Introduction to Chemical
Reactivity Hazard Management
Mikal Shabazz
U.S. Environmental Protection Agency
Mid-Atlantic Region, Office of Enforcement
Oil and Prevention Branch
Overview

What is Chemical Reactivity? What are its Hazards?

Challenges in Managing Reactive Hazards

Examples of Facilities with Reactive Chemistry Hazards

Screening Example using Case History

Principles of Reactive Hazard Management

Tools and Resources
2
3
Uses of Reactive Chemistry
5
6
7
What energy/products will be released?
• Initial conditions
• Reaction path
• Reaction thermodynamics
• Reaction kinetics
AND
How will the released energy/products interact with the environment?
• Environmental conditions
• Process equipment & controls
• Heat & mass transfer
• People/property/environment response
9
Types of Chemical Reactivity
Main Category
Subcategory
Readily SelfReacts
Polymerizes
Decomposes
Rearranges
Condenses
Readily Reacts
with Common
Environmental
Substances
Reacts with Nitrogen
Reacts with Oxygen
Reacts with Water
Reacts with Ordinary Combustibles
Reacts with Metals
Readily Reacts
with Other
Chemicals
10
Reacts with Acids
Reacts with Bases
Reacts with Hydrogen
The Problem

Chemical Safety Board Report
• 167 incidents in a 21 year period
• 108 fatalities
• Significant property damage

11
Data are incomplete, and certainly
underestimate the magnitude of the
problem
The Problem

12
In 90% + of all incidents studied,
the information necessary to have
prevented the incident was
documented and publicly available.
Groups that Use Reactive Chemistry

“No Chemistry” Users

“Unintentional Chemistry” Users

“Intentional Chemistry” Users
Or, stated another way

Storage, Handling and Repackaging

Mixing and Physical Processing

Chemical Manufacturing
13

Preliminary Screening Method

Management System Framework
Concept Book(~ 200 pages)
FREE DOWNLOAD
http://www.aiche.org/ccps/resources.htm
14
Guiding Principles
1.
Use existing information
2.
Apply appropriate levels of technology
to the level of the problem
3.
Identify areas requiring additional
testing, data generation
4.
Use existing management systems/
structures to the maximum extent
possible
15
Recommended Approach

Preliminary Screening Method

Management System Framework
16
Preliminary
Screening
for
Chemical
Reactivity
Hazards
Summary
Flowchart
Preliminary Screening: Summary Flowchart
Summary Flowchart (continued)
FACILITY:
COMPLETION DATE:
COMPLETED BY:
APPROVED BY:
Do the answers to the following questions indicate chemical reactivity hazard(s) are present? _____________
YES, NO
or NA
AT THIS FACILITY:
Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
processing of substances?
7. Is any hazardous material identified as spontaneously
combustible?
8. Is any hazardous material identified as peroxide forming?
9. Is any hazardous material identified as water reactive?
10. Is any hazardous material identified as an oxidizer?
11. Is any hazardous material identified as self-reactive?
12. Can incompatible materials coming into contact cause
hazardous consequences, based on the following analysis?
BASIS FOR ANSWER; COMMENTS
Question 1.
SCENARIO
CONDITIONS
*
NORMAL?
Example
Form for
Documenting
Chemical
Reactivity
Hazard
Screening
R, NR
**
or ?
INFORMATION SOURCES; COMMENTS
1
2
3
*Does the contact/mixing occur at ambient temperature, atmospheric pressure, 21% oxygen atmosphere, and
unconfined? (IF NOT, DO NOT ASSUME THAT PUBLISHED DATA FOR AMBIENT CONDITIONS APPLY)
**R = Reactive (incompatible) under the stated scenario and conditions
NR = Non-reactive (compatible) under the stated scenario and conditions
? = Unknown; assume incompatible until further information is obtained
An Example
Simplified retrospective of 1995
explosion / fire at Napp Technologies,
Lodi, New Jersey
Intent: Illustrate the Preliminary
Screening Method for the type of
process involved in the incident
21
Mixing Example
A toll manufacturer is contracted to prepare one
8100 lb batch of a gold precipitating agent.
• Ingredients mixed in a 125 ft3 (6 m3) cone blender
• Blender is insulated and has a steel jacket to allow
cooling and heating with a water/glycol mixture
• Dry ingredients blended: ~ 66% sodium hydrosulfite,
22% aluminum powder and 11% potassium
carbonate by weight
• Small amount of benzaldehyde added for odor control
• Product blend packaged into eighteen 55 gal drums
for shipment
22
FACILITY:
COMPLETED BY:
Mixing Example Documentation
APPROVED BY:
COMPLETION DATE:
Do the answers to the following questions indicate chemical reactivity hazard(s) are present? _____________
AT THIS FACILITY:
YES, NO
or NA
BASIS FOR ANSWER; COMMENTS
R, NR
**
or ?
INFORMATION SOURCES; COMMENTS
Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
processing of substances?
7. Is any hazardous material identified as spontaneously
combustible?
8. Is any hazardous material identified as peroxide forming?
9. Is any hazardous material identified as water reactive?
10. Is any hazardous material identified as an oxidizer?
11. Is any hazardous material identified as self-reactive?
12. Can incompatible materials coming into contact cause
hazardous consequences, based on the following analysis?
Question 1.
SCENARIO
1
2
3
CONDITIONS
*
NORMAL?
Sources of Information

