Standard operating procedure

Splash Blending
1. Introduction
Currently two major techniques are used for fuel blending, and splash blending is most
common to avoid the inaccuracy and proper mixing of the fuel. Small-scale splash
blending is common in laboratory and generally accomplished by using a simple
glassware set-up. Fire and explosions are normally associated with flammable solvent
manipulations in labs.

2. Setup
• Assemble glassware and fuels/additives (Fig. 1) inside a properly working
chemical fume hood for blending purpose.

Figure 1. Fuel mixing inside a chemical fume hood

• For a small-scale blending (0.1 L to 0.5 L, total volume): A glass made

graduated cylinder with a glass funnel should be used for mixing the fuel inside a
properly functional chemical fume hood. Use of a round bottom flask (RBF)
equipped with a magnetic stirrer will provide homogeneous fuel blending (Fig.
2).

• For a large-scale blending (1.0 L to 5.0 L, total volume): Use a proper vessel
or a set-up.

NOTE: Whenever possible avoid using a plastic graduated cylinder and a funnel
to prevent developing static charge, and some of the solvents can react with
plastic. Hold the cylinder using a clamp to avoid dislodging and solvent spill.
(Prudent practice).

Clamp Graduated measuring

cylinder

Figure 2. Fuel blending set-up inside a chemical fume hood

 • Best Practice (glassware cleaning and drying): All glassware and solvent
should be dry before blending.

Transfer funnel

Fuel reservoir

Figure 3. Fuel reservoir for low-volume direct-injection fuel system (LVDIS)

3. General use/procedure

Please describe briefly splash blending procedure here----

NOTE: The transfer of flammable solvent may cause the mixture to catch fire.

• Remove the stopper/cap from volumetric cylinder and place a glass funnel on it,
and add solvent slowly and carefully to cylinder to avoid any spills. To avoid the
chemical exposure make sure the cylinder is placed at least 6 inches inside the
fume hood behind the plane of the sash.
• Transfer blended material to fuel reservoir (Fig. 3) slowly and carefully to avoid
any spills.

4. Safety considerations

Flammable liquids can be ignited easily by a flame, hot surface, or a spark generated by
electricity or mechanical work. Highly volatile solvents/fuels pose the highest hazard
because the vapor can reach ignition sources several feet away. If the vapor is ignited, the
fire can quickly reach the bulk liquid. A flammable vapor and air mixture with a specific
concentration can explode violently. Vapors are usually heavier than air, thus will
accumulate near the floor or bottom of the hood.

4a. General safety considerations

• Keep sources of ignition away when handling flammable liquids. Be aware that there
are many ignition sources in a laboratory such as outlets, electrical equipment, light
fixtures, and static electricity build-up.

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 • Keep all containers of flammable solvents tightly closed when not in use and store
inside a flammable storage cabinet.
• Use the smallest amount of the flammable liquids necessary in the work area.
• Use flammable solvents only in well-ventilated areas such as a chemical fume hood to
avoid the build-up of an explosive atmosphere. Never pour large amounts while
working on an open bench top, and never let flammable solvents evaporate while
placed on an open bench top.

4b. Hazard identification

Perform a thorough literature search about solvent reactivity and compatibility before
starting the blending. Discuss the procedure and safe techniques with your PI or with
senior members in the lab. Relate RAMP method (The four principles of safety; Fig. 4)
for recognizing and eliminating the hazards with laboratory experiment.

The Four Principles of Safety

Recognize Hazards
Assess Risks
Minimize Hazards
Prepare for Emergencies

RAMP

Laboratory Safety for Chemistry Students: by Hill, & Finster; Wiley, ISBN: 978-1-
119-02766-9

Figure 4. RAMP

Isooctane (2,2,4-trimethyl pentane) liquid and vapors are highly flammable, and
may cause drowsiness and dizziness upon exposure.

4c. Hazard control

PPE: Long pants, closed-toed shoes, cotton-based clothing/attire, nitrile gloves, safety
glasses and cotton/flame retardant lab coat must be worn for protection against solvent
hazards.

