Minimum ignition temperatures and explosion characteristics of micron-sized aluminium powder

To forestall, control, and mitigate the detrimental effects of aluminium dust, a 20-L near-spherical dust explosion experimental system and an HY16429 type dust-cloud ignition temperature test device were employed to explore the explosion characteristics of micron-sized aluminium powder under different ignition energies, dust particle sizes, and dust cloud concentration (C_dust) values; the minimum ignition temperature (MIT) values of aluminium powder under different dust particle sizes and C_dust were also examined. Flame images at different times were photographed by a high-speed camera. Results revealed that under similar dust-cloud concentrations and with dust particle size increasing from 42.89 to 141.70 μm, the MIT of aluminium powder increased. Under various C_dust values, the MIT of aluminium dust clouds attained peak value when concentrations enhanced. Furthermore, the increase of ignition energy contributed to the increase of the explosion pressure (P_ex) and the rate of explosion pressure rise [(dP/dt)_ex]. When dust particle size was augmented gradually, the P_ex and (dP/dt)_ex attenuated. Decreasing particle size lowered both the most violent explosion concentration and explosive limits.     

Experimental study on the minimum explosion concentration of anthracite dust: The roles of O2 mole fraction,inert gas and CH4 addition

The explosion characteristics of anthracite coal dust with/without small amount of CH₄ (1.14 vol %) were investigated by using a 20 L spherical explosion apparatus with an emphasis on the roles of oxygen mole fraction and inert gas. Two methods based on overpressure and combustion duration time were used to determine the minimum explosion concentration (MEC) or the lower explosion limit (LEL) of the pure anthracite coal dust and the hybrid coal-methane mixtures, respectively. The experiment results showed that increasing oxygen mole fraction increases the explosion risk of coal dust: with increasing oxygen mole fraction, the explosion pressure (P_ex) and the rate of explosion pressure rise ((dp/dt)_ex)) increase, while MEC decreases. The explosion risk of anthracite dust was found to be lower after replacing N₂ with CO₂, suggesting that CO₂ has a better inhibition effect on explosion mainly due to its higher specific heat. However, the addition of 1.14% CH₄ moderates the inhibition effect of CO₂ and the promotion effect of O₂ on anthracite dust explosion for some extent, increasing explosion severity and reducing the MEC of anthracite dust. For hybrid anthracite/CH₄ mixture explosions, Barknecht's curve was found to be more accurate and conservative than Chatelier's line, but neither are sufficient from the safety considerations. The experimental results provide a certain help for the explosion prevention and suppression in carbonaceous dust industries.     

Effect of pyrolysis and oxidation characteristics on lauric acid and stearic acid dust explosion hazards

The effect of pyrolysis and oxidation characteristics on the explosion sensitivity and severity parameters, including the minimum ignition energy MIE, minimum ignition temperature MIT, minimum explosion concentration MEC, maximum explosion pressure P_max, maximum rate of pressure rise (dP/dt)_max and deflagration index K_st, of lauric acid and stearic acid dust clouds was experimentally investigated. A synchronous thermal analyser was used to test the particle thermal characteristics. The functional test apparatuses including the 1.2 L Hartmann-tube apparatus, modified Godbert-Greenwald furnace, and 20 L explosion apparatus were used to test the explosion parameters. The results indicated that the rapid and slow weight loss processes of lauric acid dust followed a one-dimensional diffusion model (D1 model) and a 1.5 order chemical reaction model (F1.5 model), respectively. In addition, the rapid and slow weight loss processes of stearic acid followed a 1.5 order chemical reaction model (F1.5 model) and a three-dimensional diffusion model (D3 model), respectively, and the corresponding average apparent activation energy E and pre-exponential factor A were larger than those of lauric acid. The stearic acid dust explosion had higher values of MIE and MIT, which were mainly dependent on the higher pyrolysis and oxidation temperatures and the larger apparent activation energy E determining the slower rate of chemical bond breakage during pyrolysis and oxidation. In contrast, the lauric acid dust explosion had a higher MEC related to a smaller pre-exponential factor A with a lower amount of released reaction heat and a lower heat release rate during pyrolysis and oxidation. Additionally, due to the competition regime of the higher oxidation reaction heat release and greater consumption of oxygen during explosion, the explosion pressure P_m of the stearic acid dust was larger in low concentration ranges and decayed to an even smaller pressure than with lauric acid when the concentration exceeded 500 g/m³. The rate of explosion pressure rise (dP/dt)_m of the stearic acid dust was always larger in the experimental concentration range. The stearic acid dust explosion possessed a higher P_max, (dP/dt)_max and K_st mainly because of a larger pre-exponential factor A related to more active sites participating in the pyrolysis and oxidation reaction. Consequently, the active chemical reaction occurred more violently, and the temperature and overpressure rose faster, indicating a higher explosion hazard class for stearic acid dust.     

