Highly Reactive, Oxidising & Explosive Chemicals — Hazardous Chemicals Safety Reference

💥 Class Overview — Highly Reactive, Oxidising & Explosive Chemicals

Oxidisers (H₂O₂, KMnO₄, calcium hypochlorite, sodium chlorate) fuel fire even without air — never fight a fire involving these with CO₂ or dry powder; use large volumes of water instead.
Organic peroxides (benzoyl peroxide, MEKP) are self-reactive and shock/friction-sensitive — refrigerated storage below the stated threshold and strict segregation from accelerators is mandatory in every FRP workshop.
Chlorosulphonic acid and oleum-type chemicals react explosively with water — dry sand or dry lime only, never water, for spill control.
Calcium carbide must never contact moisture — acetylene generation in a sealed space is a serious explosion risk.
Segregation is the core control: keep all chemicals in this class away from organics, reducing agents, and each other in storage layout.

📑 Jump to a Chemical

Hydrogen Peroxide >50% (H₂O₂)Potassium Permanganate (KMnO₄)Calcium Hypochlorite (Ca(OCl)₂)Chlorosulphonic Acid (ClSO₃H)Benzoyl Peroxide Sodium Chlorate (NaClO₃)Organic Peroxides — MEKP (Methyl Ethyl Ketone Peroxide)Calcium Carbide (CaC₂)

Hydrogen Peroxide >50% (H₂O₂)

Also known as: High-strength peroxide

Industrial Uses
Textile bleaching, pharmaceutical synthesis, rocket propellant

STORAGE HAZARDS

Vented containers only; segregate from organics, metals, reducing agents, dust; decomposes releasing O₂

HANDLING HAZARDS

Concentration-dependent burns; decomposes explosively if contaminated with iron, manganese, dust, organic material

PROCESS HAZARDS

O₂ pressure buildup in pipes/valves; splash from decomposing H₂O₂ ignites organic material

🛡️ Required PPE — Specific Grades & Types

Full face shield mandatory
Neoprene or PVC gloves (not rubber)
Chemical suit for >50%
No organic material on skin

🚨 Emergency Procedure — Large Spill / Major Leak

1	Dilute immediately with large volumes of water
2	No organic absorbents (sawdust, paper) — fire risk
3	Contain in non-combustible bund
4	Skin: flush 20 min; eye: flush 20 min + immediate hospital

Potassium Permanganate (KMnO₄)

Also known as: Purple crystals / PP

Industrial Uses
ETP/water treatment, dye intermediates, chemical synthesis

STORAGE HAZARDS

Oxidiser — segregate from combustibles, acids, glycerol, all organics; metal dust contamination causes fire

HANDLING HAZARDS

Reacts violently with glycerol, H₂SO₄ — can ignite spontaneously; stains tissue irreversible brown-black

PROCESS HAZARDS

Organic effluent mixing in ETP dosing systems causes localised fire; reaction with HCl produces Cl₂

🛡️ Required PPE — Specific Grades & Types

Chemical goggles
Nitrile or PVC gloves
P2 dust mask for dry crystals
No organic solvents on skin before handling

🚨 Emergency Procedure — Large Spill / Major Leak

1	Fire: CO₂ or dry sand — do NOT use water on burning KMnO₄ + organics
2	Spill: dry sand containment; no organic cleanup material
3	Skin: water wash; staining persistent but not further harmful
4	Eye: flush 20 min; medical review

Calcium Hypochlorite (Ca(OCl)₂)

Also known as: Bleaching powder / HTH

Industrial Uses
Water treatment, swimming pools, textile bleaching

STORAGE HAZARDS

Strong oxidiser; releases Cl₂ with acids; fire with combustibles; moisture causes decomposition and Cl₂ release; store in cool dry place

HANDLING HAZARDS

Irritating dust; skin/eye burns; contact with NH₃, acids, organic material hazardous

PROCESS HAZARDS

In powder mixing areas: dust cloud with organic dust can deflagrate; accidental acid contact generates Cl₂

🛡️ Required PPE — Specific Grades & Types

Chemical goggles
Nitrile gloves
P2 dust mask for bag handling
PVC apron

🚨 Emergency Procedure — Large Spill / Major Leak

1	Cl₂ release: evacuate; SCBA for responders
2	Water fog to suppress Cl₂
3	Fire: large volumes of water to prevent thermal decomposition
4	No organic extinguishing agent
5	Notify DISH for large releases

Chlorosulphonic Acid (ClSO₃H)

Also known as: Chlorosulfuric acid

Industrial Uses
Dyes, detergents (sulfonation), pharmaceuticals, saccharin production

STORAGE HAZARDS

Reacts explosively with water; store in sealed containers in dry, cool bunded area

HANDLING HAZARDS

Releases HCl + H₂SO₄ fumes on any moisture contact; extremely corrosive to all tissues

