Using thermal analysis with kinetic calculation method to assess the thermal stability of azo compound on construction materials

The application of construction polymers in engineering and alternative materials has always occupied a place in the market. In the production process of polymer resins, initiators can be used to lower the polymerization reaction energy threshold, which can improve reaction efficiency and reduce energy loss. However, as a commonly used energetic substance in the polymerization process, azos have caused related process hazards due to their exothermic characteristics. Because of this, it is essential to examine and analyze the thermal hazard characteristics of emerging azo substances, such as 2-cyanopropan-2-imemicarbazide (CABN). Although previous literature performs the calculation on related thermal hazard parameters of CABN, there is still exists a void for discussion in estimating the reaction model to avoid analogous hazards and enhance the existing thermal analysis. Based on the past literature, the reaction model is improved with thermogravimetric analysis as evidence. The revised thermal hazard parameters are calculated as the basis of control and mitigation measures, the kinetic model is used to estimate the modified safety parameters, and in the judgment of the runaway reaction, the critical temperature of the runaway is found by analyzing the influence of slight changes in ambient temperature on the reaction temperature. The results show that the critical temperature that causes CABN to enter the runaway reaction is delayed, and the hazard is lower than in the storage situation. Therefore, the thermal hazard to CABN mainly focuses on the safety environment and measures during storage.     

Modeling thermal analysis for predicting thermal hazards relevant to transportation safety and runaway reaction for 2,2′-azobis(isobutyronitrile)

The pure decomposition behavior of 2,2′-azobis (isobutyronitrile) (AIBN) and its physical phase transformation were examined and discussed. The thermal decomposition of this self-reactive azo compound was explored using differential scanning calorimetry (DSC) to elucidate the stages in the progress of this chemical reaction. DSC was used to predict the kinetic and process safety parameters, such as self-accelerating decomposition temperature (SADT), time to maximum reaction rate under adiabatic conditions (TMR_ad), and apparent activation energy (E_a), under isothermal and adiabatic conditions with thermal analysis models. Moreover, vent sizing package 2 (VSP2) was applied to examine the runaway reaction combined with simulation and experiments for thermal hazard assessment of AIBN. A thorough understanding of this reaction process can identify AIBN as a hazardous and vulnerable chemical during upset situations. The sublimation and melting of AIBN near its apparent onset decomposition temperature contributed to the initial steps of the reaction and explained the exothermic attributes of the peaks observed in the calorimetric investigation.     

Probe into effect of the initiator on the thermal runaway hazards of methyl methacrylate bulk polymerization

The bulk polymerization of methyl methacrylate (MMA) is of great importance in chemical industry, but the polymerization process is highly hazardous, and few reports have focused on the effect of initiators on its thermal hazards. In this work, to thoroughly explore the thermal hazard characteristics, the runaway behavior of MMA bulk polymerization is investigated by a combination of thermodynamics experimental and kinetics theoretical methods. The results indicate that the presence of initiator exhibits an undesirable thermal hazard to the MMA bulk polymerization, and its exothermic behavior is also greatly influenced by the type and concentration of initiator. For azobisisoheptanenitrile (ABVN), azodiisobutyronitrile (AIBN) and dibenzoyl peroxide (BPO) initiators as examples, the AIBN-initiated reaction has the shortest adiabatic induction period (39.51 min), whereas the BPO-initiated polymerization exhibits the strongest maximum temperature-rising rate and maximum pressure-rising rate. Under adiabatic runaway, the temperature and pressure change significantly with increasing AIBN concentration, revealing a great potential risk of thermal runaway. Kinetic parameters are calculated to further understand the thermal runaway mechanisms, showing a strong agreement with the adiabatic experimental data. Finally, based on the cooling failure scenario, severity grading is determined by the evaluation criteria. The current work provides extensive data as a reference and guidance for the process design and optimization of MMA bulk polymerization from the perspective of safety.     

