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Prevent the advancement of the gate to reduce the flash explosion accident
Experts emphasize that the hydrogen peroxide production process involves significant risks, and proactive measures are essential to ensure safety. At a recent Peroxide Industry Symposium, industry leaders highlighted the importance of early risk identification, scientific prevention strategies, and the establishment of robust safety management systems to ensure the stable and secure operation of production facilities.
Many domestic hydrogen peroxide units have faced flash explosion incidents in critical equipment such as storage tanks, oxidation towers, and pipelines. This has made it crucial for companies to focus on preventive measures and reduce the likelihood of such accidents.
**Managing Raw Materials: The First Step in Safety**
Static electricity is one of the main causes of flash explosions during hydrogen peroxide production. To prevent this, proper grounding of equipment and pipelines is necessary, and static charges must be removed promptly to avoid reaching the energy level required for an explosion.
Chen Jun from Jining Weida Fine Chemical Co., Ltd. suggests that controlling raw material quality is a key step in preventing such incidents. Manufacturers should analyze the composition and flash point of heavy aromatics and prioritize purchasing those with higher flash points to minimize risks at the source.
Resin quality also plays a vital role in the production process. Over time, resins may become saturated or damaged due to prolonged exposure to aqueous solutions. Proper regeneration and cleaning of resins are essential to maintain their performance and prevent potential hazards.
Zhang Ge from Hegel (Dalian) Biochemical Technology Co., Ltd. warns that improperly cleaned recycled resins can lead to dangerous reactions when exposed to acidic hydrogen peroxide solutions. Resin cleaning must be done by trained professionals to ensure safe and efficient operations.
**Temperature Control: A Critical Factor in Safety**
Experts stress that temperature control is central to ensuring safe hydrogen peroxide production. In most explosion cases, temperatures exceeded 60°C. During start-up or shutdown phases, process parameters often fluctuate, increasing the risk of flash explosions. Therefore, maintaining the oxidation system temperature below 40°C is essential.
Zhang highlights that temperature changes in the resin and hydrogen peroxide solution should not exceed 3°C. If the temperature difference exceeds this range, it may indicate a dangerous situation, requiring immediate action to stop production and replace the resin.
Monitoring pressure levels is equally important. If pressure reaches more than 30% of the design limit, immediate shutdown and pressure relief are necessary to avoid catastrophic failure.
**Feed Concentration: A Key Area of Control**
High-concentration hydrogen peroxide production introduces new safety challenges. As production processes improve, concentrations can reach up to 40-46%, increasing the complexity of the evaporation and distillation systems.
Zheng Guoyu from China Tianchen Engineering Co., Ltd. explains that higher feed concentrations mean a greater proportion of technical-grade products, which can accumulate impurities. These impurities must be removed through purification before entering the concentration system to ensure operational safety.
When high-concentration hydrogen peroxide enters the evaporation system, the impact may not be immediately visible, but it can lead to other safety issues. For example, in the case of 50% hydrogen peroxide, if the feed concentration is between 40-46%, the system may experience dry pipe conditions, leading to decomposition and potential explosions.
Zheng notes that when dilute hydrogen peroxide has a high concentration, the technical-grade product moves to the bottom of the rectification column, where lower pressure reduces the boiling point, making it safer compared to the evaporator. However, careful monitoring and control remain essential throughout the process.