The intrinsic nature of R&D activities is dynamic- the use of new chemicals and development of cutting-edge, sustainable processes at a rapid pace- can increase potential for Process Safety and Reactive Chemicals incidents. Industrial and academic laboratories have experienced several significant laboratory Process Safety and Reactive Chemicals incidents and near misses. Dow boasts a large, world-class R&D organization; internal Root Cause Investigations indicate improvements are needed in chemical hazard recognition skills, chemical storage/handling and inventory management. This work presents a Dow initiative to address and combat such incidents through the charter of a multidisciplinary team comprised of Reactive Chemicals, EH&S, Process Safety, and R&D personnel, who have collaborated to develop and deliver training modules which focus on high-interest safety topics.<br/>Module topics were chosen on the basis of reoccurrence rate and potential severity. Training material is designed to provide laboratory personnel with basic knowledge, specific topical hazard awareness, and information on how to prevent incidents with the goal to reduce the number and severity of incidents.<br/>Over a dozen modules, which highlight incidents and case studies, have been produced and delivered since the project’s inception. Modules are succinct and topics range from working with pyrophoric materials, isocyanates, peroxide-forming chemicals, packaging waste containers, and general lab process safety. One project goal is to equip laboratory personnel with the skills to perform hazard analyses, evaluate worst-case scenarios, and understand and implement appropriate safeguards.<br/>This presentation will describe project motivation, team member selection, topic choice, project deliverables, efficacy efforts and lessons learned; selected examples of the newly-developed training content will be included.

Process safety incident prevention project: An initiative to reduce incidents across Dow laboratories

ACS Spring 2022

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.