Peculiar effect of acylamino and cyan groups on thermal behavior of 2-(1-cyano-1-methylethyl)azocarboxamide

2-(1-Cyano-1-methylethyl)azocarboxamide (CABN) is a representative of new-type azo initiator in the radical polymerization industry. The peculiar water and oil soluble characters make it a versatile rising star for the industry to initiate the polymerization of monomers in either polar or nonpolar solvents based continuous phases. This paper decodes the effect of acylamino and cyan groups on thermal stability and hazards of CABN via advanced thermokinetic analysis and numerical simulation. Initially, simultaneous thermogravimetric analyzer was employed to evaluate the thermal stability of CABN and its two structurally similar azo compounds (azos), azobisisobutyronitrile (AIBN) and azodicarbonamide (AC). Followed with calorimetric experiments by differential scanning calorimetry, the effect of two functional groups on thermal behavior parameters, such as decomposition temperature, melting point, and heat of decomposition was estimated. The results indicated that the acylamino group can improve the thermal stability of CABN but with bulkier heat release. Ultimately, through the medium of thermokinetic analysis, the thermal hazard of AIBN, CABN, and AC was simulated based on auto-ignition and thermal explosion theory. The research results would provide references for the synthesis of new-type azo initiators and process safety parameters to the polymerization industry.     

The critical runaway condition and stability criterion in the phenol–formaldehyde reaction

The procedure of phenol–formaldehyde polymerization is a rather important and complicated reaction in the chemical industry. This exothermic polymeric reaction releases a huge amount of heat. The high amount of energy accumulated and increasing temperature in this reaction process always lead to runaway reaction and a hazard situation owing to the high released heat and improper operation. In this investigation, we used sodium hydroxide as alkali–catalyst in the phenol–formaldehyde polymerization and estimated the reaction kinetics parameters to evaluate the thermal hazard conditions. The critical temperatures and stable criteria of the runaway reaction in this exothermic polymerization were evaluated. This technique is important and useful for safe operation in the phenol–formaldehyde polymerization process.     

Evaluation of thermal reaction for two azo compounds by using 20-L apparatus and calorimetry

Azo compounds are widely involved in the industrial processes of dyes, pigments, initiators, and blowing agents. Unfortunately, these compounds have a bivalent unstable –NN– composition, which can be readily broken when the ambient temperature is elevated. Self-accelerating decomposition might cause a runaway reaction and lead to a fire, explosion, or leakage when the cooling system fails or other events occur. This study investigated the explosion properties, thermal stability parameters, and thermal hazard and mechanism of 2,2′–azobisisobutyronitrile (AIBN) and 2,2′–azobis–2–methylbutyronitrile (AMBN). We used a 20-L apparatus, vent sizing package 2, synchronous thermal analysis, and differential scanning calorimetry under explosive, adiabatic, and dynamic conditions to acquire the explosive curves, thermal curves, and thermodynamic parameters of the substances. Moreover, the differential isoconversional method (Friedman method) and ASTM E698 equation were employed to obtain the apparent activation energy E_a. All the experimental results revealed that AIBN is more dangerous than AMBN. The E_a of AIBN was lower than that of AMBN. The results can be used to construct an azo compound thermal hazard database for use for searches and reference examples by industry and related research areas.     

Thermal hazards analysis of styrene in contact with impurities

Styrene is a reactive monomer commonly used to produce polystyrene and other copolymers. Unintended thermal runaway polymerization reactions of styrene keep reoccurring and have led to catastrophic consequences. One of the possible causes of these runaway incidents involves the contamination of the styrene monomer by incompatible species, which was not adequately investigated and documented. This study focuses on the quantification of thermal runaway hazards of styrene in contact with a series of contamination substances by adopting calorimetric analysis. Both Differential Scanning Calorimeter (DSC) and Advanced Reactive System Screening Tool (ARSST) were employed to examine the exothermic characteristics of styrene mixed with contaminating substances at different concentration levels and mixing conditions. Key safety parameters of the exothermic reaction, such as the onset temperature, the overall heat release, the maximum self-heating rate, as well as the activation energy, were obtained. The results indicated that the thermal runaway polymerization of purified styrene was significantly altered by the presence of contaminant species. Water effectively retarded and quenched the runaway polymerization at a higher temperature range. Alkaline had no substantial effect on the thermal runaway characteristics. The presence of acid solution under both static contact and vigorous mixing condition significantly promoted the thermal polymerization of styrene. A trace amount of concentrated acid initiated violent exothermic activity even at room temperature; and the severity of the reaction was profoundly impacted by the mass-transfer. Our study demonstrates significant implications in the prevention of runaway incidents during transportation and storage of styrene.     