PROCESS HAZARDS

Even small water leaks into process equipment cause violent reaction; fume generation continuous

🛡️ Required PPE — Specific Grades & Types

Full encapsulating suit
SCBA
Butyl rubber gloves + boots
Full face shield

🚨 Emergency Procedure — Large Spill / Major Leak

1	Full SCBA + encapsulating suit — same level as oleum
2	Evacuate 100m
3	Apply dry lime or dry sand only — never water
4	Seal leak if possible; notify DISH immediately

Benzoyl Peroxide

Also known as: Organic peroxide initiator

Industrial Uses
FRP/plastic initiator, textile bleaching, pharmaceutical synthesis

STORAGE HAZARDS

Self-reactive flammable solid; decomposition above 50°C; store refrigerated; friction, shock, contamination with metal ions causes detonation

HANDLING HAZARDS

Dust/skin contact causes sensitisation; strong oxidiser — fire with reducing agents and organics

PROCESS HAZARDS

In FRP rooms: contact with promoter (cobalt naphthenate) + accelerator (DMA) causes vigorous exothermic cure — improper mixing can cause fire

🛡️ Required PPE — Specific Grades & Types

Chemical splash goggles
Nitrile gloves
Avoid friction in handling
No metal implements for scooping

🚨 Emergency Procedure — Large Spill / Major Leak

1	Fire: large volumes water spray to cool and suppress
2	Do NOT use CO₂ on burning organic peroxide — insufficient
3	Evacuate; no attempt to move burning containers
4	Store quantity <25 kg if no refrigeration available

Sodium Chlorate (NaClO₃)

Also known as: Herbicide base / bleach precursor

Industrial Uses
Textile bleaching, herbicide intermediate, paper industry

STORAGE HAZARDS

Strong oxidiser; fire with organic material even if damp; store away from all combustibles

HANDLING HAZARDS

Contact with reducing agents, sulfur, metal powders, organic acids hazardous — explosive mixtures

PROCESS HAZARDS

In textile bleaching: temperature control critical; decomposition above 300°C releases O₂ and Cl₂

🛡️ Required PPE — Specific Grades & Types

Chemical goggles
Nitrile gloves
P2 mask for dust
No organic clothing near dry product

🚨 Emergency Procedure — Large Spill / Major Leak

1	Fire: water spray — large volume cooling
2	Do NOT use CO₂ or dry powder
3	Evacuate area; notify DISH and fire services
4	Spill: wet and sweep to non-combustible container

Organic Peroxides — MEKP (Methyl Ethyl Ketone Peroxide)

Also known as: MEKP / MEK peroxide

Industrial Uses
FRP curing initiator (with polyester and vinyl ester resins), floor coatings

STORAGE HAZARDS

Self-reactive; unstable above 40°C; detonates with shock/friction; store refrigerated <30°C; segregate from all accelerators (cobalt naphthenate — explosive mixture)

HANDLING HAZARDS

Concentrated MEKP is a corrosive oxidiser; eye contact causes severe irreversible damage; MEKP + cobalt naphthenate (accelerator) without resin causes fire

PROCESS HAZARDS

In FRP shops: MEKP added to resin before cobalt — NEVER mix MEKP directly with cobalt accelerator

🛡️ Required PPE — Specific Grades & Types

Chemical splash goggles (most critical — eye loss from MEKP splash is documented)
Neoprene gloves
Full face shield for pouring
No contamination with accelerator on gloves/tools

🚨 Emergency Procedure — Large Spill / Major Leak

1	Eye splash: flush 20 min continuously with water; immediate hospital — serious irreversible injury
2	Fire: large volumes water spray
3	Do NOT move burning MEKP containers — BLEVE risk
4	Store <25 kg if no refrigeration; review quantities quarterly

Calcium Carbide (CaC₂)

Also known as: Carbide

Industrial Uses
Acetylene generation for welding/cutting, chemical synthesis

STORAGE HAZARDS

Reacts with moisture generating acetylene; store in sealed metal drums in dry area; no water contact; PESO licence for large quantities

HANDLING HAZARDS

Contact with water or moist air generates flammable and explosive acetylene; alkaline calcium hydroxide (slaked lime) co-product

PROCESS HAZARDS

In carbide lamps and portable acetylene generators: moisture control critical; impure carbide may contain phosphine and arsine impurities

🛡️ Required PPE — Specific Grades & Types

Chemical splash goggles
Dry leather or PVC gloves — no moisture on hands
Dust mask for handling
Keep away from all water sources

🚨 Emergency Procedure — Large Spill / Major Leak

1	Water contact: immediately remove from moisture source; acetylene accumulation + ignition = explosion
2	No water fire suppression — use dry sand only
3	Evacuate if acetylene accumulation suspected
4	For skin burns (alkali): flush with large amounts of water