Here are some key sources of reactivity information, if you
know what chemicals are being handled.
• International Chemical Safety Cards - accessible from CDC
website at http://www.cdc.gov/niosh/ipcs/icstart.html)
• NIOSH Pocket Guide to Chemical Hazards - online version
available at http://www.cdc.gov/niosh/npg/npg.html)
• NFPA Fire Protection Guide to Hazardous Materials [NFPA 2002]
• Bretherick's Handbook of Reactive Chemical Hazards [Urben
1999]
• Coast Guard Hazardous Information System
http://www.chrismanual.com
• NOAA Chemical Reactivity Worksheet - discussed later in this
session - http://response.restoration.noaa.gov/chemaids/react
• Sax's Dangerous Properties of Industrial Materials [Lewis and
Irving 2000]
• Data from manufacturers/suppliers, including Material Safety Data
Sheets (MSDSs)
24
Material Safety Data Sheets
 Basic
reactivity hazards of each
chemical used should be included
the Material Safety Data Sheet
provided by your chemical supplier.
 In
the U.S., the OSHA HAZCOM
Standard says what must be
included in an MSDS, but does not
give a required format.
25
Material Safety Data Sheets

The widely used ANSI Standard Z400.1 gives a consistent format
for MSDSs. Reactivity information might be found in:
• Section 5:
Fire-Fighting Measures Look for water reactivity and the consequences of heating the
material in a fire situation, including decomposition, polymerization, and the
generation of gaseous reaction products.
• Section 10:
Stability and Reactivity
The primary section for reactivity hazards. Look for information on chemical stability,
conditions to avoid, incompatibility with other materials, hazardous decomposition,
and hazardous polymerization.
• Section 14:
Transport Information
Look for the hazardous material description, the hazard class, and the UN/NA
identification number. One place to look up what the classes and numbers mean is in
the DOT Emergency Response Guidebook.
• Section 16:
Other Information Look for hazard ratings (such as the NFPA instability rating) and
other possible clues such as how the material is prepared.
26
Material Safety Data Sheets
 WARNING:
• MSDSs often contain incomplete or contradictory
information.
The U.S. EPA issued a Safety Alert warning not
to rely on a single data source in emergency
situations.
• The same is true when attempting to identify
reactivity hazards that need to be avoided or
managed.
Other MSDS limitations are listed in Section 4.2
of the CCPS Essential Practices book.
27
Screening Question 1
Question 1
Is intentional
chemistry performed
at your facility?
Mixing Example Documentation
AT THIS FACILITY:
Question 1. Is intentional chemistry performed?
YES, NO
or NA
NO
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Question 2
Is there any
mixing or combining of
different substances?
Mixing Example Documentation
AT THIS FACILITY:
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
YES, NO
or NA
NO
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
Question 6
Is any
heat generated
during the mixing or
physical processing of
substances?
Mixing Example Documentation
AT THIS FACILITY:
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
YES, NO
or NA
NO
YES
NA
NA
NA
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
Mixing Example Documentation
AT THIS FACILITY:
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
processing of substances?
YES, NO
or NA
NO
YES
NA
NA
NA
NO
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Question 7
Is any
substance identified
as spontaneously
combustible?
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
Expect chemical reactivity
hazard(s) to be present;
Go to Chapter 4 for
information on identifying and
managing hazards
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
NO
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
