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


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.


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

Radioactive Waste Consulting

Process engineering for safe storage of spent nuclear fuel (SNF) is a global challenge in which Fauske & Associates, LLC (FAI) is actively involved.  For example, at the U.S. Department of Energy (DOE) Hanford site, metallic SNF in degraded condition has been stored under water at a location called the K West basin. This fuel is similar to the Magnox fuel stored at the Sellafield (UK) pond designated FGMSP, and in particular one route for remediation is to move the fuel from wet pond storage to intermediate-term dry storage.  Wet storage of degraded fuel has evolved a large volume of uranium-metal bearing sludge, presenting unique challenges in developing potential remediation processes.

Request a Quote

Expertise and Solutions

FAI has broad expertise in chemical issues that arise in decontamination and decommissioning (D&D) and nuclear waste technology.  In particular, we have decades of experience in performing research and development to support remediation of the U.S. Department of Energy nuclear facilities. Our Waste Technology department has provided process engineering and safety support through analyses, software development and experiments for a wide variety of nuclear-chemical engineering issues.

 Major project and facility applications related to spent fuel processing are:

  • Idaho National Laboratory:  Technical basis for aluminum/grout chemical reactions and hydrogen flammability; Dust explosion technical basis for mixed-waste treatment
  • K Basins Closure at Hanford, SNF Particulate: R&D, process development and software development for spent nuclear fuel particulate vacuum drying
  • K Basins Closure at Hanford, SNF Sludge:  Process simulation for spent nuclear fuel sludge chemical/thermal treatment using FAI’s FATETM software
  • Plutonium Finishing Plant, PFP/PRF at Hanford:  Aerosol release basis for litigation, experiments and analysis explaining the PRF explosion accident
  • Spent Nuclear Fuel Project at Hanford:  Four of seven fundamental technical basis documents for passivation and storage of 2000 metric tons of damaged Uranium metal fuel; software for process safety, Uranium-metal reactions and pyrophoricity
  • Spent Nuclear Fuel Sludge Project at Hanford:  Chemically reactive sludge property technical basis; radiolysis, flammable gas and process analyses
  • Nuclear Waste Tanks at Savannah River and Hanford:  Adiabatic calorimetry and propagation tube experiments for chemically reactive waste; hydrogen mixing and solvent burning experiments; software for process safety
  • Waste Encapsulation & Storage Facility at Hanford:  Technical basis for Strontium and Cesium capsule disposition
  • Waste Treatment Plant at Hanford: Explosive hazards analysis; due diligence and management transition; flammable gas design guide
  • Waste Receiving and Packaging Facility at Hanford:  Fire and source term analysis

Processing For Dry Storage

The most difficult SNF stream to process is a stream of metallic uranium particulate created from handling the damaged SNF elements. FAI has performed basic research and development on the physical and chemical processes unique to the vacuum drying of metallic SNF particulate. The purpose of the effort was to provide the technical basis for minimal design changes to an existing cold vacuum drying (CVD) process used for damaged SNF elements.  (The earlier development of CVD process specifications for intact but damaged fuel was also supported by FAI.)

FAI addressed thermal stability of the SNF particulate using a graded approach beginning with simplified models and eventually including multi-dimensional transient calculations (see illustration below). The nature of thermal instability in particulate was found to be significantly different than for large SNF scrap pieces and highly damaged fuel elements. The end products of the effort were:

  • Upgrades to the process simulation software FATETM to cover the dynamic range of metallic SNF particulate, scrap and fuel vacuum drying process design and safety analysis needs
  • Independent reports containing details of the physical and chemical phenomena
  • Verification and validation of FATETM with simplified methods
  • Calculations for normal processing and accident scenarios for CVD of SNF particulate

A summary of the R&D effort is publicly available as “Physical and Chemical Processes During Vacuum Drying of Metallic Spent Nuclear Fuel,” Paper 59114, Proceedings of the ASME 2011 14th International Conference on Environmental Remediation and Radioactive Waste Management, ICEM2011, Reims, France, September 25-19, 2011. 




Sludge Handling

Processing of sludge that contains heavy, gas-generating embedded particles presents unique difficulties.  In particular, such sludge has a high yield stress, so the gas generated inside a container of sludge cannot readily escape.  Rather than rise through the sludge, gas bubbles tend to coalesce within the sludge, potentially growing into a much larger mechanically stable bubble that can displace the overlying material.  This can have the unwanted consequence of plugging filters or even releasing sludge from the container.

Stable bubbles are clearly undesirable, so it is important to be able to predict bubble instability (breakup) and if necessary evaluate possible container design features that can disrupt or prevent the formation of stable bubbles.  FAI has extensive analytical and experimental experience in analyzing nuclear waste tank sludge.

FAI performed basic research and development on the stability of sludge gas bubbles, using Taylor stability theory to develop a criterion for sludge bubble breakup.  This predictive criterion was then validated by a series of experiments using various geometries and scales (see example illustrations below).  Specific design features related to the container wall were evaluated to demonstrate their effectiveness at preventing or disrupting bubble formation.


Spent fuel  photo






Dynamic Benchmarking of Tremolo - A Program for Pipeline Two-Phase Flow Transient Analysis
FAI Recognized for Contributions to Hanford Spent Nuclear Fuel Technical Basis
Hydrogen Generation for Select FTS Scenarios
Fate Flow Aerosol Thermal Explosion Model
Physical Behavior of Uranium-Metal-Bearing Hanford K East Basin Sludge Materials
How to Use Expert Judgement to Assess Uncertanties