Process Safety Management: Safeguarding Innovation in Chemical Manufacturing

A tech start-up was developing a new process to mass-produce chemicals for lithium-ion batteries. This process involved using hazardous materials that are regulated by OSHA’s safety standards and the EPA’s Risk Management Program. Although the amounts used were below the regulated limits, the company wanted to be prepared for future regulations as they planned to scale up production. They also aimed to manage potential risks both on and off their site proactively.

Antea Group helped by leading a detailed safety analysis called a HAZOP (Hazard and Operability Study). They brought together a team that included the client’s own staff as well as their design and construction partners. Even though the hazardous materials were below the regulated limits, Antea Group conducted a Process Hazard Analysis (PHA) to identify any risks early on. They used PHA Pro® software to carefully document every step of the analysis and provided clear recommendations for any needed safety improvements.

The start-up gained valuable insights from this proactive safety review. They received a thorough safety analysis that helped them manage risks effectively as they prepared to scale up. The on-site assessment identified potential issues and offered practical solutions for corrective actions or ongoing improvements. By understanding the impact of the risks on people, the environment, property, and business operations, the start-up was better equipped to grow their business safely and confidently.