Charge reduction on polypropylene granules and suppression of incendiary electrostatic discharges by using a novel AC electrostatic ionizer

As a method to prevent or mitigate electrostatic charge and/or discharges, we have developed a novel AC electrostatic ionizer. In this study, we evaluated experimentally the practical version of the novel AC electrostatic ionizer with a modeling test system and a pneumatic powder transport facility. In addition, electrostatic discharges generated inside a silo while loading polypropylene (PP, 3 mm) granules were observed visually with/without the novel AC ionizer. The specific charge was clearly decreased with the novel AC electrostatic ionizer. The specific charge obtained with the four arranged AC electrostatic ionizers used was approximately one eighth of that without the AC ionizer. The incendiary bulk surface discharges completely died out inside the silo by using the four arranged ionizers.     

非平衡式双极性离子风消电技术与应用

为实现风送管道物料静电监测与控制，预防料仓静电燃爆事故，提高聚烯烃装置料仓安全水平，基于非平衡式双极性离子风消电技术，开发了双极性离子风消电器；基于离子风消电器和静电监测器，探讨了石化粉体料仓用离子风消电控制系统组成、电路、气路布局；对非平衡式双极性离子风消电系统进行现场应用测试。结果表明:基于此管道粉体消静电技术，合理调节正、负侧控制电压，可有效控制管道物料荷质比稳定在±0.3 μC/kg以内，保障聚烯烃装置料仓安全、稳定运行。     

Suppression of cone discharges in a powder silo using a grounded metal rod

While filling a large silo with coarse nonconductive powders, strong electrostatic sparks known as a cone discharge, which can become sufficiently energized to ignite a flammable dust cloud, often occur on the surface of a powder heap. In an attempt to mitigate or eliminate a cone discharge, a long metal rod with a pointed tip or a flat tip was vertically installed in the center of an experimental silo (1.5 m in diameter, 2 m in effective height) with the objective that the static charge might be released by the corona discharges or the surface potential of the powder heap reduced by the electric field reducing effect. The experimental results are summarized as follows:(1) No cone discharges were observed while the silo was being filled with polypropylene pellets when either a pointed tip or a flat-tip rod was installed so that its lower end was located 10 cm above or 30 cm below the heap surface level. A corona discharge that occurred on the pointed tip was shown to be effective to some extent in reducing the charge of the powder heap.(2) Brush discharges were observed near the metal rod and its support. However, we assume that the maximum energy was not high enough to ignite a dust cloud with minimum ignition energy greater than 3 mJ.     

Experimental study on the relationship between the charge amount of polypropylene granules and the frequency of electrostatic discharges while silo loading

This paper is a report on the relationship between the charge amount (charge to mass ratio, q/m) of polypropylene (PP, 2–3 mm) granules and the frequency of electrostatic discharges that occur while loading a metal silo. The feedback control system was used in order to control the q/m of PP granules. The electrostatic discharges inside the silo were also observed using a conventional image-intensifier system. The charging control range for PP granules was from 0 to −12 μC/kg in the q/m. The results obtained from the experiments show that (1) two kinds of electrostatic discharges were clearly observed inside a metal silo while loading PP granules, i.e., brush discharges and incendiary bulk surface discharges; (2) the number of brush discharges and incendiary bulk surface discharges increased with the increase in the q/m of PP granules, almost reaching saturation; and (3) brush discharges and incendiary bulk surface discharges began to occur at the −1.16 μC/kg and −2.33 μC/kg points in the q/m, respectively, in this study.     

Experimental study on electrostatic charging of polymer powders in mixing processes

Powder mixing is often carried out in the chemical and pharmaceutical industries. Electrostatic charges generated on polymer powders during mixing may lead to electrostatic problems due to the poor conductivity of those powders. In this study, we investigated the electrostatic charges, surface potential, and apparent volume resistivity of sample powders using a simple mixing device utilizing the Faraday cup method. To neutralize the charged powders, we also applied an AC-type ionizer in the mixing study. A commercial polyethylene powder with a mean particle size of 585 μm was tested in this experiment. The charge-to-mass ratios at the end of 600 s of mixing were ?0.075 nC/g at 295 rpm agitation speed, ?0.21 nC/g at 495 rpm, and ?0.31 nC/g at 660 rpm, high enough to cause electrostatic agglomeration and adhesion. The electric fields based on the surface potential on the powders were several hundreds of V/cm, too small to give rise to brush discharge. The apparent volume resistivity of powders estimated by a simple measurement system is 1.0 × 10¹⁶ Ωm, in reasonable agreement with that acquired by the conventional test cell method (5.9 × 10¹⁵ Ωm). The charging level on the polymer powders was reduced with an AC-ionizer.     