Hazard evaluation for chlorination and amination reactions of fluorocytosine production process

Reaction thermal runaway is one of the most important reasons leading to chemical accidents. With the rapid development of the chemical industry in the world, especially the fine chemical industry, various safety accidents also occur frequently. Therefore, it is necessary to study the exothermic behavior of the reaction process. In this study, reaction calorimeter was used to study the exothermic phenomena during the chlorination reaction and amination reaction. Differential scanning calorimetry was performed on the reactants, and thermogravimetric experiments were performed on the products. In addition, adiabatic experiment was performed to study the thermal runaway behavior of amination products under adiabatic conditions. The results showed that the target reactions generated a large amount of heat in the initial stage. The maximum temperature of amination reaction is higher than the initial decomposition temperature of the amination product under adiabatic condition. The pyrolysis of amination product was divided into three stages. The product had a high apparent activation energy at the beginning of decomposition, and the apparent activation energy decreased as the decomposition progressed.     

Applications of thermal hazard analyses on process safety assessments

In 2011, a large petrochemical complex in Taiwan incurred several fire and explosion accidents, which had considerable negative impact for the industry on both environmental and safety issues. Reactive substances are widely used in many chemical industrial fields as an initiator, hardeners, or cross-linking agents of radical polymerization process with unsaturated monomer. However, the unpredictable factors during the process having risk to runaway reaction, thermal explosion, fire, and exposure to harmful toxic chemicals release due to the huge heat and gas products by thermal decomposition could not be removed from the process. This study used differential technology of thermal analysis to characterize the inherent hazard behaviors of azo compounds and organic peroxides in the process, to seek the elimination of the source of the harmful effects and achieve the best process safety practices with zero disaster and sound business continuity plan.     

Thermal hazard assessment for synthesis of 3-methylpyridine-N-oxide

The exothermic oxidation of 3-methylpyridine with hydrogen peroxide was analyzed by Reaction Calorimeter (RC1e) in semi-batch operation. Heat releasing rate and heat conversion were studied at different operating conditions, such as reaction temperature, feeding rate, the amount of catalyst and so on. The thermal hazard assessment of the oxidation was derived from the calorimetric data, such as adiabatic temperature rise (ΔT_ad) and the maximum temperature of synthesis reaction (MTSR) in out of control conditions. Along with thermal decomposition of the product, the possibility of secondary decomposition under runaway conditions was analyzed by time to maximum rate (TMR_ad). Also, risk matrix was used to assess the risk of the reaction. Results indicated that with the increase of the reaction temperature, the reaction heat release rate increased, while reaction time and exotherm decreased. With the increase of feeding time, heat releasing rate decreased, but reaction time and exotherm increased. With the amount of the catalyst increased, heat releasing rate increased, reaction time decreased and exothermic heat increased. The risk matrix showed that when the reaction temperature was 70 °C, feeding time was 1 h, and the amount of catalyst was 10 g and 15 g, respectively, the reaction risk was high and must be reduced.     

Thermal risk analysis of cumene hydroperoxide in the presence of alkaline catalysts

Many studies have been performed to clarify the basic thermal runaway hazards and kinetics of cumene hydroperoxide (CHP) decomposition. However, materials that are incompatible with CHP have not been clearly identified. Alkaline solutions have been used as a catalyst to form dimethylphenyl carbinol (DMPC) and dicumyl peroxide (DCPO); however, these solutions also affect the reaction and storage temperature of CHP. In this study, thermal calorimeters, differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2), were used to compare the effects of various bases on the decomposition of CHP in cumene. Specifically, the exothermic onset temperature, change in pressure over time, self-heating rate and heat of decomposition were evaluated. Moreover, to appraise the degree of hazard associated with the use of CHP, the compatibility of CHP with various substances was analyzed, and a risk matrix for thermal runaway reactions was obtained. The results of the present study could be used to design safety procedures for the production of CHP and its derivatives.     

