The applications of gas chromatography–mass spectrometry (GC–MS) in process safety

Gas chromatography–mass spectrometry (GC–MS) is a powerful tool in process safety, widely applied to identify and monitor hazardous chemicals in industrial environments. Its ability to separate complex mixtures and unambiguously characterize components makes it essential for detecting leaks, monitoring volatile organic compound emissions, analyzing contaminants, and ensuring regulatory compliance. This paper highlights GC–MS applications in fire risk assessment, chemical hazard evaluation, and transportation safety. Key studies include compositional analysis of flammable gases emitted during battery thermal runaway, following UL 9540A to inform fire and explosion protection standards (NFPA 855, IFC 608, UL 9540). GC–MS has also been used to quantify flammable gases from expandable polymeric beads and molding compounds, supporting safe handling and transport decisions under UN Test U.1 for UN 2211 and UN 3314 classifications. In fire investigations, GC–MS identifies ignitable liquid residues using ASTM E1618, enhancing understanding of fire origin, fuel load, and incendiary characteristics. Additional applications include verifying refrigerant blends for safety classification (ASHRAE Standard 34) and coupling GC–MS with calorimetric tools such as ARC, VSP2, and RC‐1. This integration provides complementary chemical, physical, and kinetic data, enabling deeper insight into reaction mechanisms, dynamic hazard mitigation, and accident prevention during scale‐up processes.