Assessment of explosion risks caused by cone discharges when filling silos and containers with pellets

It is well known that during the filling of silos and containers with bulk material, so-called cone discharges can occur because of electrostatic charges. Whether or not cone discharges occur at all depends on whether the breakdown field strength of air under atmospheric conditions of 3 MV/m is reached at the silo and container inner wall. This in turn depends on the charge to mass ratio of the bulk, the bulk resistivity, the bulk density, the relative permittivity of the bulk material, the silo or container diameter and the filling rate. If cone discharges can't be avoided, the energy of cone discharges can be estimated according to the equation given in the relevant guidelines TRGS 727 (2016) and IEC/TS 60079-32-1 (2013). Therefore, the coarse fraction must be considered. As soon as the energy of the cone discharge is greater than or equal to the minimum ignition energy of the bulk material introduced, there is a risk of dust explosion. Here the fine fraction of the bulk material is relevant.The investigations described are a practical example how computer models can be used to assess the occurrence of cone discharges. It is calculated for which silo and container diameters and filling rates the critical field strength of 3 MV/m is reached. In these calculations the charge relaxation during pneumatic filling with bulk material is taken into account. The results of the computational modelling together with operational boundary conditions serve as a decision basis whether exclusion of incendive ignition sources is an adequate safety measure or whether further explosion protection measures must be considered. Finally, a brief overview of other possible explosion protection measures is given.     

Ignitability of aluminous coating powders due to electrostatic spark

Electrostatic Powder coating which is a surface finishing technique has widely been used in paint industry since its invention in the 1960s. However, so far, insufficient attention has been paid to the powder fires and/or explosion hazards caused by electrostatic spark during coating process. This paper is a report of the electrostatic spark ignitability of aluminous coating powders (dry blend-type) used in practical electrostatic powder coating. The Hartman vertical-tube apparatus was used for the minimum ignition energy (MIE) test. Various aluminous coating powders, different with respect to the amount of aluminum pigment, were used in this study. Experimental results obtained in this study are as follows: (1) The aluminous coating powder was so sensitive that even an electrostatic spark with an energy as low as 10 mJ could ignite it. (2) The particle size of aluminous coating powder has a considerable effect on the ignitability when the aluminum pigment concentration is within 6 wt% of the practical coating powder manufacturing standards. Thus, the conventional expression for estimating the MIE can be useful when assessing the electrostatic hazards associated with aluminum coating powders.     

Minimum ignition energies of pure magnesium powders due to electrostatic discharges and nitrogen's effect

This paper experimentally investigated the relation between the minimum ignition energy (MIE) of magnesium powders as well as the effect of inert nitrogen (N₂) on the MIE. The modified Hartmann vertical-tube apparatus and four kinds of different-sized pure magnesium powders (median particle size, D50; 28.1 μm–89.8 μm) were used in this study. The MIE of the most sensitive magnesium powder was 4 mJ, which was affected by the powder particle size (D50; 28.1 μm). The MIE of magnesium powder increased with an increase in the N₂ concentration for the inerting technique. The magnesium dust explosion with an electrostatic discharge of 1000 mJ was suppressed completely at an N₂ concentration range of more than 98%. The experimental data presented in this paper will be useful for preventing magnesium dust explosions generated from electrostatic discharges.     

Why seeking feedback from diverse sources may not be sufficient for stimulating creativity: The role of performance dynamism and creative time pressure

We explore how the impact of seeking feedback from different sources (i.e., feedback source variety) on employee creativity is shaped by perceptions of the work environment. Specifically, we argue that two contextual factors, namely, performance dynamism (Study 1) and creative time pressure (Study 2), moderate the relationship between feedback source variety and creativity such that under conditions of high performance dynamism and low creative time pressure, individuals benefit from diverse feedback information. In Study 1 (N = 1,031), the results showed that under conditions of high performance dynamism, the relationship between feedback source variety and self‐reported creativity was nonlinear, with employee creativity exponentially increasing as a function of feedback source variety. Similarly, in Study 2 (N = 181), we found that under conditions of low creative time pressure, the relationship between feedback source variety and employee creativity was nonlinear, with supervisor‐rated creative performance exponentially increasing at higher levels of feedback source variety. Such results highlight that the relationship between feedback source variety and creative performance is affected by the perceptions of the work environment in which feedback is sought.     