NO
YES
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Sodium hydrosulfite is water reactive;
uncoated aluminum powder is DOT/UN
Hazard Class 4.3, Dangerous when Wet
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
NO
YES
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
NO
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Sodium hydrosulfite is water reactive;
uncoated aluminum powder is DOT/UN
Hazard Class 4.3, Dangerous when Wet
No indication from MSDS or literature
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
NO
YES
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
NO
YES
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Sodium hydrosulfite is water reactive;
uncoated aluminum powder is DOT/UN
Hazard Class 4.3, Dangerous when Wet
No indication from MSDS or literature
Heating of sodium hydrosulfite can
initiate self-sustaining exothermic
decomposition
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide
peroxideforming?
forming?
9. Is any substance identified as water
water reactive?
reactive?
NO
YES
10. Is any substance identified as an oxidizer?
oxidizer?
11. Is any substance identified as self-reactive?
self-reactive?
NO
YES
12. Can incompatible materials coming into contact cause
undesired consequences, based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Sodium hydrosulfite is water reactive;
uncoated aluminum powder is DOT/UN
Hazard Class 4.3, Dangerous when Wet
No indication from MSDS or literature
Heating of sodium hydrosulfite can
initiate self-sustaining exothermic
decomposition
Mixing Example Documentation
Do the answers to the following questions indicate chemical reactivity hazard(s) are present?
AT THIS FACILITY:
YES, NO
or NA
Question 1. Is intentional chemistry performed?
2. Is there any mixing or combining of different substances?
3. Does any other physical processing of substances occur?
4. Are there any hazardous substances stored or handled?
5. Is combustion with air the only chemistry intended?
6. Is any heat generated during the mixing or physical
NO
YES
NA
NA
NA
NO
processing of substances?
7. Is any substance identified as spontaneously
combustible?
YES
8. Is any substance identified as peroxide forming?
9. Is any substance identified as water reactive?
NO
YES
10. Is any substance identified as an oxidizer?
11. Is any substance identified as self-reactive?
NO
YES
12. Can incompatible
incompatiblematerials
materials
coming
coming
intointo
contact
contact
cause
undesired
cause
undesired
consequences,
consequences?
based on the following analysis?
YES
BASIS FOR ANSWER; COMMENTS
Loading, blending, and packaging only
Blending of ingredients in cone blender
No indication of heat generation from
previous batch or from nature of blend
Sodium hydrosulfite is DOT/UN Hazard
Class 4.2, Spontaneously Combustible
Material; finely divided aluminum powder is pyrophoric without oxide coating
No indication from MSDS or literature
Sodium hydrosulfite is water reactive;
uncoated aluminum powder is DOT/UN
Hazard Class 4.3, Dangerous when Wet
No indication from MSDS or literature
Heating of sodium hydrosulfite can
initiate self-sustaining exothermic
decomposition
Chemical Compatibility Determinations

Public literature (e.g., Sax, Brethericks,
MSDS, etc.)

Chemical Compatibility Charts (ASTM E
2012-00 – Standard Guide for the
Preparation of a Binary Chemical
Compatibility Chart, Coast Guard chart,
etc.)

NOAA Chemical Reactivity Worksheet
46
NOAA Chemical Reactivity Worksheet

The Chemical Reactivity Worksheet is a PC
Application written by the National Oceanic and
Atmospheric Administration (NOAA).

It is included on the CD available at this session, or
as a free download from the NOAA website.

The page which contains the download link as well
as other information on the worksheet is:

http://response.restoration.noaa.gov/chemaids/react.html
47
NOAA Chemical Information
48
NOAA Compatibility Chart
49
NOAA Compatibility Chart
50
FACILITY:
Mixing
Example
Documentation
Napp
Technologies,
Inc., Lodi,
New Jersey
(continued)
Do the answers to the following questions indicate chemical reactivity hazard(s) are present? 1 ___YES____
AT THIS FACILITY:
Question
1. Is intentional
chemistry
performed?
12. Can incompatible
materials
coming
into contact cause
2.
Is thereconsequences,
any mixing or combining
of different
undesired
based on the
followingsubstances?
analysis?
3. Does any other physical processing of substances
occur?
CONDITIONS
SCENARIO
2
4. Are there any hazardous substances stored or NORMAL?
handled?
1 Vacuum
seal cooling
water
enters
blender,intended?
No – N2
5.
Is combustion
with air
the only
chemistry
powder
atmosphere,
6. reacts
Is anywith
heataluminum
generated
duringand
the sodium
mixing or physical
hydrosulfite,
and initiates exothermic
confinement
processing
of substances?
decomposition
in blender
7. Is any substance identified as spontaneously combustible?
2 Glycol/water mixture leaks from jacket into
No – N2
blender, reacts with aluminum powder and
atmosphere,
sodium hydrosulfite, and initiates
confinement
decomposition
in blender
8. exothermic
Is any substance
identified as peroxide forming?
YES, NO
or NA
NO
YES
YES
R,NA
NR
3
orNA
?
R
NA
NO
BASIS FOR ANSWER; COMMENTS
Loading,
blending,
See
analysis
belowand packaging only
analysis
below
Blending of ingredients in cone blender
INFORMATION SOURCES; COMMENTS
Both aluminum powder and sodium
hydrosulfite
reactive from
No
indicationare
of water
heat generation
previous batch or from nature of blend
YES
Sodium hydrosulfite is DOT/UN Hazard
R
NOAA4.2,
Worksheet
indicatesCombustible
combining
Class
Spontaneously
sodium hydrosulfite
withaluminum
ethylenepowder
glycol
Material;
finely divided
is pyrophoric
“explosive due
to vigorous
reaction or
is
without
oxide coating
reaction
products
produce
NO
No
indication
frommay
MSDS
or literature
detonation,” “may cause fire,” and
Sodium
water
reactive;
9. Is any substance identified as water reactive?
YES
indicateshydrosulfite
“flammableisgas
generation”
uncoated
is DOT/UN
and “heat aluminum
generationpowder
by chemical
Hazard
Dangerous
When Wet
reaction,Class
may 4.3,
cause
pressurization”
10.
Is any substance identified as an oxidizer?
NO
No indication from MSDS or literature
1
Use Figure 3.1 with answers to Questions 1-12 to determine if answer is YES or NO
11.
Is any substance identified as self-reactive?
YES
Heating of sodium hydrosulfite can
2
Does the contact/mixing occur at ambient temperature, atmospheric pressure, 21% oxygen atmosphere, and
initiate self-sustaining
exothermic
unconfined? (IF NOT, DO NOT ASSUME THAT PUBLISHED DATA FOR AMBIENT
CONDITIONS
APPLY)
3
decomposition
R = Reactive (incompatible) under the stated scenario and conditions
NR =Can
Non-reactive
(compatible)
stated
scenario
12.
incompatible
materials under
comingtheinto
contact
causeand conditions
YES
See analysis below
? = Unknown; assume incompatible until further information is obtained
undesired consequences, based on the following analysis?
An Example
For this retrospective example:

Preliminary Screening Method would
indicate that chemical reactivity hazards
need to be managed at this facility

Multiple indicators present
• Individual chemicals are spontaneously
combustible, water reactive, thermally
sensitive
• Interaction scenarios indicate potential
incompatibilities
52
Preliminary
Screening
for
Chemical
Reactivity
Hazards
Summary
Flowchart
Incident
April 21, 1995

5 worker
fatalities

~300
evacuated

Facility
destroyed

Surrounding
businesses
damaged
Ed Hill, The Bergen Record
Used with permission
54
Appropriate Management Systems

Identification of the reactive nature and
interaction of the materials

Use of a compatible heating / cooling
medium

Mechanical integrity program to
decrease the likelihood of leaks

Training of personnel (operations and
emergency response) on possible upset
situations and appropriate response
55
Essential Management Practices
4.1 Put Into Place a System to Manage
Chemical Reactivity Hazards
4.2 Collect Reactivity Hazard Information
4.3 Identify Chemical Reactivity Hazards
4.4 Test For Chemical Reactivity
4.5 Assess Chemical Reactivity Risks
4.6 Identify Process Controls and Risk
Management Options
56
Essential Management Practices
4.7 Document Chemical Reactivity Risks
and Management Decisions
4.8 Communicate and Train on Chemical
Reactivity Hazards
4.9 Investigate Chemical Reactivity
Incidents
4.10 Review, Audit, Manage Change and
Improve Hazard Management
Practices and Program
57
Summary

Preliminary screening method
• Useful for identifying where chemical
reactivity hazards are likely to exist

Management system framework
• Applicable to all levels of complexity and
sophistication
• Builds on existing management systems
• Supplemented with tools appropriate for
chemical reactivity hazards
58
Ongoing Reactivity Initiatives

OSHA Chemical Reactivity Hazards
Management Alliance
• http://www.osha.gov/SLTC/reactivechemicals/

Reactivity Management Roundtable
• http://www.aiche.org/CCPS/ActiveProjects/RMR/
index.aspx
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Reactive Hazard Resources CD

The CD available at this session
includes the following:
• Complete text of CCPS concept book
• CSB reactive hazards investigation
reports and alerts
• NOAA Reactivity Worksheet
• Collection of reactive chemical MSDSs
• EPA chemical reactivity safety alerts
• This presentation
60