Engineering Controls: A fume hood equipped with a vertical sash or equipped with a
combination sash will serve as an effective engineering control. The chemical fume
hood should be free of unwanted items and chemicals, especially ignition sources.

Administrative controls: Do not deviate from the instructions described in the SOP,
literature, or prior discussions with the PI. The lab supervisor and researcher for the
large-scale procedures may need to take additional precautions and conduct a new risk
assessment when preparing to conduct a large-scale reaction.

5. Emergency response
5a. Exposures
Skin and Eye Exposure: Immediately wash all the affected areas of skin with plenty of
water. Flush eyes with tepid water while keeping the eyelids apart. Immediately seek
medical advice.
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 Inhalation: Move person into fresh air in case flammable solvent breathed in. Consult a
physician.
Ingestion (Swallowing): Rinse mouth with water. Never give anything by mouth to an
unconscious person.

5b. Spills & decontaminations

Small spills: Any spills of a flammable solvent should be cleaned up immediately, using
non-flammable absorbent pads or other inert absorbent material such as sand or cat litter.
Have enough material readily available before working with flammable solvents. Do not
use paper towels to soak up flammable liquids as the paper contributes material that is
more flammable. Place the used absorbent material into a heavy-duty plastic bag (if the
solvent will not dissolve the plastic) or sealable container and dispose of as flammable
waste through EH&S.

Large spills: DO NOT attempt to clean up. Cordon off the area to prevent the spread of
the solvents (e.g. close doors to affected area, post-warning signs, alert others in the
immediate vicinity to avoid the spill area). Notify others in the area of the spill.
Immediately contact EH&S (265-5000) during work hours and 911 after hours.

5c. Decontamination of glassware and other items

Remove or transfer all blended solvent into a tightly closed container. If necessary, rinse
the glassware with acetone to remove the greasy stuff from surface.

6. Storage of flammable solvents

Keep containers tightly closed and away from heat, spark and open flames. Separate all
flammable solvent away from strong acids particularly from nitric acid and perchloric
acid. The hazard communication label on the container must read ‘Flammable’.

7. Waste/Unwanted material disposal

Unwanted fuels/solvents should be disposed of through UW Safety Dept. Use of a
solvent waste carboy is recommended for collecting used solvents/blends.

REFERENCES

This Safety Guidelines document/SOP was prepared exclusively for the use of University of
Disclaimer:
Wisconsin-Madison students, staff and faculty engaged in activities related to their education, research,
and/or employment. The content is intended to provide safe operational practices currently believed to
represent best practices in the use and handling of chemicals involved in the process, and is not intended to
replace hands-on practical training in the techniques described. It remains the responsibility of the Principal
Investigator to assure that his/her co-workers are properly trained on hazard management, which may
include adaptation contained within this document to meet specific needs to address specific hazards in a
particular experiment in a laboratory. Reference to any specific commercial product, process, or service by
trade name, trademark, manufacturer, or otherwise, does not imply its endorsement or recommendation by
University of Wisconsin-Madison.

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Example: Hazard Assessment splash blending (What if strategy)

Department: Description of Operation: By:

Chemistry/Biochemistry Use of LAH for organic syntheses Review Team Date 11/09/2017

What if? Answer Probability Consequences Recommendations

Volumetric cylinder is not Discharge of high Fire and Use a slightly larger size volumetric cylinder
enough to hold the blended fuel from the chemical even for a small-scale blending to contain the
fuel cylinder exposures solvents for proper mixing.

Electrical equipment are Electrical spark high Fire/explosion Remove all electrical equipment from
present inside the chemical chemical fume hood to avoid any electrical
fume hood spark.
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This file is excerpted from “Identifying and Evaluating Hazards in Research Laboratories: Guidelines
developed by the Hazard Identification and Evaluation Task Force of the American Chemical Society’s
Committee on Chemical Safety”.
© Copyright 2015 American Chemical Society