Scaling of dust explosion violence from laboratory scale to full industrial scale – A challenging case history from the past

The standardized K_St parameter still seems to be widely used as a universal criterion for ranking explosion violence to be expected from various dusts in given industrial situations. However, this may not be a generally valid approach. In the case of dust explosion venting, the maximum pressure P_max generated in a given vented industrial enclosure is not only influenced by inherent dust parameters (dust chemistry including moisture, and sizes and shapes of individual dust particles). Process-related parameters (degree of dust dispersion, cloud turbulence, and dust concentration) also play key roles. This view seems to be confirmed by some results from a series of large scale vented dust explosion experiments in a 500 m³ silo conducted in Norway by CMI, (now GexCon AS) during 1980–1982. Therefore, these results have been brought forward again in the present paper. The original purpose of the 500 m³ silo experiments was to obtain correlations between P_max in the vented silo and the vent area in the silo top surface, for two different dusts, viz. a wheat grain dust collected in a Norwegian grain import silo facility, and a soya meal used for production of fish farming food. Both dusts were tested in the standard 20-L-sphere in two independent laboratories, and also in the Hartmann bomb in two independent laboratories. P_max and (dP/dt)_max were significantly lower for the soya meal than for the wheat grain dust in all laboratory tests. Because the available amount of wheat grain dust was much larger than the quite limited amount of available soya meal, a complete series of 16 vented silo experiments was first performed with the wheat grain dust, starting with the largest vent area and ending with the smallest one. Then, to avoid unnecessary laborious changes of vent areas, the first experiment with soya dust was performed with the smallest area. The dust cloud in the silo was produced in exactly the same way as with the wheat grain dust. However, contrary to expectations based on the laboratory-scale tests, the soya meal exploded more violently in the large silo than the wheat grain dust, and the silo was blown apart in the very first experiment with this material. The probable reason is that the two dusts responded differently to the dust cloud formation process in the silo on the one hand and in the laboratory-scale apparatuses on the other. This re-confirms that a differentiated philosophy for design of dust explosion vents is indeed needed. Appropriate attention must be paid to the influence of the actual dust cloud generation process on the required vent area. The location and type of the ignition source also play important roles. It may seem that tailored design has to become the future solution for tackling this complex reality, not least for large storage silos. It is the view of the present author that the ongoing development of CFD-based computer codes offers the most promising line of attack. This also applies to design of systems for dust explosion isolation and suppression.     

The effects of appraisal instrument,feedback and goal-setting on worker satisfaction and commitment

Twenty managers and 125 subordinates participated in a field experiment performed in the Israel Airport Authority. The managers received intensive training in giving performance feedback and setting specific goals when conducting appraisals of their subordinates. Following training, the managers were assigned randomly to one of four conditions: feedback and goals using BOS-based appraisal; feedback using BOS-based appraisal with no goals; feedback and goals using GRS-based appraisal; feedback alone using GRS-based appraisal. Work satisfaction and organizational commitment were measured before and after the performance appraisals were conducted. A two-way analysis of variance followed by univariate analyses by means of a studentized range test revealed that (1) the use of BOS-based appraisal increased work satisfaction significantly more than the use of GRS-based appraisal, (2) feedback followed by goal-setting resulted in significantly higher work satisfaction and organizational commitment than feedback alone, regardless of the appraisal scale that was used, and (3) the combination of BOS-based appraisal, feedback and goal-setting led to significantly higher work satisfaction than was the case in the other experimental conditions.     

Experimental study on ignitability of pure aluminum powders due to electrostatic discharges and Nitrogen's effect

In order to prevent dust explosions due to electrostatic discharges (ESD), this paper reports the minimum ignition energy (MIE) of aluminum powders in the air and the effective nitrogen (N₂) concentration for the inert technique. The Hartman vertical-tube apparatus and five kinds of different sized pure aluminum powders (median particle size, D50; 8.53 μm–51.2 μm) were used in this study. The statistic minimum ignition energy (MIE_s) of the most sensitive aluminum powder used in this study was 5 mJ, which was affected by the powder particle size (D50; 8.53 μm). In the case of aluminum powder, the inerting effects of N₂ were quite different from the polymer powders. The MIE of aluminum powder barely changed until the N₂ concentration was 89% in comparison with that of the normal air. When the N₂ concentration was 90%, the MIE of aluminum powders suddenly exceeded 1000 mJ, which does not occur easily with ESD in the industrial process.     

