• Major new production introduction into an API facility involving four major synthesis and isolation steps with use of water reactive chemicals and exothermic reactions.
• €10m capacity expansion involving gas evolving reactions and unstable materials.
• Upgrade to waste handling tank farm involving varying mixtures of potentially incompatible materials.
• New Gas Boiler system for a minerals processing facility with a particular focus on the integrity of various interlocks per IEC 61511.
• Upgrade of a Gas Boiler system for a fine chemical manufacturer.
• ReHAZOP of a batch chemical process involving highly complex gas evolving and exothermic reactions.
• High Pressure Oxygen and Argon supply system installation.
• Vent header system with particular consideration of flashback risks. The review led to consolidation of safeguards (detonation arresters etc.) with significant capital savings.
• Wastewater UV treatment system involving hydrogen peroxide and sulphuric acid.
• PHA Revalidation of a process involving unstable and detonable compounds.
• New process introduction involving highly reactive hydrazine, as well as exothermic reactions and toxic gases.
• Hydrogenator including hydrogen venting and nitric acid handling.
• Major Brewery Upgrade.
• New pharmaceutical milling project.
• New process involving thermally unstable materials and exothermic reactions. All operations from reaction to drying.
• Ground-breaking supercritical water oxidation project.
• New Grignard-based process from reaction to drying with significant reaction hazards.
• Upgrade to a mineral processing facility.
• ReHAZOP of a pharmaceutical facility following a major industrial accident.
• Review of project involving hydrogenation, pyrophoric materials, hydrogen evolution, water reactive chemicals, exothermic and gas evolving reactions, as well as flammable solvents and potent/high toxicity compounds. All operations from reaction to drying.
• All powder handling operations (drying, sieving, milling) in a facility involving 9 different products
• Review of new tank farm involving over 20 tanks and 14 different solvents.
• New Filter/Dryer project including cleaning and decontamination cycle as well as normal processing
• Update and Revalidation of HAZOP for spray drying facility in new location
• Hydrogenation processes involving pyrophoric catalysts, exothermic reactions and water reactive chemicals
• Carbon Air Abatement System
• New Thermal oxidiser and Vent Collection System (several examples)