Ministry of Emergency Management of the People’s Republic of China: Three key measures to ensure the safety of hydrogen peroxide production processes
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The technical complexity of hydrogen peroxide production and the hazards associated with its production process mean that there are certain safety risks involved. This is especially true for newly installed facilities, where it is crucial to strengthen regular safety measures; it is very important to understand the key safety procedures for carrying out the production process. So what are the potential risks in the production process of hydrogen peroxide, and how can accidents be effectively prevented? 1 Basic properties: The chemical formula of hydrogen peroxide is H2O2. Pure hydrogen peroxide is a pale blue, viscous liquid that can be mixed with water in any proportion. It is a strong oxidizing agent; its aqueous solution, commonly known as hydrogen peroxide solution, is a colorless and transparent liquid. 2 Hazard: Hydrogen peroxide is not flammable on its own, but it can react with combustible materials to release large amounts of heat and gas, thereby causing fires and explosions. Hydrogen peroxide is most stable at a pH of 3.5 to 4.5; it decomposes easily in alkaline solutions, and it can also decompose when exposed to strong light, especially short-wavelength radiation. When heated above 100°C, it begins to decompose rapidly. It forms explosive mixtures with many organic substances such as sugars, starches, alcohols, and petroleum products, and can explode upon impact, heating, or exposure to electric sparks. When in contact with many inorganic compounds or impurities, hydrogen peroxide decomposes rapidly, leading to an explosion that releases large amounts of heat, oxygen, and water vapor. At present, the anthraquinone process is primarily used in the production of hydrogen peroxide in our country, and there are potential sources of accident risk at every stage of production; it is therefore very important to minimize the occurrence of accidents.
To effectively prevent potential risks in the hydrogen peroxide production process, the Ministry of Emergency Management of the People’s Republic of China has proposed the following three measures: 1. Strictly implement conventional safety and technical preventive measures, including sound safety management systems, scientific production processes, and safe operating procedures. Workers must follow these regulations to ensure standardized and orderly operations, thereby guaranteeing the safety and reliability of the production process. 2. Strengthen inspections and supervision, conduct a comprehensive assessment of potential safety hazards in the hydrogen peroxide production process, carry out timely safety inspections and rectification of such hazards, to ensure the safety of the production environment. At the same time, it is necessary to strengthen training and education for employees to improve their safety awareness and emergency response capabilities. 3. Formulate and enforce industry standards, strengthen supervision over hydrogen peroxide manufacturers, establish a unified national system for tracking production quality to ensure product safety, and impose severe penalties on those companies that fail to meet the standards, thereby reducing accidents at their root. .
Safety measures adopted in the process design: 1. Ensure the appropriate pH level of the working fluids used in the hydrogenation and oxidation reactions. In the anthraquinone process for hydrogen peroxide production, the hydrogenation reaction takes place under alkaline conditions, while the oxidation of the hydrogenated fluid and the extraction of hydrogen peroxide must occur under acidic conditions. If the oxidizing solution is alkaline, hydrogen peroxide will decompose, leading to an accident. Therefore, analysis points are set up in processes such as the hydrogenation process, oxidation process, and extraction process, and it is important to monitor the acidity and alkalinity of the working fluid at all times. 2 Improve the alkali treatment process: When the alkali treatment step does not function properly, gases can carry away a portion of the alkali solution from the tower; if this mixture is not properly separated in the separator, it can cause the alkalinity level in the working fluid to exceed normal levels by hundreds of times. If the operation of the alkali tower in a certain plant is abnormal, the alkalinity of the working fluid fed into the alumina regenerator can reach as high as 3.9 g/ml. The alkali in this working fluid enters the extraction tower through hydrogenation and oxidation processes; there, hydrogen peroxide reacts violently with the alkali, resulting in an explosion at the top of the tower and a fire. 3. Strictly control the oxygen content in the oxidized exhaust gases. These exhaust gases contain a certain amount of flammable gases; when hydrogen peroxide is decomposed during its production, the oxygen concentration in the resulting mixed gases can exceed 15%, leading to the formation of explosive gas mixtures. Therefore, strictly controlling the levels of combustible gases and oxygen in the exhaust gases is an issue we need to consider carefully. In general production, the oxidation exhaust gases are diluted with nitrogen to keep their oxygen content below 10%, thereby ensuring production safety.
Storage management and safety measures for hydrogen peroxide 1. Storage management: Keep the container sealed, store it in a cool and well-ventilated warehouse, away from sources of fire and heat. It should be stored separately from flammable materials, reducing agents, food containers, etc.; mixed storage is strictly prohibited. Use explosion-proof lighting and ventilation facilities. The use of mechanical equipment and tools that may generate sparks is prohibited. The storage area should be equipped with emergency response equipment for leaks and appropriate containment materials. Prevent physical damage, friction, or impact to the container, and regularly check for any leaks. 2. Use engineering controls for protection: keep the production process enclosed, ensure adequate ventilation, and provide safety showers and eye-washing facilities. Respiratory protection: When there is a possibility of exposure to its vapors, a filtered gas mask (full-face mask) should be worn. Eye protection: Respiratory protection is in place. Physical protection: Wear polyethylene protective clothing. Hand protection: Wear neoprene gloves. Others: Smoking is strictly prohibited at the work site. After work, take a shower and change clothes. Maintain good hygiene* habits.
Emergency protection and response measures 1 First aid measures: Skin contact: Immediately remove the contaminated clothing and rinse the affected area with plenty of flowing water for at least 15 minutes. Seek medical attention. Eye contact: Immediately lift the eyelids and rinse thoroughly with plenty of flowing water or saline for at least 15 minutes. Seek medical attention. Inhalation: Quickly move to a place with fresh air. Keep the airway clear. If there is difficulty breathing, administer oxygen. If breathing stops, perform artificial respiration immediately. Seek medical attention. 2. In the event of a leak, evacuate people from the contaminated area to a safe zone promptly, isolate the area, strictly restrict access, and eliminate any sparks, sources of ignition, or fires. It is recommended that emergency responders wear self-contained positive-pressure breathing apparatus and protective clothing. If it will not cause injury to people, cut off the source of the leak as much as possible. Cover areas such as sewers near the leak site with industrial coatings or adsorbents/absorbents to prevent it from entering water bodies, water sources, drainage ditches, and other confined spaces. Minor leaks: Absorb with sand, vermiculite, or other inert materials. It can also be rinsed with a large amount of water, and the diluted wash water can then be discharged into the wastewater system. Large-scale leakage: Build dikes or dig pits to contain it. Spray water to cool and dilute steam, protect personnel on site, and dilute the leak into a non-flammable substance. Use a pump to transfer the leakage into a tank truck or a dedicated collector, for recycling or transport to a waste disposal facility for disposal. 3 Firefighters must wear full-body fire and poison-resistant suits when extinguishing fires from the upwind side. Move the container away from the fire area to an open space as much as possible. Water spray is used to keep the containers at the fire site cool until the firefighting is completed. If a container in a fire has changed color or noises are coming from its safety pressure relief device, it must be evacuated immediately. Extinguishing agents: water, fogged water, dry powder, sand. Be sure to extinguish the fire from a distance as much as possible.
The oxidation tower and the extraction tower are the key reactors in the hydrogen peroxide production process. The oxidation tower serves as the reaction vessel for the core step, namely the oxidation process; the hydrogen peroxide produced as a result of this reaction is then subjected to countercurrent extraction in the extraction tower, resulting in a hydrogen peroxide solution with a concentration of over 27.5%.