Investigations on explosion characteristics of ethyl acetate

In this study, the confined explosion characteristics of ethyl acetate were investigated in a constant volume explosion vessel using the initial pressure of 1–4 bar, the initial temperature of 358–418 K, and the equivalence ratio of 0.8–1.4. It was revealed that the peak explosion pressure and the maximum pressure rise rate of ethyl acetate increased as the initial pressure increased and the initial temperature decreased. The peak explosion pressure and maximum pressure rise rate were obtained at the equivalence ratio of 1.2 due to increased heat release rate. Furthermore, the explosion time decreased as the initial pressure decreased. In summation, EA experimental and theoretical deflagration index were investigated and compared. The experimental deflagration index showed that EA explosion was less dangerous, whereas the theoretical deflagration predicted that the explosion could be more hazardous.     

Experimental research on methane/air explosion inhibition using ultrafine water mist containing methane oxidizing bacteria

In order to deeply understand the inhibitory effect of ultrafine water mist containing methane-oxidizing bacteria on methane explosion, a small-sized semi-closed visual experimental platform was built. Five different application mist amounts (0.7 mL, 2.1 mL, 3.5 mL, 4.9 mL, 6.3 mL) of ultrafine water mist containing methane-oxidizing bacteria on 9.5% methane explosion were studied experimentally. Ultrafine water mist was generated by the ultrasonic atomization generator, and mist size was measured by a winner319 laser particle size analyzer. During the methane explosion, a high-frequency pressure sensor collected pressure change data, and a high-speed camera recorded the flame development process. The results indicated that the maximum explosion overpressure (ΔP_max) decreased with time, and the arrival time of the maximum explosion overpressure (ΔP_max) delayed. The appearance time of the “tulip” shaped flame delayed, and the flame propagation speed decreased. The ultrafine water mist and deposition can effectively inhibit the methane explosion. The explosion suppression effect of the second step spraying water mist was better. The improvement of the explosion suppression effect of the ultrafine water mist containing methane-oxidizing bacteria was attributed to the degradation effect of the methane-oxidizing bacteria. Under long-term degradation, methane-oxidizing bacteria in water mist play a role in inhibiting methane explosion.     

PAN dust explosion inhibition mechanisms of NaHCO3 and Al(OH)3

We investigate the PAN dust explosion inhibition behaviors of NaHCO₃ and Al(OH)₃ in a 20 L spherical explosion system and a transparent pipe explosion propagation test system. The results show that, in the standard 20 L spherical explosion system, the highest PAN dust explosion concentration is 500 g/m³, the maximum explosion pressure is 0.661 MPa, and the maximum explosion pressure increase rate is 31.64 MPa/s; adding 50% NaHCO₃ and 60% Al(OH)₃ can totally inhibit PAN dust explosion. In the DN0.15 m transparent pipe explosion propagation test system, for 500 g/m³ PAN dust, the initial explosion flame velocity is 102 m/s, the initial pressure is 0.46 MPa, and the initial temperature is 967 °C; adding 60% NaHCO₃ and 70% Al(OH)₃ can totally inhibit PAN dust explosion flames. Through FTIR and TG analyses, we obtain the explosion products and pyrolysis patterns of the explosion products of PAN dust, NaHCO₃, and Al(OH)₃. On this basis, we also summarize the PAN dust explosion inhibition mechanisms of NaHCO₃ and Al(OH)₃.     

