Magnum Venus Plastech INNOVATOR II CONTROL UNIT - Manual (Page 6)

INSTALATION/OPERATIONS MANUAL
INNOVATOR II
MAGNUM VENUS PLASTECH REV 1.40
MAY 2012 PAGE 6
2.2 Catalyst (Methyl Ethyl Ketone Peroxide)
MEKP is among the more hazardous materials found in commercial channels. The safe handling of the “unstable (reactive)” chemicals presents a definite challenge to the plastics industry. The highly
reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage,
transportation, handling, processing and disposal. MEKP is a single chemical. Various polymeric forms may exist which are more or less hazardous with respect to each other. These differences may
arise not only from different molecular structures (all are, nevertheless, called “MEKP”) and from possible trace impurities left from the manufacture of the chemicals, but may also arise by contamination of
MEKP with other materials in its storage or use. Even a small amount of contamination with acetone, for instance, may produce an extremely shock-sensitive and explosive compound.
Contamination with promoters or materials containing promoters, such as laminate sandings, or with any readily oxidizing mate rial, such as brass or iron, will cause exothermic “redox”
reactions which can become explosive in nature. Heat applied to MEKP, or heat build-up from contamination reactions can cause it to reach what is called its Self-Accelerating
Decomposition Temperature (SADT).
Researchers have reported measuring pressure rates-of-rise well in exc ess of 100,000 psi per second when certain MEKP’s reach their SADT. (For comparison, the highest pressure rate-of-rise listed in
NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi per second for an explosion of 12% acetylene and air. The maximum value listed for a hydrogen explosion is 10,000 psi per second. Some forms
of MEKP, if allowed to reach their SADT, will burst even an open topped container. This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate-of-rise. The
user should be aware that any closed container, be it a pressure vessel, surge chamber, or pressure accumulator, could explode under certain conditions. There is no engineering substitute for care by the
user in handling organic peroxide catalysts. If, at any time, the pressure relieve valve on top of the catalyst tank should vent, the area should be evacuated at once and the fire department called. The
venting could be the first indication of a heat, and therefore, pressure build-up that could eventually lead to an explosion. Moreover, if a catalyst tank is sufficiently full when the pressure relief valve vents,
some catalyst may spray out, which could cause eye injury. For this reason, and many others, anyone whose job puts them in an area where this vented spray might go, should always wear full eye
protection even when laminating operations are not taking place.
Safety in handling MEKP depends to a great extent on employee education, proper safety instructions and safe use of the chemicals and equipment. Workers should be thoroughly informed of the
hazards that may result from improper handling of MEKP, especially in regards to contamination, heat, friction and impact. They should be thoroughly instructed regarding the proper action to be taken in
the storage, use and disposal of MEKP and other hazardous materials used in the laminating operation. In addition, users should make every effort to:
Store MEKP in a cool, dry place in original containers away from direct sunlight and away from other chemicals.
Keep MEKP away from heat, sparks and open flames.
Prevent contamination of MEKP with other materials, including polyester over spray and sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless steels.
Never add MEKP to anything that is hot, since explosive decomposition may result.
Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all times. During clean-up of spilled MEKP, personal safety equipment, gloves and eye protection must be
worn. Firefighting equipment should be at hand and ready.
Avoid spillage, which can heat up to the point of self-ignition.
Repair any leaks discovered in the catalyst system immediately, and clean up the leaked catalyst at once in accord ance with the catalyst manufacturer’s instructions.
Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst system (i.e.: hoses, fitting, etc.) because a dangerous chemical reaction may result between
substituted parts and MEKP.
Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank, such catalyst should be diluted with copious
quantities of clean water and disposed of in accordance with the
catalyst manufacturer’s instructions.
The extent to which the user is successful in accomplishing these ends and any additional recommendations by the catalyst manufacturer determines largely the safety that will be present in his operation.