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You work as a chemical engineer at a CPI facility which produces nitroaniline exothermically with a reaction between chloronitrobenzene and aqueous ammonia in a batch process. Discuss, in 4-5 sentences, the importance of adopting process safety standards beyond regulations for any aspects of the process.
Batch process reaction rates are controlled with temperature control devices; other external factors are difficult to control in batch processes. Any mishandling of the reactants, such as overcharging the reactor with the limiting reagent, or running the reaction at the wrong temperature, may lead to a thermal runaway with calamitous consequences: in the worst case, the reactor may explode violently. Thus, robust safeguards must be implemented to protect the facility and personnel from a potential catastrophe. Adequate and well-maintained temperature control and pressure relief systems ought to be included in the system design for incident prevention, with rigorous standards of maintenance. Also, a Process Hazard Analysis should be performed for this process even if the Threshold Quantity according to CFR regulations does not require it.
Write a paragraph outlining the workplace benefits of going beyond regulations. Bring in elements and knowledge from your own experiences.
Going beyond regulations means actively participating in a rigorous Process Hazard Analysis, identifying the aspects of the process which are hazardous, and implementing controls and safeguards to prevent an incident. This involves taking a proactive approach and not waiting until regulation is passed by the local, state, or federal government. You and the company know the process better than anyone, and with this knowledge comes the responsibility to regulate and control the process in the safest manner possible. It is extremely important to understand what the standard regulations are for your process and to go beyond them, as appropriate, to ensure everything is as safe as it can be. Since some regulations do not protect from every chemical hazard, you should be confident in everything you are doing and make sure that each angle of your process is as protected as possible. As we know- If you think safety is expensive, try having an accident.