S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 1 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

NOTE: THIS DOCUMENT IS ONLY TO BE USED IN CONJUNCTION WITH THE GUIDANCE PROVIDED IN DOC REF 18.1.157

AND MUST BE COMPLETED AS FAR AS POSSIBLE BEFORE THE SHE ASSESSMENT MEETING

S H E S U M M A R Y S H E E T

SHE REF No. MISC85

DESCRIPTION OF PROCESS OR ACTIVITY: Operation of the Graphene Reactor. This involves charging 

the reactor with water, dispersant and graphite. The system is then run in recirculation mode prior to discharging 

through an in-line filter unit. The graphene dispersion is collected as a product and graphite is recovered as a wet 

cake for reuse

DATE: 31/03/14 NEXT REVIEW:

Review after first 

batch processed 

through the reactor 

and filter Author: PL Team Members: PL (Process Engineer), LG (Senior Technician), SR (QHSE Manager), JP (Process 

Manager)

WHAT IS THE WORST CASE SCENARIO WITH THIS PROCESS? (Describe below) HAZOP REQUIRED? No DATE COMPLETED N/A

Technicians are exposed to significant quantities of airborne graphene nanoplatelets over an extended period. HAZOP REF No. N/A

Note: a HAZOP is also required if one of the following is true:

1. If new technology is involved, e.g. plant/equipment.

2. If the project involves a new process or new materials of which we have no experience.

A HAZOP, IF REQUIRED, MUST BE COMPLETED BEFORE CONDUCTING THE SHE ASSESSMENT.

HAZARD 

REF. NO. HAZARD ACTION REQUIRED ACTION BY (date/initials)

ACTION 

COMPLETE

1/A Charging reactor with 

demineralised water 1. Consider use of a suitable pump to charge demineralised water into the reactor. PL 11/04/14 Y

3/A Charging reactor with graphite 2. Ensure procedure states that graphite must either as a wet cake or a slurry. PL 01/04/14 Y

1/B Manual issues associated with 

charging graphite into reactor. 3. Update and communicate the spillage procedure and cleanliness policy for the area. JP 11/04/14 Y

4/B Interaction with other 

processes (1) 4. Decontaminate adjacent reactor. LG 11/04/14 Y

4/B Interaction with other 

processes (2) 5. Remove and dispose all unwanted samples in Pilot Plant. LG 11/04/14 Y

4/D Fire / explosion – Pilot Plant is 

a zoned area 6. Confirm with Works Engineer how to officially “dezone” the Pilot Plant PL 11/04/14 Y

4/F

Overpressurisation of reactor 

leading to a violent release of 

energy (1)

7. Update procedure to account for operation of the inline filter. PL 11/04/14 Y

4/F

Overpressurisation of reactor 

leading to a violent release of 

energy (2)

8. Confirm the trip overload setting on the pump. PL 11/04/14 Y

5/C Traps, crush, in-running nips. 9. Update procedures to state that the inline filter stirrer must be shut down before the 

filter is opened up PL 01/04/14 Y
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 2 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

SECTION 1: ASSESSMENT OF COSHH & ENVIRONMENTAL HAZARDS

Using the guidance, DOC REF 18.1.157, identify each of the substances or wastes to be used/produced during this process.

SUBSTANCES (to be completed by R&D/Production BEFORE the SHE Meeting)

Hazard 

Ref. No. Substance Name PHYSICAL FORM WELMg/m3

HEALTH /SAFETY AND 

ENVIRONMENTAL HAZARDS

1

Demineralised 

water Liquid N/A N/A

2 Dispersant (ionic) Powder 10 mg/m3 

Not a hazardous substance or mixture 

according to Regulation (EC) No 

1272/2008

Not a hazardous substance or mixture 

according to EC-directives 67/548/EEC or 

1999/45/EC.

3 Graphite Flakes or Wet Cake

4 mg/m3 

Taken from 

Sigma-Aldrich 

Data Sheet for 

product 332461

HEALTH

Acute Toxicity-Not Classified

Eye Corrosion-Sub-category 2A

Skin Corrosion-Not Classified

Skin Sensitization-Category 3

Mutagenicity-Not Classified

Carcinogenicity-Not Classified

Reproductive/Development- Not 

Classified

Target Organ Toxicity-Not Classified

H319 – Causes serious eye irritation

H335 – May cause respiratory irritation

ENVIRONMENTAL

Natural graphite is an insoluble, inorganic 

substance and is not expected to present 

any environmental hazards other than 

those expected for an insoluble 

particulate.
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 3 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

Hazard 

Ref. No. Substance Name PHYSICAL FORM WELMg/m3

HEALTH /SAFETY AND 

ENVIRONMENTAL HAZARDS

4

Graphene 

Dispersion

Liquid Unknown

Ultrafine dust may cause irritation of the 

eyes and respiratory system. Electrostatic 

discharges may be generated from dry 

material during handling. CAUTION: this 

form of carbon has not yet been fully 

tested regarding health, safety and 

environmental effects. 

