Lower explosion limit of hybrid mixtures of burnable gas and dust

Hybrid mixtures – mixtures of burnable dusts and burnable gases – pose special problems to industries, as their combined Lower Explosion Limit (LEL) can lie below the LEL of the single substances. Different mathematical relations have been proposed by various authors in literature to predict the Lower Explosion Limit of hybrid mixtures (LEL_hybrid). The aim of this work is to prove the validity or limitations of these formulas for various combinations of dusts and gases. The experiments were executed in a standard 20 L vessel apparatus used for dust explosion testing. Permanent spark with an ignition energy of 10 J was used as ignition source. The results obtained so far show that, there are some combinations of dust and gas where the proposed mathematical formulas to predict the lower explosible limits of hybrid mixtures are not safe enough.     

A correlation of the lower flammability limit for hybrid mixtures

Hybrid mixtures are widely encountered in industries such as coal mines, paint factories, pharmaceutical industries, or grain elevators. Hybrid mixtures explosions involving dust and gas can cause great loss of lives and properties. The lower flammability limit (LFL) is a critical parameter when conducting a hazard assessment or developing mitigation methods for processes involving hybrid mixtures. Unlike unitary dust or gas explosions, which have been widely studied in past decades, only minimal research focuses on hybrid mixtures, and data concerning hybrid mixtures can rarely be found. Although methods to predict the LFL have been developed by using either Le Chatelier's Law, which was initially proposed for homogeneous gas mixtures, or the Bartknecht curve, which was adopted for only certain hybrid mixtures, significant deviations still remain. A more accurate correlation to predict an LFL for a hybrid mixtures explosion is necessary for risk assessment. This work focuses on the study of hybrid mixtures explosions in a 36 L dust explosion apparatus including mixtures of methane/niacin, methane/cornstarch, ethane/niacin and ethylene/niacin in air. By utilizing basic characteristics of unitary dust or gas explosions, a new formula is proposed to improve the prediction of the LFL of the mixture. The new formula is consistent with Le Chatelier's Law.     

A review on hybrid mixture explosions: Safety parameters,explosion regimes and criteria,flame characteristics

The hybrid mixture of combustible dusts and flammable gases/vapours widely exist in various industries, including mining, petrochemical, metallurgical, textile and pharmaceutical. It may pose a higher explosion risk than gas/vapor or dust/mist explosions since the hybrid explosions can still be initiated even though both the gas and the dust concentration are lower than their lower explosion limit (LEL) values. Understanding the explosion threat of hybrid mixtures not only contributes to the inherent safety and sustainability of industrial process design, but promotes the efficiency of loss prevention and mitigation. To date, however, there is no test standard with reliable explosion criteria available to determine the safety parameters of all types of hybrid mixture explosions, nor the flame propagation and quenching mechanism or theoretical explanation behind these parameters. This review presents a state-of-the-art overview of the comprehensive understanding of hybrid mixture explosions mainly in an experimental study level; thereby, the main limitations and challenges to be faced are explored. The discussed main contents include the experimental measurement for the safety parameters of hybrid mixtures (i.e., explosion sensitivity and severity parameters) via typical test apparatuses, explosion regime and criterion of hybrid mixtures, the detailed flame propagation/quenching characteristics behind the explosion severities/sensitivities of hybrid mixtures. This work aims to summarize the essential basics of experimental studies, and to provide the perspectives based on the current research gaps to understand the explosion hazards of hybrid mixtures in-depth.     

基于绝热火焰温度混合气体爆炸下限的预测

准确地预测可燃混合气体的爆炸极限,对防止工业生产中时有发生的混合气体爆炸事故有着重大的意义。通过采用Gaseq软件计算CH4,C3H8,C2H4,C3H6,CH3OCH3和CO的绝热火焰温度(CAFT),分析初始温度对甲烷和丙烷混合气体(体积比1∶1)爆炸下限(LEL)的影响。结果表明:随着初始温度的升高,临界火焰温度基本不变,而LEL线性下降。使用计算绝热火焰温度法对不同比例的二元混合气体(体积比1∶1,3∶1,1∶3)以及三元混合气体(体积比1∶1∶1)的LEL进行预测,在选取的35组不同组份的混合气体中,LEL的预测值与文献值的平均绝对误差为0.081 8,平均相对误差为0.02。     

Minimum ignition energy of LDPE dust/ethylene hybrid mixture

An experimental device for evaluating the minimum ignition energy (MIE) of LDPE dust/ethylene hybrid mixture was built with the innovative mixing mode. The MIE of the hybrid mixture that contained ethylene below its lower explosive limit (LEL) was studied. The result indicated that adding a small amount of ethylene significantly reduced the MIE of the original dust cloud. All the MIEs with five different particle sizes were found to show similar trends of exponential attenuation with the increase of ethylene concentration; such attenuating effect grew as the dust particle size rose. When ethylene concentration increased and approached to its LEL, the reaction mechanism dominated by combustible dust turned into one dominated by combustible gas. The MIE decreased first and then increased with the dust mass and increased with the dust particle size. A multifactor mathematical correlation model of the MIE with the dust particle size and ethylene concentration was developed.     

