Chemical Process Evaluation

Chemical processing data to make smarter, faster decisions 

Gather and integrate chemical reaction hazard data to flawlessly design, scale or validate your chemical processes.
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Understand and evaluate the data behind your potentially hazardous materials, without delay.

Integrating chemical reaction hazard data into your process project shouldn’t be difficult. We understand that waiting weeks to receive a quote and then even longer lead times for your results isn’t sustainable for you, your project or your business.

Sigma-HSE’s CPE laboratory provides actionable test data within weeks, not months. Allowing you to focus on what really matters.

Scale-up

Accelerate your journey from laboratory-scale synthesis to large-scale production

Build your chemical process flows from inception and utilise our thermal screening tools at any point during the exploration of your synthetic routes.

  • Screen: from product identification through to route optimisation, understand and screen for highly energetic materials, decomposition limits, and pressure generation.
  • Guide: receive and implement preliminary data collected during the screening stage to guide your teams in their process development journey.
  • Optimise: integrate reaction calorimetry data with low-phi factor adiabatic calorimetry information to provide data sets that are representative of your process at scale. Gather detailed enthalpic information to gain insight into optimisation opportunities.

For any product or process journey, Sigma-HSE can develop a supporting Chemical Process Evaluation (CPE) testing strategy.

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Process Design

Design and maintain safe processes with reproducible datasets, tailored to you

Utilise time, temperature, pressure, concentration, and explosive data to design, build and implement plant, process, and transport control parameters.

  • Verify: identify and verify questionable data, literature calculations, and materials that may have evolved due to manufacturing changes in plant design, raw material grade or supplier changes.
  • Control & Calibrate: use appropriate data, adequate control alarms and instrumentation to detect the early signs of onset of thermal runaway, and ensure your process control systems have been calibrated and maintained to deal with this scenario.
  • Create: bespoke testing packages from our suite of chemical reaction hazard testing methods to suite your project goals, with the ability to extend beyond basic thermal stability analysis and offer insight into reagent accumulation, gas flow, time-to-maximum rate, and vent-sizing data.

Sigma-HSE can provide CPE data to a support the safe design and maintenance of your chemical processes.

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Management of Change

Improve your Management of Change systems with validated data 

Systematically implement and manage organisational and process change throughout your operations.

  • Assess: understand your operating envelope, P&IDs and equipment specifications so you can properly assess whether your proposed change management is acceptable, or an increasing risk factor.
  • Modify: guarantee that your valid data supports formal process modifications. Change, no matter how minor can lead to undesired events.
  • Execute: valid and tailored testing data of your chemical process provides the best foundation on which to execute risk assessments, appropriate staff training or QA/QC documentation practices.

Sigma-HSE can support your change management processes by providing and validating your chemical processes and organisational change strategy.

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Chemical Process Evaluation Tests

Differential Scanning Calorimetry (DSC) 

ASTM E 537-24
Test conducted as a screening method to assess the extent and presence of enthalpic changes and to approximate both the temperature of initiation and enthalpies (heats) of solids, liquids or slurries. 
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Accelerating Rate Calorimetry (ARC)

ASTM E 1981-22
Test conducted to assess the time, temperature and pressure data of a material as it undergoes a physicochemical change under near adiabatic conditions.
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Reaction Calorimetry (RC)

Bespoke to reaction under study
Testing method is used to identify potential reactive chemical hazards in processes. Each test involves a bespoke developed method depending on the specific requirements of the chemical reaction to be studied.
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Carius Tube

Recognised industry standard test
It is primarily undertaken to investigate exothermic activity and gas generation. It can aid in the detection of exothermic activities such as onset temperatures and identify the pressure effects of gas generation.
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Advanced Reactive System Screening Tool (ARSST)

Recognised industry standard test
Test is a pseudo-adiabatic calorimeter batch reactor tool that is used to quickly identify potential reactive chemical hazards in processes including the determination of thermal decomposition onsets.
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Vent Sizing Package 2 (VSP2)

Recognised industry standard test
Test method is an adiabatic calorimeter batch/semi-batch reactor tool with a strong reputation, that is used to quickly identify potential reactive chemical hazards in processes. Standard instrument for vent sizing.
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Fast, reliable, reproducible Chemical Process Evaluation data you can count on

91% Rated Excellent Turnaround

90% Rated Excellent Response to Contact

83% Rated Excellent for Report Content

Gather thermal runaway and/or decomposition data to correctly scale and design chemical processes without having to wait months for results or without having to pay tiered premiums. Learn how we have supported various companies in our case studies below.
Process Design

Design of Emergency Relief System via Chemical Reaction Hazards Assessment and Vent Size Screening

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Scale-Up

Chemical Brand Supported Through New Process R&D Scale-Up 

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Chemical Manufacturer

“Great Service all-round. Friendly and helpful contacts, and good turnaround time.”

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Chemical Process Evaluation Testing Solutions for Every Industry

Our chemical process evaluation expertise and knowledge spans multiple industries and our solutions can be applied to your specific chemical processing operations.
Aerospace
Agrochemicals & Pesticides
Pharmaceuticals
Life Sciences
Chemical Manufacturing
Contract Manufacturers
Research & Development
Transportation & Logistics
Paints & Solvents
Fine Chemcials

How to test and analyse your potentially hazardous materials

Receive quick and accurate testing data in just a few simple steps

Contact us

Get in touch and one of our experts will reach out to learn about your process and testing requirements.

Prepare & ship

Prepare your material samples and ship them to our laboratory.

Analysis & Reports

Once we've received your samples, we'll begin testing and analysing. We'll then create and send you an actionable in-depth report.

Post-project support

If you need support after receiving your report, our team will be on hand to assist you with any questions you may have.

Request a Free CPE Technical Consultation

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Resources

Learn more about our Chemical Process Evaluation Tests

Discover our range of CPE testing solutions and how we can integrate them into your chemical processes
Choosing the right screening tools are essential for the correct design of a safety system and ensuring an appropriate Basis of Safety for a process is achieved.
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