03.03.2026 by Aileen Sammler
Scale-Up & Safety: How NETZSCH Termica Neo Predicts What Could Go Wrong
This blog article is the second of our five-part series “The New Dimension of Thermal Analysis with NETZSCH Termica Neo: Software for the Thermal Simulation of Chemical Reactions on an Industrial Scale.”
Stay tuned and read about the following topics over the next few weeks: From the Kinetic Model to Real-World Applications; Scale-up & Safety; Polymer Curing; Thermoplastic CrystallizationCrystallization is the physical process of hardening during the formation and growth of crystals. During this process, heat of crystallization is released.Crystallization (PA12); Ceramic SinteringSintering is a production process for forming a mechanically strong body out of a ceramic or metallic powder. Sintering
Initial Situation: The batch looked perfect on paper until the temperature began to climb.
Every DSC curve appeared within acceptable limits. Every small-scale test was stable. Then, in a 50-kilogram drum, heat built faster than expected from DSC data only.
With NETZSCH Termica Neo, you will never be surprised by such a moment. It reveals how heat travels, concentrates, and turns an ordinary formulation into a potential Thermal runawayA thermal runaway is the situation where a chemical reactor is out of control with respect to temperature and/or pressure production caused by the chemical reaction itself. Simulation of a thermal runaway is usually carried out using a calorimeter device according to accelerated rate calorimetry (ARC).thermal runaway before the first large-scale trial begins.
From Insight to Prevention — A Continuation of Blog 1
In our previous article, we explored how Termica Neo brings kinetics to life in a 3D space. Now, this same spatial intelligence becomes a safety instrument, allowing engineers to predict thermal risk with scientific precision rather than relying on rules of thumb.
Why Traditional Safety Factors Miss the Real Hazard
The Φ-factor once seemed enough; a simple ratio to correct for Thermal inertiaThe thermal inertia is equivalent to the PHI-factor. Both describe the ratio of mass and specific heat capacity of a sample or sample mixture compared to that of the vessel or sample container.thermal inertia. However, real materials rarely behave ideally:
- Liquids distribute heat by convection.
- Solids and viscous systems rely on slow heat conduction.
- Reaction fronts move unevenly, triggering secondary exotherms.
The result? Safety conditions can differ greatly for the same Φ-factor.
Predicting SADT with Termica Neo
NETZSCH Termica Neo connects your kinetic data from the NETZSCH Kinetics Neo software with real geometry and boundary conditions. It automatically calculates the Self-Accelerating Decomposition reactionA decomposition reaction is a thermally induced reaction of a chemical compound forming solid and/or gaseous products. Decomposition Temperature (SADT), showing exactly where and when the temperature will exceed safe limits.
Users can:
- Switch between AdiabaticAdiabatic describes a system or measurement mode without any heat exchange with the surroundings. This mode can be realized using a calorimeter device according to the method of accelerating rate calorimetry (ARC). The main purpose of such a device is to study scenarios and thermal runaway reactions. A short description of the adiabatic mode is “no heat in – no heat out”.adiabatic and non-AdiabaticAdiabatic describes a system or measurement mode without any heat exchange with the surroundings. This mode can be realized using a calorimeter device according to the method of accelerating rate calorimetry (ARC). The main purpose of such a device is to study scenarios and thermal runaway reactions. A short description of the adiabatic mode is “no heat in – no heat out”.adiabatic scenarios.
- Test different container materials, diameters, and surrounding media.
- Visualize temperature and conversion fields in 2D and 3D.
Case Study for the Same Φ-factor: When Size Changes Everything
In a 7-cm sample, produced heat dissipates easily, whereas at 56 cm, it accumulates dangerously. Termica Neo shows how the core temperature in larger samples rises faster, igniting secondary Decomposition reactionA decomposition reaction is a thermally induced reaction of a chemical compound forming solid and/or gaseous products. decomposition. The initial temperature and Φ-factor remain constant, but the risk does not.
Reality Check – Accelerating Rate Calorimetry (ARC)The method describing isothermal and adiabatic test procedures used to detect thermally exothermic decomposition reactions.ARC® Validation
Simulations are only valuable when they mirror reality. NETZSCH validated Termica Neo results using the Accelerating Rate Calorimetry (ARC)The method describing isothermal and adiabatic test procedures used to detect thermally exothermic decomposition reactions.ARC® 305 Accelerating Rate Calorimeter with DTBP (di-tert-butyl peroxide) in toluene. The agreement between the simulated and experimental curves proves that Termica Neo captures both onset and peak temperatures with striking accuracy.
From Guesswork to Foresight
With the NETZSCH Termica Neo software, process and safety teams can:
- Quantify SADT and critical size limits before scale-up.
- Safely simulate worst-case AdiabaticAdiabatic describes a system or measurement mode without any heat exchange with the surroundings. This mode can be realized using a calorimeter device according to the method of accelerating rate calorimetry (ARC). The main purpose of such a device is to study scenarios and thermal runaway reactions. A short description of the adiabatic mode is “no heat in – no heat out”.adiabatic events on a screen.
- Identify hotspot locations that sensors might miss.
- Replace empirical safety margins with predictive confidence.
Rather than reacting to heat-runaway events, you can now prevent them.
About This Blog Series
This post continues the NETZSCH series: “The New Dimension of Thermal Analysis with Termica Neo.”
- Previously:From Kinetic Model to Real-World Application – How Termica Neo Brings Thermal Reactions to Life
- Coming next:
- Polymer Curing – How Termica Neo Makes Crosslinking Visible
- Thermoplastic CrystallizationCrystallization is the physical process of hardening during the formation and growth of crystals. During this process, heat of crystallization is released.Crystallization – Understanding PA12 in Cooling
- Ceramic SinteringSintering is a production process for forming a mechanically strong body out of a ceramic or metallic powder. Sintering – From Green Body to DensityThe mass density is defined as the ratio between mass and volume. Density Gradient
Simulate Before You Scale. See your process before it happens. Explore NETZSCH Termica Neo.
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Useful Links:
Get your free demo version:Request Demo Version of Temica Form - NETZSCH Termica Neo
Download the new brochure to learn more:Termica Neo Brochure
Direct contact:Feature Request - NETZSCH Kinetics Neo
Learn even more:Termica Neo - NETZSCH Termica Neo
