Combustible Dust Testing

Laboratory testing to quantify dust explosion & reactivity hazards

Flammable Gas & Vapor Testing

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Chemical Reactivity Testing

Laboratory testing to quantify reactive chemical hazards, including the possibility of material incompatibility, instability, and runaway chemical reactions

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 safety handle the effluent discharge from an overpressure event

Thermal Stability

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

UN-DOT

Classification of hazardous materials subject to shipping and storage regulations

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Biological

Model transport of airborne virus aerosols to guide safe operations and ventilation upgrades

Radioactive

Model transport of contamination for source term and leak path factor analysis

Fire Analysis

Model transport of heat and smoke for fire analysis

Flammable or Toxic Gas

transport of flammable or toxic gas during a process upset

OSS consulting, adiabatic & reaction calorimetry and consulting

Onsite safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up

Mechanical, Piping, and Electrical

Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid flow, electric power systems

Battery Safety

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

Hydrogen Safety

Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen

Spent Fuel

Safety analysis for packaging, transport, and storage of spent nuclear fuel

Decommissioning, Decontamination and Remediation (DD&R)

Safety analysis to underpin decommissioning process at facilities which have produced or used radioactive nuclear materials

Laboratory Testing & Software Capabilities

Bespoke testing and modeling services to validate analysis of DD&R processes

Nuclear Overview

Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant.

Severe Accident Analysis and Risk Assessment

Expert analysis of possible risk and consequences from nuclear plant accidents

Thermal Hydraulics

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Environmental Qualification (EQ) and Equipment Survivability (ES)

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Laboratory Testing & Software Capabilities

Testing and modeling services to support resolution of emergent safety issues at a power plant

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 (DSC/ARC supplies, CPA, C80, Super Stirrer)

Products and equipment for the process safety or process development laboratory

FERST

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

FATE

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

Blog

Our highly experienced team keeps you up-to-date on the latest process safety developments.

Process Safety Newsletter

Stay informed with our quarterly Process Safety Newsletters sharing topical articles and practical advice.

Resources

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

Reaction Calorimetry

Don Knoechel at the RC1.jpgOne of the keys to safely scaling up a chemical process is managing the energy or heat flux that the intended chemical reaction produces, especially when that chemical transformation is exothermic in nature. When considering process scale-up whether the heat is removed via a jacket, a condenser, or a side loop heat exchanger in the plant reactor or partially allowed to heat up the mass, it is imperative to balance the cooling capacity at scale versus the projected heat flux rate and understand the total energy available due to the desired reaction should that cooling fail.  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 this task and Fauske & Associates, LLC maintains a variety of devices so that we can design the most appropriate experiment to gather the vital heat rate and adiabatic potential data needed 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.

We currently utilize three Reaction Calorimeters of varying size and capability:

THT - URC

THT uRC-screenprint (2)THT-mRC - this device is reaction calorimetry in a vial. The reactor is a GC vial or a metal pressure (SS or HC) cell, volume ~1.5 ml.

Features

  • 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 microwatt sensitivity 

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.   

METTLER-TOLEDO RC1

Mettler-Toledo RC1 AP00_0 5_RTC_1dosing_UCB_condenser_angle (2)The RC1 is a heat flow calorimeter. As such, the heat leaving or entering the reactor 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 and the heat transfer coefficient, U, is calibrated for via an immersed calibration heater before and after the reaction.

Features

  • 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 TeflonR 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 or dropping funnel with a solenoid valve and can also be slaved to pH.

CHEMISENS

ChemiSensdiagThe 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.

Features

  • Temperature range is -50°C to 200°C
  • 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 against pressure using a pressure syringe pump
  • The pressure reactor has been outfitted for hydrogenation studies complete with a gas induction impeller and gas uptake rig
  • Operation under reflux with or without gas generation is also possible   

*Fauske & Associates, LLC (FAI) is the sole distributor in North America of ChemiSens Reaction Calorimeter Systems and we operate a unit in our testing laboratory.

TRAINING

Our team is happy to help train your staff in the understanding of technical issues, process safety programs or audits, regulations and more.  We perform process safety audits as part of a comprehensive hazards analysis and can work with you to make sure your staff is supplied with skills training needs in many ways including: 

Level I - Gap Analysis
Level II - training & consulting
Level III - Program Development and Implementation

Partial List of Services Offered:
• Reviews and upgrades of all your safety process systems and regulatory requirements
• VPP Consulting
• Audits, reviews, and upgrades of all your Operating, Safety, and Maintenance Procedures
• Training program evaluations for both completeness and effectiveness (from technical skills to professional development) and upgrades where
needed
• Reviews and upgrades of your program elements such as Employee Participation and Process Safety Information for effectiveness and completeness
• Work process effectiveness evaluations and upgrades
• Overall organizational development (e.g., motivation, work processes)
• Stress reduction
• Evaluations of the effectiveness of communication

We design, custom develop and deliver any site specific training materials needed by your organization. Our Consultants, Engineers and Technical Specialists are available to deliver the classroom, lab or on-the-job training your staff needs. In addition, we will assist with the identification and procurement of commercially available training materials where available.

CTA_Strip_Bg-1.jpg

Learn how to achieve safer scale-up of batch, semi-batch and continuous processes

Download the Guide