Preventing fires and explosions in pilot plants

While the magnitude of potential consequences might vary, most hazards encountered in pilot plant operations are the same as those experienced in full scale commercial facilities. For example, safeguarding hazardous chemicals storage and transfer, protecting reaction vessels against catastrophic failure or runaways, all require careful consideration regardless of scale. We, however, want to address some aspects of pilot plants which can introduce hazards unique or more common to their operation. To illustrate, we present some case histories from our own pilot plant experience in BASF's Chemical Engineering Department, and include a brief discussion of some corresponding safeguards to mitigate these situations.