Determination of explosion parameters of methane-air mixtures in the chamber of 40 dm3 at normal and elevated temperature

The experimental results of the measurements of the explosion pressure and rate of explosion pressure rise as a function of molar methane concentration in the mixture with air in the 40 dm³ explosion chamber are presented. The research was aimed at determination of the explosion limits, according to the EU Standard. The influence of initial temperature of the mixture (changing in the range of 293–473 K) on the fundamental explosion parameters was also investigated. The ignition source was an induction electrical spark of the power equal to approximately 10 W. It was stated, that the increase of initial temperature of the methane-air mixture causes a significant increase of the explosion range.     

Inhibiting effects of gas–particle mixtures containing CO2, Mg(OH)2 particles,and NH4H2PO4 particles on methane explosion in a 20-L closed vessel

The main risk factors from methane explosion are the associated shock waves, flames, and harmful gases. Inert gases and inhibiting powders are commonly used to prevent and mitigate the damage caused by an explosion. In this study, three inhibitors (inert gas with 8.0 vol% CO₂, 0.25 g/L Mg(OH)₂ particles, and 0.25 g/L NH₄H₂PO₄ particles) were prepared. Their inhibiting effects on methane explosions with various concentrations of methane were tested in a nearly spherical 20-L explosion vessel. Both single-component inhibitors and gas–particle mixtures can substantially suppress methane explosions with varying degrees of success. However, various inhibitors exhibited distinct reaction mechanisms for methane gas, which indicated that their inhibiting effects for methane explosion varied. To alleviate amplitude, the ranking of single-component inhibitors for both explosion pressure (P_ex) and the rate of explosion pressure rise [(dP/dt)_ex] was as follows: CO₂, NH₄H₂PO₄ particles, and Mg(OH)₂ particles. In order of decreasing amplitude, the ranking of gas‒particle mixtures for both P_ex and (dP/dt)_ex was as follows: CO₂–NH₄H₂PO₄ mixture, CO₂‒Mg(OH)₂ mixture, and pure CO₂. Overall, the optimal suppression effect was observed in the system with the CO₂–NH₄H₂PO₄ mixture, which exhibited an eminent synergistic effect on methane explosions. The amplitudes of P_ex with methane concentrations of 7.0, 9.5, and 11.0 vol% decreased by 37.1%, 42.5%, and 98.6%, respectively, when using the CO₂–NH₄H₂PO₄ mixture. In addition, an antagonistic effect was observed with CO₂‒Mg(OH)₂ mixtures because MgO, which was generated by the thermal decomposition of Mg(OH)₂, can chemically react with water vapor and CO₂ to produce basic magnesium carbonate (xMgCO₃·yMg(OH)₂·zH₂O), thereby reducing the CO₂ concentration in a reaction system. This research revealed the inhibiting effects of gas‒particle mixtures (including CO₂, Mg(OH)₂ particles, and NH₄H₂PO₄ particles) on methane explosions and provided primary experimental data.     

Spray and explosion characteristics of methanol and methanol-benzene blends near azeotrope formation: Effects of temperature,concentration, and benzene content

The explosion hazard of flammable liquids leaking to form spray in storage and transportation at ambient temperature has not been systematically investigated. This work presents new results from experimental investigations of the atomization and explosion characteristics of methanol, and methanol-benzene blends forming near the azeotrope under different initial conditions (initial temperature (298.15–318.15 K), methanol concentration (198–514.8 g/m³) and benzene content (41–81%)) in a 20-L spherical vessel. The empirical formulas for Sauter Mean Diameter (SMD) of the droplets and the maximum explosion pressure with respect to the initial temperature and methanol concentration were obtained from the quantitative analysis. Compared to the explosion hazard of pure methanol and methanol-benzene blends spray, the results showed that the maximum rate of pressure rise and maximum explosion temperature of methanol-benzene blends were relatively low. Furthermore, the effect of carbon soot formation on the explosion hazard during explosion development was analyzed.     