Thermal research on the uncontrolled behavior of styrene bulk polymerization

Thermal runaway can occur during the styrene bulk polymerization process because of easily formed local hotspots resulting from the high viscosity of reactants and the difficulty of heat dissipation. To obtain the thermal hazard characteristics, the polymerization behavior of styrene was investigated using differential scanning calorimetry (DSC) at a scanning rate of β = 2 °C/min. Experimental results showed that the exothermic peaks obtained for heat initiation were different from those obtained when initiator was added. The exothermic peak changed from one to two after the initiator was added. The exothermic onset temperature (T₀) was also reduced. Phi-tech II was utilized to study the bulk polymerization of styrene in an adiabatic environment. The adiabatic temperature rise (ΔT_ad), starting temperature of uncontrolled polymerization (T_star), maximum temperature (T_end), and heat of polymerization (ΔH) under different conditions were acquired. When the dose of the additive was increased, the starting temperature of uncontrolled polymerization (T_star) decreased and the adiabatic temperature rise (ΔT_ad) increased gradually. Severity grading was performed based on the severity evaluation criteria of runaway reaction. The results can help designers decide whether it is necessary to take certain measures to reduce risk.     

Reaction mechanism and process safety assessment of acid-catalyzed synthesis of tert-butyl peracetate

Esterification during the synthesis of tert-butyl peracetate (TBPA) is highly exothermic. Since peroxides (tert-butyl hydroperoxide TBHP and TBPA) are intrinsically thermosensitive, this synthesis process is potentially dangerous. In this work, the exothermic process and mechanism of TBPA synthesis using acetic anhydride (Ac₂O) and TBHP under the catalysis of sulphuric acid (H₂SO₄) were clarified by calorimetry, infrared spectroscopy, and high-performance liquid chromatography. To substantially alleviate the thermal risk of the reaction, and to feasibly select appropriate synthesis conditions for ensuring the process safety of the synthesized products, several sets of isothermal and isoperibol experiments were performed using calorimetry. The intermediates formed and concentration changes during the reaction were monitored using in-situ Fourier-transform infrared spectroscopy. Differential scanning calorimetry and adiabatic calorimetry were used to assess the thermal hazard of the materials during the synthesis process. The reaction mechanism was verified using density functional theory calculations. The results revealed that a controlled increase in exothermicity could be achieved by adding aqueous TBHP to Ac₂O in semi-batch experiments in isothermal mode, and accordingly, the highest yield was 95.71%. Experiments combined with theoretical calculations revealed that the primary exothermic event was the TBPA formation reaction, and the removal of a large amount of water from TBHP prior to this is favourable for the reaction. The criticality classes of this reaction were of Grade 2.     

Investigation on the self-decomposition and explosion hazard of azo compounds

Azo compounds are self-reactive chemicals that violently produce flammable gases with heat release (i.e., an exothermic reaction). However, the explosion mechanism and ignition probability of azo compounds have not been clearly defined for storage or transportation. In this study, explosion scene analyses and various pyrolysis tests were performed to evaluate the thermal decomposition characteristics and explosion phenomena of azo compounds in a storage facility. The chemical debris collected from a fire scene was determined to be similar to the pyrolyzate of one of the tested azo compounds used by Py-GCMS. The minimum amounts of azo compounds, which could be ignited by self-decomposition heat, were calculated from the results of differential scanning calorimetrys and the heat transfer equation. The results were used to discuss a safety and response strategy for preventing the propagation of an explosion accident, namely a chemical backdraft.     

Using thermal analysis with kinetic calculation method to assess the thermal stability of 2-cyanopropan-2-yliminourea

Azo compounds, which are commonly used as initiators and blowing agents, are also typical self-reactive materials capable of undergoing runaway reaction during storage and transportation, which can cause severe fires and accidents. To ensure the thermal safety of azo compounds in the process, transportation, and applications, this study investigated 2-cyanopropan-2-yliminourea, which can also be called V-30. First, thermal decomposition characteristics under the non-isothermal conditions were obtained using differential scanning calorimetry. Second, the collected data were combined with a mathematical model to evaluate the primary thermal hazard during the process for V-30. Then, based on a heat-transfer model, the self-accelerating decomposition temperature (SADT) was extrapolated for consideration and non-consideration of consumption of chemicals. The results showed that SADT of V-30 was less than 80 °C. Therefore, it is essential to avoid a temperature beyond SADT or the cooling system will fail. The influence of consumption was also considered for SADT in this study.     

