reactor has a pressure rating to 20 bar though reactors of other materials of construction and higher pressure ratings are available. Stirring is via a magnetically coupled drive (2000 rpm) with a variety of impellers and inserts. Additions can be performed using a pressure syringe pump. The pressure reactor has been outfitted for hydrogenation studies complete with a gas induction impeller, baffles and gas uptake rig. Operation under reflux with or without gas generation is also possible. The ChemiSens is best when operated in isothermal mode, however, FAI has done some creative temperature scanning work as well. A variety of inserts allow for batch injection of solids, torque measurement if desired.

If you have Reaction Calorimetry needs please contact to learn how we can help.

Topics: Combustible Dust, Process Safety, Thermal Stability, Reaction Calorimetry, Reactive Chemicals


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