Effect of initial temperature on explosion characteristics of 2, 3, 3, 3–Tetrafluoropropene

The flammability of refrigerants is a major cause of refrigerant explosion incidents. Studying the explosion characteristics of refrigerants at different initial temperatures can provide significant benefits for solving the safety problems of refrigerants under actual working conditions. This paper studied the effects of the initial temperature and refrigerant concentration on the explosion characteristics of refrigerant 2, 3, 3, 3-tetrafluoropropene (R1234yf) at 0.1 MPa. The curves of explosion characteristics with different initial temperature revealed the same variation trend ranged from 25 °C to 115 °C. Specifically, as the refrigerant concentration was raised, the peak overpressure, the maximum rate of pressure rise, and laminar burning velocity increased initially and decreased afterwards, along with maximum values at the refrigerant concentration of 7.6%. When the refrigerant concentration was 7.6%, the peak overpressure declined exponentially with the initial temperature rise, while the maximum rate of pressure rise increased linearly. The laminar burning velocity calculated from the spherical expansion method indicated that the flame propagation was gradually accelerated by the increase of initial temperature, which coincided with the change of the maximum rate of pressure rise. Meanwhile, experiments and CHEMKIN simulation results demonstrated the effects of elevated temperature from 20 °C to 50 °C on the explosion limits of R1234yf. The lower explosion limit reduced and the upper explosion limit increased with rising initial temperature. In general, R1234yf exhibited moderate combustion and lower explosion risk, compared with traditional refrigerants.     

Effect of flame propagation regime on pressure evolution of nano and micron PMMA dust explosions

Experiments using an open space dust explosion apparatus and a standard 20 L explosion apparatus on nano and micron polymethyl methacrylate dust explosions were conducted to reveal the differences in flame and pressure evolutions. Then the effect of combustion and flame propagation regimes on the explosion overpressure characteristics was discussed. The results showed that the flame propagation behavior, flame temperature distribution and ion current distribution all demonstrated the different flame structures for nano and micron dust explosions. The combustion and flame propagation of 100 nm and 30 μm PMMA dust clouds were mainly controlled by the heat transfer efficiency between the particles and external heat sources. Compared with the cluster diffusion dominant combustion of 30 μm dust flame, the premixed-gas dominant combustion of 100 nm dust flame determined a quicker pyrolysis and combustion reaction rate, a faster flame propagation velocity, a stronger combustion reaction intensity, a quicker heat release rate and a higher amount of released reaction heat, which resulted in an earlier pressure rise, a larger maximum overpressure and a higher explosion hazard class. The complex combustion and propagation regime of agglomerated particles strongly influenced the nano flame propagation and explosion pressure evolution characteristics, and limited the maximum overpressure.     

A sneak peek into the phenomenology of fuel mist explosions: The key role of vapor fractions

The modern world depends greatly on hydrocarbons, which are ubiquitous, indispensable fuels used in nearly every existing industry. Although important, their use may trigger dangerous incidents, whether in their production, handling, storage, or transporting phase, especially when aerosolized. In light of proposing a standard procedure to assess the flammability and explosivity of fuel mists, a new test method was established based on the EN 14034 standards series. For the previous purposes, a gravity-fed mist generation system was designed and employed in a modified 20 L explosion vessel. This test method allowed the determination of the ignition sensitivity of several fuels. In addition, their explosion severity was represented by the explosion overpressure P_ex, and the rate of pressure rise dP/dt_ex, two thermo-kinetic parameters determined with a specifically developed control system and custom software. Nonetheless, a noticeable difference in the ignition sensitivity and the explosion severity was perceived when changing suppliers or petroleum cuts of some fuels. Moreover, sensitivity studies showed that both the droplet size distribution and the temperature of the droplets play a significant role in fuel mist explosion. These parameters can be directly related to the vapor fraction surrounding a droplet during its ignition. Consequently, this study focuses on the influence of varying the composition of three well-known and abundantly used fuels. Different petroleum cuts were introduced in different fractions into isooctane, Jet A1 aviation fuel, and diesel fuel mixtures, which were then aerosolized into a uniformly distributed turbulent mist cloud and ignited using spark ignitors of 100 J. Subsequently, complementary tests were executed in a vertical flame propagation tube coupled with a high-speed video camera allowing the visualization of the flame and the determination of the spatial flame velocity, and a tentative estimation of the laminar burning velocity. The latter was also estimated from the pressure-time evolution in the 20 L sphere using existing correlations. Indeed, the determination of the laminar burning velocity can be useful in modeling such accidents. Finally, highlighting the essential role of the mist and vapor fraction during their ignition has led to a better understanding of their explosion mechanisms.     