Precautionary statement – P285: In case 

of inadequate ventilation wear respiratory 

protection.
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 4 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

WASTES AND EMISSIONS (to be completed by R&D/Production BEFORE the SHE Meeting)

Hazard 

Ref. No. Substance Name PHYSICAL FORM EXPOSURE HEALTH /SAFETY AND ENVIRONMENTAL HAZARDS

5

Processed 

Graphite Wet Cake 4 mg/m3

As per dry graphite above. The graphite 

wet cake will be collected in a barrel and 

will be reprocessed.
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 5 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

SECTION 1: ASSESSMENT OF COSHH & ENVIRONMENTAL HAZARDS – EXPOSURE

Using the guidance, DOC REF 18.1.157, identify the level of exposure to each of the substances or wastes mentioned above.

(Occupational health surveillance should be taken into account when considering controls – see PSI MISC 27 for details of current arrangements)

Hazard 

Ref. No.

IDENTIFIED EXPOSURE (CHARGING / 

DISCHARGING /WASTE RELEASE ETC)

NUMBER EXPOSED/MEDIUM OF 

RELEASE

EXPOSURE TIME / 

INTENSITY PPE CODE OTHER CONTROLS IN PLACE

1/A Charging reactor with demineralised water 2 - Contact < 60 min Std.

2/A Charging reactor with dispersant 1 - Contact / Inhalation < 60 min Std. (+ G) Paper dust mask - G

3/A Charging reactor with graphite 2 - Contact / Inhalation < 60 min Std. (+ G)

Feed graphite in as either 

a wet cake or a slurry to 

minimise dust formation

4/A Discharge reactor through inline filter 2 – Contact < 60 min Std. Wear a plastic apron

5/A Discharge graphite wet cake from filter 2 - Contact < 60 min Std. Wear a plastic apron

PPE KEY (additional to basic hat, glasses & safety shoes)

A: Half-face mask with A1B1E1K1P3 filter. B: Full-face mask with A2B2E2K2P3 filter. C: ‘Airstream’ air-fed hood. D: ‘Tornado’ air-fed hood.

E: Half-face mask’ 3M 6059’ for Fine Chem. F: Visor and apron G: Paper dust mask
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 6 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

SECTION 2: IDENTIFICATION OF OTHER HAZARDS

Using the table in the guidance, DOC REF 18.1.157, identify any other hazards not already mentioned above.

Hazard 

Ref. No. HAZARD DESCRIPTION CAUSES CONSEQUENCES CONTROLS IN PLACE

1/B Manual issues associated with charging 

water into reactor.

- Lifting containers of water 

and pouring into the reactor

- Potential for spillages of water 

– especially in the presence 

of electrical equipment;

- Injuries to the operator when 

lifting the water – he will need 

to work on a raised platform;

- Potential for a fall – especially 

when working on the platform.

- Training / supervision / SOPs

- Filling the reactor will be a two person 

job;

- Only fill the reactor using containers 

containing no more than 5 L of water;

- In line mixer motor is IP 55 rated;

- Use hand pump to fill reactor direct 

from IBC of DMW

4/B Interaction with other processes (1)

- Operation of the equipment 

adjacent to graphene 

reactor

- Potential for gas explosions or 

exposure of the technicians 

working on the graphene 

reactor to other 

nanomaterials.

- Training / supervision / SOPs

- Methane gas supply to adjacent reactor 

has been blanked off;

- Inline mixer motor is ATEX Rated;

- Standard instruction to be issued to 

operators to avoid running adjacent 

equipment simultaneously;

- Adjacent reactor to be decontaminated.

4/C Spillages of process materials – in particular 

graphene dispersion or wet graphite cake.

- Incorrect valve operation;

- Leaks from pipelines / 

process equipment;

- Spillages when transferring 

materials or charging or 

discharging the reactor or 

filter;

- Maintenance activity on the 

reactor leading to break ins 

of process lines.

- If the graphene dispersion 

dries the operators could be 

exposed to graphene 

nanoplatelets – especially as 

airborne particles;

- Graphite is a mineral and 

contains some silica in the 

form of quartz: therefore there 

is the potential to expose the 

operators, maintenance 

technicians or anyone else 

operating the equipment to 

quartz dust.