Effect of initial pressure on the lower explosion limit of nicotinic acid/acetone mixture

In the work presented in this paper, the effect of initial pressure on the lower explosion limit (LEL) of the hybrid nicotinic acid/acetone mixture was investigated through standard explosion tests carried out in the 20 L sphere. From experimental results, the flammability diagram was built in the plane (concentration/minimum explosive concentration) of nicotinic acid versus (concentration/LEL) of acetone. Interestingly, it has been found that, in going from low pressures (P < 1 atm) to high pressures (P > 1 atm), the extension of the flammability region increases. This behavior has been attributed to the fact that the turbulence kinetic energy (and thus the energy dissipation) decreases with increasing initial pressure. Bartknecht's correlation for LEL of hybrid mixtures was modified to take into account the effect of pressure, and two correlations were obtained able to give satisfactory predictions of experimental data at both low pressures and high pressures.     

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.     

Influences of coal dust components on the explosibility of hybrid mixtures of methane and coal dust

In order to study the influences of coal dust components on the explosibility of hybrid mixture of methane and coal dust, four kinds of coal dust with different components were selected in this study. Using the standard 20 L sphere, the maximum explosion pressure, explosion index and lower explosion limits of methane/coal dust mixtures were measured. The results show that the addition of methane to different kinds of coal dust can all clearly increase their maximum explosion pressure and explosion index and decrease their minimum explosion concentration. However, the increase in the maximum explosion pressure and explosion index is more significant for coal dust with lower volatile content, while the decrease in the minimum explosion concentration is more significant for coal dust with higher volatile content. It is concluded that the influence of methane on the explosion severity is more pronounced for coal dust with lower volatile content, but on ignition sensitivity it is more pronounced for coal dust with higher volatile content. Bartknecht model for predicting the lower explosion limits of methane/coal dust mixture has better applicability than Le Chatelier model and Jiang model. Especially, it is more suitable for hybrid mixtures of methane and high volatile coal dust.     

柴油汽车掺烧LPG降低黑烟排放技术

研究了柴油机掺烧液化石油气(LPG)以降低黑烟排放的技术方案，并开发出了一种以独特型板调节装置为特征的机械控制式柴油/LPG双燃料供给系统。发动机不改变原有结构加装该系统后即成为柴油/LPG双燃料发动机，可以同时燃烧柴油和LPG两种燃料，并且在整个工作范围内，随着工况变化能够按照预先优化设定的型板型线规律而自动调节柴油／LPG供给量比例，使烟度降低50％以上，同时满足经济性、动力性以及操作性能等要求，此外，也可以切换为单独燃烧柴油，而不改变发动机的原有性能。该系统结构简单、成本低廉，非常适合于改装城市在用公交车，降低其黑烟排放。     

Application of the TNO multi-energy and Baker-Strehlow-Tang methods to predict hydrogen explosion effects from small-scale experiments

Analytical models or abacus are of importance to predict explosion effects in open and congested areas for industrial safety reasons. The goal of this work is to compare overpressure and flame speed values of small-scale deflagration experiments to predicted values from the TNO multi-energy (TNO ME) method and the Baker-Strehlow-Tang (BST) method. Experiments were performed in cylindrical congested volumes of hydrogen – air mixtures varying from 1.77 L to 7.07 L. The reactivity was controlled by the equivalence ratio of hydrogen-air mixtures, ranging from 0.5 to 2.5. The congestion was realized with varying numbers of grid layers and configurations. The influence of the obstacle density and the importance of the mixture reactivity to choose the strength index in order to predict the effects of an explosion has been highlighted for the TNO ME method. Predictive flame speed values from the BST method are in accordance with almost half of the experimental results and the method is conservative in most tested configurations. The use of the TNO ME method has been validated on a small-scale experiment to predict maximal overpressures generated by the deflagration of medium and large-scale H₂/air clouds.     