Comparative assessment of the explosion characteristics of alcohol–air mixtures

Explosion characteristics of five alcohol–air (ethanol, 1-butanol, 1-pentanol, 2-pentanol and 3-pentanol) mixtures were experimentally conducted in an isochoric chamber over wide ranges of initial temperature and pressure. The effect of temperature and pressure on the different explosion behaviors among these alcohols with various structures were investigated. Results show that the peak explosion pressure is increased with the decrease of temperature and increase of pressure. Maximum rate of pressure rise is insensitive to the temperature variation while it significantly increases with the increase of initial pressure. Among the 1-, 2-, and 3-pentanol–air mixtures, 1-pentanol has the highest values in peak explosion pressure and maximum rate of pressure rise and 2-pentanol gives the lowest values at the initial pressure of 0.1 MPa. These differences tend to be decreased with the increase of initial pressure. Among the three primary alcohol–air (ethanol, 1-butanol and 1-pentanol) mixtures, a similar explosion behavior is presented at the lean mixture side because of the combined effect of adiabtic temperature and flame propagation speed. At the rich mixture side, 1-pentanol gives the highest values in peak explosion pressure and maximum rate of pressure rise and ethanol gives the lowest values. This phenomenon can be interpretated from the combining influence of heat release and heat loss, since the flame speeds of ethanol-, 1-butanol-, 1-pentanol–air mixtures are close at rich mixture side.     

Theoretical estimation of the lower flammability limit of fuel-air mixtures at elevated temperatures and pressures

We present an approach for predicting the lower flammability limits of combustible gas in air. The influence of initial pressure and temperature on lower flammability limit has been examined in this study. The lower flammability limits of methane, ethylene and propane in air are estimated numerically at the pressure from one to 100 bar and the temperature from ambient to 1200 K. It was found that the predicted LFLs of methane, ethylene and propane decrease slightly with the elevated pressure at the high temperature. The LFLs variation for methane-air mixture is 0.17, 0.18, 0.18 volume% with the initial pressure from one to 100  bar at the initial temperature of 800 K, 1000 K and 1200 K respectively, which is significantly higher than that at lower temperature. And the LFL of methane-air mixture at 1200 K and 100 bar reaches 1.03 volume% which is much lower than that at 1 bar and ambient temperature. On the other hand, the LFLs variation is 0.11–0.12 volume% for ethylene-air mixture and 0.06–0.07 volume% for propane-air mixture with the initial temperature from 800 K to 1200 K at the same range of pressure. The LFL values at high temperatures and pressures represent higher risk of explosion.     

The explosion parameters of methanol under variable pressures and 423 K

The high-temperature and high-pressure methanol one-step oxidation has been the primary process for the mass production of dimethoxymethane. However, the risk of explosion for this process is still not properly defined. This paper presents new results from the experimental study on the explosion characteristics, including the explosion pressure and the explosion limits for methanol/air mixtures with a variable oxygen level, under an initial pressure between 0.3 MPa and 0.75 MPa and at the initial temperature of 423 K. The upper explosive limits were found to increase along with the initial pressure. If the limits for normal air are known, the oxygen effect on flammability is predictable from the thermal balance method. With a correlation for the pressure effect and a method for the oxygen effect, we can have the flammable range predictable.     

Suppression of metal dust deflagrations

Dust explosions continue to pose a serious threat to the process industries handling combustible powders. According to a review carried out by the Chemical Safety Board (CSB) in 2006, 281 dust explosions were reported between 1980 and 2005 in the USA, killing 119 workers and injuring 718. Metal dusts were involved in 20% of these incidents. Metal dust deflagrations have also been regularly reported in Europe, China and Japan.The term “metal dusts” encompasses a large family of materials with diverse ignitability and explosibility properties. Compared to organic fuels, metal dusts such as aluminum or magnesium exhibit higher flame temperature (T_f), maximum explosion pressure (P_max), deflagration index (K_St), and flame speed (S_f), making mitigation more challenging. However, technological advances have increased the efficiency of active explosion protection systems drastically, so the mitigation of metal dust deflagrations has now become possible.This paper provides an overview of metal dust deflagration suppression tests. Recent experiments performed in a 4.4 m³ vessel have shown that aluminum dust deflagrations can be effectively suppressed at a large scale. It further demonstrates that metal dust deflagrations can be managed safely if the hazard is well understood.     