- Training / supervision / SOPs

- All spillages will be promptly cleaned up 

using the existing procedures;

- There is a bund underneath the reactor 

to catch any spilt material;

- Prior to carrying out any maintenance 

activity the equipment will need be 

decontaminated and suitable PPE worn 

if handling dry material or if the spillage 

has been allowed to dry.

4/D Fire / explosion – Pilot Plant is a zoned area

- Presence of methane and 

hot surfaces / sparks from 

electrical equipment

- Injury to personnel and 

damage to equipment

- Methane supply has been capped off –

effectively removing the need to Zone 

off the area;

- Adjacent reactor will not be used at the 

same time as the graphene reactor;

- The In Line Mixer is ATEX Rated.

1/C Working at heights when charging reactor: 

potential for falls from height

- Falling over when working 

on raised platform

- Injury to individual;

- Spillage of reactants.

- Training / supervision / SOPs

- Use of a suitable raised platform;
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 7 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

Hazard 

Ref. No. HAZARD DESCRIPTION CAUSES CONSEQUENCES CONTROLS IN PLACE

- Awareness of hazards when working 

on raised platform;

- Charging the reactor will be a twoperson job, so that the individual 

working on the platform will be passed 

any reactants that need to be fed into 

the reactor.

4/E Slips, trips and falls

- Poor housekeeping;

- Trip hazards due to wiring, 

raised objects etc.

- Injury to individual;

- Spillages of reagents;

- Damage to equipment

- Housekeeping standards in the rotary 

furnace room.

5/B Services failure - Loss of electricity supply

- Potential for filter to block up 

and over-pressurise. Could 

lock in material into the filter. 

Provided the pump also 

stops, we won’t pressurise up 

the unit;

- If the in line mixer stops, there 

is no adverse impact on the 

process apart from ceasing 

the exfoliation.

- The system has been designed for 

containment: the pressure rating of the 

filter and the pipelines are above the 

pump dead head pressure;

- If the in line shear mixer stops, the 

material can be reslurried.

4/F Overpressurisation of the reactor leading to a 

violent release of energy

- Incorrect valve operation 

leading to the inline mixer 

being dead-headed;

- Blockages in the line or the 

filter.

- Loss of containment of 

reactants;

- Damage to equipment – in 

particular the inline filter mesh 

if the differential pressure is 

too high.

- Operating procedures – in particular 

ensuring valves are in the correct 

position;

- System is designed for inherent safety: 

we cannot exceed the maximum line / 

filter pressure rating as we have 

stainless steel pipes at the pump 

discharge and the filter is rated above 

the pump dead-head pressure.

5/C Traps, crush, in-running nips. - Running with inline filter unit 

open.

- Injury to individual

- Standard operating procedure to 

ensure inline mixer stirrer is shut down 

before the filter is opened up.
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 8 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

SECTION 3: RISK EVALUATION

USE THE MATRIX IN GUIDANCE, DOC REF 18.1.157, to evaluate the risk presented by each of the hazards identified in Sections 1 and 2 - with 

the EXISTING control measures in place (identified earlier).

NOTES: 1. Any risks evaluated as HIGH or VERY HIGH must be reduced using additional control measures.

2. Risks evaluated as MEDIUM may have to be reduced using additional control measures.

2. All actions must be assigned to a person and timescales included.

3. Record the Residual Risks of each hazard with ALL control measures in place & actions completed. 

Hazard 

Ref. No. HAZARD DESCRIPTION HAZARD/SEVERITY

LIKELIHOOD/ 

EXPOSURE

RISK

(No./level)

ACTION REQUIRED ACTION BY (DATE 

& PERSON)

RESIDUAL 

RISK

1/A Charging reactor with 

demineralised water 2 3 6 / Very Low 1. Consider use of a suitable pump to charge demineralised water into the reactor. PL – 11/04/14 6 / Very Low

2/A Charging reactor with dispersant 2 2 4 / Very Low

3/A Charging reactor with graphite 7 2 14 / Low 2. Ensure procedure states that graphite 

must either as a wet cake or a slurry. PL – 11/04/14 14 / Low

4/A Discharge reactor through inline 

filter 7 2 14 / Low

5/A Discharge graphite wet cake from 

filter 7 2 14 / Low

1/B Manual issues associated with 

charging graphite into reactor. 2 3 6 / Very Low

As per action 2 to ensure that graphite is fed 

into the reactor as a wet cake or a slurry to 

minimise the likelihood of exposure.

3. Update and communicate the spillage 

procedure and cleanliness policy for the area.

JP – 11/04/14 14 / Low

4/B Interaction with other processes. 7 2 14 / Low

4. Decontaminate adjacent reactor.

5. Remove and dispose all unwanted 

samples in Pilot Plant.