Experimental study on the competing effect of ceramic pellets on premixed methane-air flame propagation in a duct

It is urgent to explore effective suppression methods for gas fires and explosions to ensure the safe utilizations of combustible gases in industrial processes. In this work, experiments are performed to study the effect of spherical ceramic pellets on premixed methane-air flame propagation in a closed duct. High-speed schlieren photography and pressure transducers are used to record the flame propagation and pressure transient, respectively. Behaviors of the flame propagating through a section of the duct filled with ceramic pellets in mixtures at different equivalence ratios are scrutinized. Three different diameters of pellets are considered in the experiments. The result shows that the flame can be quenched in the case with a smaller pellet diameter (3 mm) for a wide range of equivalence ratios from fuel-lean to fuel-rich mixture. For larger pellet diameter (5 or 10 mm), flame extinction occurs in fuel-rich mixtures (e.g. Φ = 1.1, 1.2). For the cases of flame surviving through the pellets bed, the pellets show a significant influence on the flame structure and behavior. The flame propagation depends on the porosity and the mean void diameter of the porous media in the pellets bed. Small void diameter is beneficial to flame quenching, while large porosity can accelerate the flame propagation. The pressure dynamics evolution is closely related to the interaction of flame with the pellets, and it depends on whether the flame quenches in the pellets bed. Overall, d = 3 mm ceramic pellets display the best suppression effect on flame propagation and pressure buildup in this study. The results of this study are of great significance to guide the safety design of spherical suppression materials in engineering applications for process safety researchers and engineers.     

Electrostatic charges during liquid leakage

Leakage accidents of pressurized flammable liquids often occur in chemical plants. To investigate electrostatic hazards due to liquid leakage, the amounts of electrostatic charge during the leakage were observed. The electric field of the clouds generated by liquid leakage was also examined. Various types of pipeline have been designed in consideration of potential leakage that might lead to accidents during industrial processes. Leakage pressure in the range of 0.1–0.3 MPa was used. With regard to the materials, water and kerosene were used. The results obtained from the experiments show that electrostatic charges depend on leakage parameters, such as the type of liquid, the gasket material between flanges, and the pipeline pressure. In all tests, the amount of the electrostatic charges of water, 0.12–0.83 μC/kg, was larger than that of kerosene, ?0.04 to 0.16 μC/kg. The maximum value of the electric field, generated from the leakage liquid in this study, 40.9 v/cm, is a safe level. No incendiary electrostatic sparks, such as brush and/or spark discharges, were detected in our tests.     

Synergism of Ergonomics,Safety, and Quality—A Behavioral Cybernetic Analysis

Abstract

This report extends a control systems or cybernetic model of behavior to the behavior of groups of many individuals—organizations and institutions—operating together with technology as complex sociotechnical (ST) systems. The premise is that the level of quality in performance of a complex ST system is predicated upon the degree to which its organizational design incorporates elements of a closed-loop behavioral control system: control goals and objectives, sensory receptors, sensory feedback, learning and memory, effectors, and sensory feedback control. From a control systems perspective, ergonomics is essential to effective organizational self-regulation. If working conditions are poorly designed, work performance and safety and quality outcomes cannot be closely controlled. Conversely, as shown by field evidence, good design promotes synergism between ergonomics, safety, and quality as a closed-loop consequence of effective employee and organizational self-control of system performance, safety, and quality.     

The impact of feedback and self-efficacy on performance in training

This field experiment examined the main and interactive effects of self-efficacy and feedback (i.e. the use of feedback versus no feedback) on performance in a speed reading class. Results showed that the provision of feedback was beneficial to the performance of all subjects, however as subject self-efficacy increased, the beneficial effects of feedback to the subject's performance also increased. Subjects who received feedback on their performance experienced significantly greater increases in self-efficacy than subjects who received no feedback. The more positive the performance feedback received, the greater the increase in individual self-efficacy. The implications of these results for training programs are discussed.     

