Considerations for the safe handling and processing of unstable materials

Abstract We evaluate the instability hazards of initiators, monomers, and other unstable materials during storage and handling in individual containers, pallets of containers, and storage and process vessels. We propose a simplistic model to analyze the temperature–time profile of an unstable chemical, given heat transfer from/to the environment, heat generation due to decomposition and other reaction kinetics, and heat generated from auxiliary equipment (e.g., agitators/mixers, pumps, vessel jackets). Lumped capacitance‐based heat transfer and decomposition kinetics are integrated to predict self‐accelerating decomposition temperature (SADT), self‐accelerating polymerization temperature (SAPT), and the temperature profile given exposure conditions (e.g., ambient temperature and additional sources of heat). Case studies related to the storage and processing of unstable liquid monomers (i.e., methyl methacrylate, MMA), and organic peroxides, (i.e., tert‐butyl peroxybenzoate, TBPB), are presented. We also provide recommendations on determining safe storage and processing temperatures and steps to prevent emergency situations and include an overview of thermal analysis and data treatment procedures which might affect chemical process safety recommendations.