JP – 11/04/14

LG – 11/04/14 14 / Low

4/C

Spillages of process materials – in 

particular graphene dispersion or 

wet graphite cake.

7 3 21 / Medium As per action 3 above. JP – 11/04/14 14 / Low

4/D Fire / explosion – Pilot Plant is a 

zoned area 5 1 5 / Very Low 6. Confirm with Works Engineer how to officially “dezone” the Pilot Plant PL – 11/04/14 5 / Very Low

1/C

Working at heights when charging 

reactor: potential for falls from 

height

4 3 12 / Low

4/E Slips, trips and falls 4 4 16 / Low

5/B Services failure 1 2 2 / Very Low
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 9 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

Hazard 

Ref. No. HAZARD DESCRIPTION HAZARD/SEVERITY

LIKELIHOOD/ 

EXPOSURE

RISK

(No./level)

ACTION REQUIRED ACTION BY (DATE 

& PERSON)

RESIDUAL 

RISK

4/F

Overpressurisation of reactor 

leading to a violent release of 

energy

7 2 14 / Low

7. Update procedure to account for operation 

of the inline filter if made permanent.

8. Confirm the trip overload setting on the 

pump.

PL – 11/04/14

PL – 11/04/14 14 / Low

5/C Traps, crush, in-running nips. 4 2 8 / Low

9. Update procedures to state that the inline 

filter stirrer must be shut down before the 

filter is opened up

PL -01/04/14 8 / Low

Major Accident Hazard Assessment (COMAH)

(See Doc Ref 18.1.157 for guidance)

DOES THE PROCESS CONSTITUTE A MAJOR ACCIDENT HAZARD? No

Dangerous Substances and Explosive Atmospheres Regulations (DSEAR)

DOES THE PROCESS ALTER THE DSEAR RATING OF THE PLANT INVOLVED? Yes

SECTION 4: OVERALL FINAL ASSESSMENT OF RISK

THE OVERALL RISK IS THE HIGHEST INDIVIDUAL RESIDUAL RISK LEVEL IDENTIFIED IN SECTION 3

OVERALL 

RISK LEVEL CRITERIA FOR DECISION / ACTIONS REQUIRED SELECT

1

LOW or

VERY LOW

While this allows some actions to be carried out on an ongoing basis, THE PROCESS OR ACTIVITY MAY BE 

PROGRESSED.

X

2 MEDIUM

Efforts may be required to reduce the risk. Risk reduction measures may be required within a defined time period. The 

process may be commenced as long as the personnel present at the SHE Assessment Meeting agree that the risk has 

been reduced ‘as far as is reasonably practicable’.

3

MEDIUMHIGH

Risk reduction measures should be implemented within a defined time period to reduce the overall risk to MEDIUM or 

LOWER.

Where the risk involves work in progress, action should be taken within a short time period, or the work should be 

stopped.

4

HIGH or 

VERY HIGH

The process or activity SHOULD NOT BE COMMENCED until the risk has been reduced to MEDIUM or LOWER.

Where the process or activity is already in progress, it SHOULD BE STOPPED IMMEDIATELY & only restarted once 

the risk has been reduced to an acceptable level.
S H E A S S E S S M E N T F O R M

Doc. Ref: 18.1.138 Page 10 of 10 Amend: 20 Issued: October 2012 Supersedes 16 / Jan 2012

PERSONNEL PRESENT AT THE SHE ASSESSMENT MEETING:

PRE-PRODUCTION AUTHORISATION:

The COMAH implications of this process should have already been checked as part of PSI CLE 16.

Please confirm by checking the box that this is the case. Checked X

All actions necessary prior to commencement of this process or activity have been completed. Any other actions must be completed by 

the target date and reported to the Production Administrator as and when complete.

SIGNED: JP / PL POSITION: Operations / Process Manager: <SIGNED ON ORIGINAL> DATE: 01 April 14

N.B. The operation/process to which this SHE relates must not be started until the Process Manager or deputy has signed above.

(NOTE: This assessment has been carried out to comply with current COSHH, IPPC, COMAH, PUWER, LOLER, Management of Health & Safety Regulations, 

and the Thomas Swan & Co. Management System.)

SECTION 5: REVIEWS

SUMMARY OF REVIEWS CARRIED OUT:

(Information to be recorded should include: date, reason(s) for review, changes made, new controls introduced, actions, persons present at 

review

DATE DETAILS OF REVIEW ACTIONS REVIEWED BY

15 Jul 14 Review following 3 months of operation Nothing to report: we have changed the recipe but this does not 

affect the scope and actions from this SHE Assessment PJL