Chemical processing specialized testing

The intent of this Guidelines book is to provide the principles for the evaluation of chemical reactivity and for use of this information to design and operate safer chemical plant processes. Special emphasis is placed on the use of state-of-the-art methodology in the areas of theory, testing methods, and applications in design and operation of inherently safer processes. 

Table A.4, taken from the CCPS Guidelines for Chemical Reactivity Evaluation and Application to Process Design, shows the questions which need to be asked regarding the safety of the proposed reaction, the data required to answer those questions and some selected methods of investigation. The experimental analysis is extremely specialized, and companies should consider outsourcing the tests if they do not have specialists in this area.

Scale-up techniques for using the results of pilot plant or bench scale test w ork to establish the equivalent process results for a commercial or large scale plant mixing system design require careful specialized considerations and usually are best handled by the mixer manufacturer s specialist. The methods to accomplish scale-up will vary considerably, depending on whether the actual operation is one of blending, chemical reaction tvith product concentrations, gas dispersions, heat transfer, solids suspensions, or others. 

With materials like the stainless steels, which may be either active or passive in a test environment, it is common practice to produce a particular initial level of passivity or activity by some special chemical treatment prior to exposure. With stainless steels this objective may be subsidiary to eliminating surface contamination, such as iron from processing tools, by treatment in a nitric acid solution which might also be expected to achieve substantial passivity incidental to the cleaning action (ASTM A380 1988). 

Variations in solution composition throughout a test should be monitored and, if appropriate, corrected. Variations may occur as a result of reactions of one or more of the constituents of the solution with the test specimen, the atmosphere or the test vessel. Thus, it is important that the composition of the testing solution is what it is supposed to be. Carefully made-up solutions of pure chemicals may not act in the same way as nominally similar solutions encountered in practice, which may, and usually do, contain other compounds or impurities that may have major effects on corrosion. This applies particularly to artificial sea-water, which is usually less corrosive than natural sea-water. This subject is discussed in detail in a Special Technical Publication of ASTM, and tests with natural, transported and artificial sea-water have been described . Suspected impurities may be added to the pure solutions in appropriate concentrations or, better still, the testing solutions may be taken directly from plant processes whenever this is practical. 

Physical characterization of polymers is a common activity that research and development technologists at the Dow Chemical Company perform. A material property evaluation that is critical for most polymer systems is a tensile test. Many instruments such as an Instron test frame can perform a tensile test and, by using specialized software, can acquire and process data. Use of an extensometer eliminates calibration errors and allows the console to display strain and deformation in engineering units. Some common results from a tensile test are modulus, percent elongation, stress at break, and strain at yield. These data are then used to better understand the capabilities of the polymer system and in what end-use applications it may be used. 

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