Experimental investigation of the lower flammability limit of volatile liquid fuel-aluminum powder mixtures in air

Aluminum powder was always chosen as an additive to improve the explosive performance. In this work, experiments were performed to investigate the lower flammability limit (LFL) of volatile liquid fuel-aluminum powder mixtures using a 20 L closed spherical stainless steel vessel at a temperature of 20 °C (293 K) and 40 °C (313 K). The volatile liquid fuels tested in the work were diethyl ether (DEE), epoxypropane (PO), n-pentane and n-hexane. DEE, PO and n-pentane are in the liquid phase at room temperature and can easily transition to the gas phase at 40 °C (313 K). Through a series of experiments carried out, it was found that the change in phase would affect the interaction between the components. Aluminum powder always has an inhibitory effect on the flammability of the mixtures when it is mixed with gas-phase fuels. The inhibition effect was most obvious when the aluminum powder concentration reached 200 g/m³. While the interaction between aluminum powder and liquid-phase volatile fuels was promotion and was influenced by the component proportion and the type of the volatile fuels.     

Experimental study on the inhibition of methane/air explosion by modified attapulgite powder

In order to explore the influence of attapulgite powder on the methane explosion, a small-size semi-closed visual explosion experiment platform was built, and experiments were carried out. The effect of spraying powder on the whole process of methane explosion was studied when methane concentration was 7%, 8%, 9.5%, 11% and 12%, respectively. When the methane concentration was 11%, the maximum explosion overpressure dropped by modified spraying attapulgite powder was as high as 33.26%, and at the same time, the reduction rate of flame propagation velocity reached the maximum value of 36.65%. Furthermore, when the methane concentration was 9.5%, the experimental results when the powder spraying amount of modified attapulgite was 120 mg, 160 mg, 200 mg, 240 mg and 280 mg showed that when the powder spraying was 240 mg, the maximum explosive overpressure decreased by 33.14%, and the reduction rate of the peak flame propagation velocity reached the maximum value of 33.73%. Through the video images recorded by the high-speed camera, the flame structure, shape, color, etc. Were analyzed. The characterization analysis illustrated that the modified attapulgite powder has a small particle size, relatively large porosity and specific surface area. Also, it has a high weight loss rate. Combined with the results of characterization analysis, the explosion suppression mechanism of modified attapulgite powder was discussed. It was found that the modified attapulgite powder could effectively absorb the active free radicals generated in the explosion, and the modified new chemical components have a better thermal decomposition and endothermic effect and a better suppression of methane explosions.     

Innovative work behavior and sex‐based stereotypes: Examining sex differences in perceptions and evaluations of innovative work behavior

Building on role congruity theory, we predict that innovative work behaviors are stereotypically ascribed to men more than to women. Because of this bias, women who innovate may not receive better performance evaluations than those who do not innovate, whereas engaging in innovative work behaviors is beneficial for men. These predictions were supported across 3 complementary field and experimental studies. The results of an experiment (Study 1; N = 407) revealed that innovative work behaviors are stereotypically associated with men more than women. In Studies 2 and 3, using multisource employee evaluation data (N = 153) and by experimentally manipulating innovative work behaviors (N = 232), respectively, we found that favorable performance evaluations were associated with innovative work behaviors for men but not for women. These studies highlight a previously unidentified form of sex bias and are particularly important for those wishing to increase innovative behaviors in the workplace: We need to address this phenomenon of “think innovation‐think male.”     

A laboratory experiment testing the antecedents of leader cognitions

A laboratory experiment was conducted to test relationships between leadership style, feedback on subordinate performance within the context of either the vision or goals of the organization, and leader cognitions representing a modified version of Wofford and Goodwin's (1994) cognitive processing model of leadership. The results indicated that: (1) positive feedback leads to the access of transformational cognitions, whereas negative feedback leads to the access of transactional cognitions; (2) negative feedback about subordinate performance causes transformational leaders to access transactional cognitions in response to subordinates; (3) the relationship between transformational leadership behavior and transformational cognitions is strengthened when feedback received about subordinates is vision‐related compared to feedback that is goal‐related; and (4) the relationship between transactional leadership behavior and transactional cognitions is strengthened when feedback received is goal‐related compared to feedback that is vision‐related. Limitations and future research directions are discussed. Copyright © 2000 John Wiley & Sons, Ltd.