Education and Collaboration to Manage the Risks of High Energy Materials in Research and Development

Hazard recognition is crucial for mitigating risks in research laboratory settings where new chemicals and processes are introduced frequently. Where hazards are familiar to the researcher, successful mitigation strategies are likely similarly well-known. While some high energy materials (i.e., chemicals that decompose rapidly with significant energy release) are easily recognized even by nonexperts, the exploratory nature of chemical research can result in the inadvertent formation of high energy materials both known and unknown, putting researchers and their science at risk of a safety incident. In this paper, we discuss approaches at The Dow Chemical Company to enhance hazard recognition and control with a focus on high energy materials. First, researchers are educated in hazard recognition and basic safety decision-making with decision aids made available to help them independently assess their work for hazards. These preliminary hazard assessments guide researchers in identifying and mitigating risks without direct expert engagement. When hazards are identified that researchers cannot resolve independently, reactive chemical subject matter experts and other safety personnel provide additional support. We share cases where hazard identification failed and the lessons, both technical and cultural, that resulted. Overall, the iterative learning process aims to optimize safety and use incidents as learning opportunities for future improvements.