Reaction hazard and mechanism study of H2O2 oxidation of 2-butanol to methyl ethyl ketone using DSC,Phi-TEC II and GC-MS

Methyl ethyl ketone (MEK) oxidation via H₂O₂ with tungsten-based polyoxometalate catalysts has gained much attention with an ever-growing body of knowledge focusing on the development of environmentally benign processes in chemical industry. In this study, two calorimetry techniques, differential scanning calorimetry (DSC) and Phi-TEC II adiabatic calorimetry, were employed to analyze the thermal hazards associated with the 2-butanol oxidation reaction system. Hydrogen peroxide was the oxidant and a tungsten-based polyoxometalate as the catalyst. Gas chromatography-mass spectrometry was used for identification of the organic products. Important thermal kinetic data were obtained including “onset” temperature, heat of reaction, adiabatic temperature rise and self-heat rate. From DSC results, three exothermic peaks were detected with a total heat generation of approximately 1.26 kJ/g sufficiently to induce a thermal runaway. Possible reaction pathway for three stages were proposed based on both DSC and GC-MS results. One exotherm was detected by Phi-TEC II calorimeter and the pressure versus temperature profile together with the DSC and GC-MS data demonstrate the complexity of 2-butanol reaction system under both thermal screening and adiabatic conditions.     

Investigation of how pressure influences the thermal decomposition behavior of azodicarbonamide

Azodicarbonamide (ADC) is a type of azo compound with outstanding application performance, it is always used as a blowing agent in the production of foamed plastics. Based on previous studies, it has been considered harmless in its practical application process. Nevertheless, our research has overturned this standpoint and denoted the special exothermic behavior of ADC under specific use processes, especially when it was placed in a high-pressure system. In this study, a simultaneous thermogravimetric analyzer (STA) was employed to preliminarily evaluate the thermal stability of ADC under atmospheric pressure. Followed with calorimetric experiments by high-pressure differential scanning calorimetry (HP DSC), the exothermic behaviors of ADC under different initial furnace pressures were investigated. The obtained results revealed that the thermal decomposition rate of ADC linearly increases along with increasing testing pressure, which shows a highly autocatalytic characteristic. The peak power of DSC curve breathtakingly reached 73 W/g when the initial testing pressure was set at 4 MPa, and the overall decomposition heat reached 1261 J/g with the scanning rate at 4 ^°C/min. Furthermore, the decomposition mechanism, thermal hazards, and explosion potential were comprehensively evaluated in this study for the first time.     

自反应性化学物质热危险性综合评估

自反应性化学物质热危险性评估的关键在于表征参数的选择和量化,单一的评估参数往往仅表征其热危险性的某一方面。综合考虑自反应性物质发生热分解反应的难易程度及其造成后果的严重程度两个方面,分别选取放热反应初始温度(To)和反应热(-ΔH)作为相应的表征参数,通过半正态分布函数对这两个指标进行标准化处理。在此基础上根据风险的定义提出了一种新的自反应性化学物质的热危险性综合评估指数(THI指数),并建立相应的热危险性分级标准,对自反应性化学物质的热危险性进行综合评估与分级。结果表明,建立的THI指数所确定的热危险性分级结果与基于活化能和最大绝热温度的RHI指数的反应危险性等级基本一致,该指数能够对自反应性化学物质的热危险性进行定量评估。     

Effects of ferric oxide on decompositions of methyl ethyl ketone peroxide

Methyl ethyl ketone peroxide (MEKPO) is a widely used initiator for polymerization reaction and hardener in glass-reinforced plastic. However, MEKPO is an unstable reactive chemical and has caused several serious accidents all over the world. This work studied the thermal stability of MEKPO in the presence of ferric oxide as the contaminant through calorimetric and kinetic studies. The calorimetry was performed using Automatic Pressure Tracking Adiabatic Calorimeter (APTAC) to identify the effects of ferric oxide (different concentration) on important reactive hazards such as onset temperature and pressure hazard. Kinetic modeling was then performed to study the kinetics of the runaway reaction and estimate important kinetic parameters. The results indicate that in the low concentration range (<0.3%), ferric oxide has no significant effect on the thermal stability of MEKPO. However, in the high and intermediate concentration range of ferric oxide (i.e., 10%), the negative effect on the thermal stability of MEKPO was observed. This result is in agreement with the kinetic study result that the activation energy and frequency factor decrease dramatically in the high ferric oxide concentration range. The results provide necessary process safety information for the handling of MEKPO and also technical basis for the further study in this area.