Designing a safer process: hazard, scale and waste · seed 1 · A4, ink-friendly. The answer key prints on its own page for grown-ups.
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When small reactions grow up

Science · Chemistry · ages 21-22
Name ______________________   Date ____________
  1. Stopping a reagent feed guarantees that an exothermic batch immediately stops releasing reaction energy, even when reactive material remains inside.

    Circle one:   True   False

  2. A reaction worked safely in a small flask. What does this establish about a proposed reactor batch?

    • The flask's stable temperature establishes sufficient reactor cooling.
    • The flask result does not establish safety in the proposed reactor.
    • The unchanged reagent ratios establish adequate reactor cooling.
  3. SDS toxicity and exposure information should inform glove and ventilation choices, together with compatibility data and the task's risk assessment.

    Circle one:   True   False

  4. A batch generates 200 W of heat while cooling removes 120 W. With no other energy transfers or phase change, what happens?

    • Net heating is 80 W; the batch temperature rises.
    • Net heating is 320 W; the batch temperature rises.
    • Net cooling is 80 W; the batch temperature falls.
  5. A ketone-to-alcohol route uses toxic solvent H. B and C meet conversion and purity targets. B lowers assessed overall risk; C lowers toxicity but raises overall risk through flammability. Recovery and waste are equal. Which substitution is best supported?

    • Keep H because the existing solvent's performance gives it priority over the alternatives.
    • Use C because its lower toxicity outweighs the increased fire risk.
    • Use B because it meets the route's targets and lowers assessed overall risk.
  6. An ideal gas has absolute pressure 1.6 atm at 320 K. Its amount and volume stay fixed, with no leakage or phase change. It warms to 400 K. What is its new absolute pressure, in atm?

    Answer: ______________

  7. Every length of a similar reactor is multiplied by 4. Heat generation per unit volume and cooling capacity per unit wall area stay fixed. By what factor does heat load per unit wall area grow?

    • 16 times, from the wall-area factor alone.
    • 64 times, because wall area stays unchanged.
    • 4 times, from volume factor divided by area factor.
    • 1 time, because similar shapes have equal cooling loads.
  8. A batch warms because cooling is insufficient. Measurements show the exothermic reaction accelerates as temperature rises. Which feedback can cause runaway?

    • Warming slows heat release by reducing the reaction rate.
    • Warming balances heat release by increasing the cooling rate.
    • Warming increases heat release by accelerating the reaction.
  9. A proposed kilogram batch may overheat if cooling fails. Which plan directly evaluates that failure before operation?

    • Measure heat release and assess the revised design against cooling failure.
    • Measure the normal cooling rate and size the jacket to match that operating load.
    • Measure total reaction heat and choose a vessel that can hold the larger batch.
  10. A process produces wash water, used solvent and filter cake. Recovery and disposal options are not yet assessed. Which planning approach fits?

    • Combine the liquid streams for solvent recovery and send the cake for disposal.
    • Assess each stream for compatible reduction, recovery and approved disposal.
    • Treat the liquid streams by dilution and send the cake for disposal.
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Answer key

For grown-ups. Fold this page away before handing over the rest.

When small reactions grow up W1-mt_5zhSYCYU_o-s1

  1. False · Stopping further addition does not remove material already in the reactor. That material may continue reacting.
  2. The flask result does not establish safety in the proposed reactor. · The flask result concerns one setup. Scale-up changes heat transfer, mixing and hazardous inventory.
  3. True · Protection depends on exposure hazards and the task. Glove selection also needs chemical compatibility and permeation information.
  4. Net heating is 80 W; the batch temperature rises. · Generation exceeds removal by 80 W. Energy accumulates, so the batch warms under the stated conditions.
  5. Use B because it meets the route's targets and lowers assessed overall risk. · B meets conversion and purity targets and lowers assessed overall risk. C's lower toxicity does not offset its stated increase in overall risk. Equal recovery and waste do not change this comparison.
  6. 2 · P2 = 1.6 x 400/320 = 1.6 x 1.25 = 2 atm absolute.
  7. 4 times, from volume factor divided by area factor. · Volume grows by 4 cubed = 64 and wall area by 4 squared = 16. Heat load per unit wall area grows by 64/16 = 4.
  8. Warming increases heat release by accelerating the reaction. · Accumulated heat raises temperature. The faster reaction can then release heat faster, reinforcing the initial rise.
  9. Measure heat release and assess the revised design against cooling failure. · The stated failure requires assessing heat release when cooling is lost. Matching the normal cooling load or providing enough vessel volume does not evaluate that failure.
  10. Assess each stream for compatible reduction, recovery and approved disposal. · Assess streams separately, including compatibility and further waste from recovery or treatment. Dilution alone does not remove waste mass.
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