Explosibility of micron- and nano-size titanium powders

Explosibility of micron- and nano-titanium was determined and compared according to explosion severity and likelihood using standard dust explosion equipment. ASTM methods were followed using a Siwek 20-L explosion chamber, MIKE 3 apparatus and BAM oven. The explosibility parameters investigated for both size ranges of titanium include explosion severity (maximum explosion pressure (P_max) and size-normalized maximum rate of pressure rise (K_St)) and explosion likelihood (minimum explosible concentration (MEC), minimum ignition energy (MIE) and minimum ignition temperature (MIT)). Titanium particle sizes were ?100 mesh (<150 μm), ?325 mesh (<45 μm), ≤20 μm, 150 nm, 60–80 nm, and 40–60 nm. The results show a significant increase in explosion severity as the particle size decreases from ?100 mesh with an apparent plateau being reached at ?325 mesh and ≤20 μm. Micron-size explosion severity could not be compared with that for nano-titanium due to pre-ignition of the nano-powder in the 20-L chamber. The likelihood of an explosion increases significantly as the particle size decreases into the nano range. Nano-titanium is very sensitive and can self-ignite under the appropriate conditions. The explosive properties of the nano-titanium can be suppressed by adding nano-titanium dioxide to the dust mixture. Safety precautions and procedures for the nano-titanium are also discussed.     

Comparison of explosion parameters for Methane–Air mixture in different cylindrical flameproof enclosures

Flameproof enclosures having internal electrical components are generally used in classified hazardous areas such as underground coalmines, refineries and places where explosive gas atmosphere may be formed. Flameproof enclosure can withstand the pressure developed during an internal explosion of an explosive mixture due to electrical arc, spark or hot surface of internal electrical components. The internal electrical component of a flameproof enclosure can form ignition source and also work as an obstacle in the explosion wave propagation. The ignition source position and obstacle in a flameproof enclosure have significant effect on explosion pressure development and rate of explosion pressure rise. To study this effect three cylindrical flameproof enclosures with different diameters and heights are chosen to perform the experiment. The explosive mixture used for the experiment is stoichiometric composition of methane in air at normal atmospheric pressure and temperature.It is observed that the development of maximum explosion pressure (P_max) and maximum rate of explosion pressure rise (dp/dt)_ex in a cylindrical flameproof enclosure are influenced by the position of ignition source, presence of internal metal or non-metal obstacles (component). The severity index, K_G is also calculated for the cylindrical enclosures and found that it is influenced by position of ignition source as well as blockage ratios (BR) of the obstacles in the enclosures.     

Flame regime estimations of gasoline explosion in a tube

Flame regime of gasoline-air mixture explosion is related to chemical reaction, turbulent flow and heat and mass transfer. Experimental data of gas velocity, pressure and flame temperature of gasoline-air mixture explosion in a tube at the equivalence ratio of 0.72, 1.00 and 1.28 were preliminarily acquired. Then, fluctuating velocities, overpressures, and burned and unburned gas temperatures at early stage (50 ms), intermediate stage (150 ms) and last stage (250 ms) in three explosions were determined through the analysis of the experimental data. Finally, the Damköhler number and Reynolds number of the early, intermediate and late stage were calculated respectively, and the flame regimes for each stage were estimated through the Damköhler number vs. Reynolds number diagram. Results show that all the flames at early, intermediate and late stage of the three explosions have the same regime of flamelets-in-eddies. The conclusions can provide some useful references for further study of the flame regime and the numerical analysis model selection of gasoline-air mixture explosion.     

Coupling effects of venting and inerting on explosions in interconnected vessels

The coupling effects of venting and CO₂ inerting on stoichiometric methane-air mixture explosions were investigated in an isolated vessel and interconnected vessels. The results indicate that venting mitigates the explosion intensity, especially for small vessels. For vessels connected by pipes, a venting design following EN 14994 (2007) and NFPA 68 (2013) could not meet the venting requirements. For an isolated big vessel and interconnected vessels, increasing the CO₂ volume fraction (Φ) from 0 to 15.0 vol% decreased the maximum explosion overpressure (P_max) and maximum rate of overpressure rise ((dP/dt)_max) and delayed t_max. For closed interconnected vessels, P_max varied approximately linearly with Φ. For both isolated vessel and interconnected vessels, the coupling effects of venting and CO₂ inerting on methane-air explosion were more efficient than those of individual mitigative method (that is, venting alone or CO₂ inerting alone).