Experimental investigation of limiting oxygen concentration of hybrid mixtures

An investigation into the limiting oxygen concentration (LOC) of fifteen combustible dusts and methane, ethanol and isopropanol hybrid mixtures in the standard 20 L explosion chamber was performed. Three ignition energies (10 J, 2 kJ and 10 kJ) were used. The results show that a 10 J electrical spark ignition leads to significantly higher limiting oxygen concentration values than either 2 kJ or 10 kJ pyrotechnic igniters. This could be due to the “overdriving” effect of the chemical igniters, which produce a hot flame that virtually covers the entire explosion chamber during combustion. With respect to hybrid mixture investigation, the 20 L sphere was modified to allow the input of methane gas and flammable solvents. The limiting oxygen concentrations of the hybrid mixtures were found to be considerably lower than those of dust air mixtures when the relatively weaker spark igniter was used. There was no significant change in limiting oxygen concentration when the higher energy chemical igniters were used.     

Explosion behavior of hydrogen–methane/air mixtures

The effects of enriching natural gas with hydrogen on local flame extinction, combustion instabilities and power output have been widely studied for both stationary and mobile systems. On the contrary, the issues of explosion safety for hydrogen–methane mixtures are still under investigation.In this work, experimental tests were performed in a 5 L closed cylindrical vessel for explosions of hydrogen–methane mixtures in stoichiometric air. Different compositions of hydrogen–methane were tested (from pure methane to pure hydrogen) at varying initial pressures (1, 3 and 6 bar).Results have allowed the quantification of the combined effects of both mixture composition (i.e., hydrogen content in the fuel) and initial pressure on maximum pressure, maximum rate of pressure rise and burning velocity. The measured burning velocities were also correlated by means of a Le Chatelier’s Rule-like formula. Good predictions have been obtained (at any initial pressure), except for mixtures with hydrogen molar content in the fuel higher than 50%.     

Effect of inert species on the laminar burning velocity of hydrogen and ethylene

The maximum laminar burning velocity (LBV) of a fuel-air mixture is an important input parameter to vapor cloud explosion (VCE) blast load prediction methods. In particular, the LBV value has a significant impact on the predicted blast loads for high reactivity fuels with the propensity to undergo a deflagration-to-detonation transition (DDT). Published data are available for the maximum LBV of many pure fuel-air mixtures. However, little test data are available for mixtures of fuels, particularly for mixtures of fuels and inert species. Such mixtures are common in the petroleum refining and chemical processing industries. It is therefore of interest to be able to calculate the maximum LBV of a fuel/inert mixture based on the mixture composition and maximum LBV of each component.This paper presents measured test data for the maximum LBV of H₂/inert and C₂H₄/inert mixtures, with both nitrogen and carbon dioxide as the inert species. The LBV values were determined using a constant-volume vessel and the pressure rise method. This paper also provides a comparison of the measured LBV values with simplified LBV prediction methods.     

Study of the propagation of kerosene explosions inside a partitioned vessel

The aim of this work is to present a simple modelling in order to predict the evolution of the thermodynamical characteristics of the combustion of kerosene droplets in each compartment of a closed or a vented vessel.A simple representation of the combustion phenomena based on energy transfers and the action of specific molecular species is presented.The fuel ratio of the mixture is defined by the experimental determination of the partial pressure of the kerosene vapors. The total mass rate of gaseous substances due to the difference of pressure between adjacent compartments or the surrounding atmosphere is calculated by the standard orifice equations. A calculation methodology is developed to simulate the transmission of the explosion from one compartment to another adjacent compartment in simple structures with a possible extension to complex multi-partitioned structures. The model allows the study in each compartment of the influence of various parameters such as the fuel ratio of the mixture, the size of the inner openings or the venting effects.Calculation and experimental results show that in all cases, overpressures appear in the adjoining areas to the ignition compartment.     

Hybrid H2/Al dust explosions in Siwek sphere

Explosion indices and explosion behaviour of Al dust/H₂/air mixtures were studied using standard 20 l sphere. The study was motivated by an explosion hazard occurring at some accidental scenarios considered now in ITER design (International Thermonuclear Experimental Reactor). During Loss-of-Vacuum or Loss-of-Coolant Accidents (LOCA/LOVA) it is possible to form inside the ITER vacuum vessel an explosible atmosphere containing fine Be or W dusts and hydrogen. To approach the Be/H₂ explosion problem, Be dust is substituted in this study by aluminium, because of high toxicity of Be dusts. The tested dust concentrations were 100, 200, 400, 800, and 1200 g/m3; hydrogen concentrations varied from 8 to 20 vol. % with 2% step. The mixtures were ignited by a weak electric spark. Pressure evolutions were recorded during the mixture explosions. In addition, the gaseous compositions of the combustion products were measured by a quadruple mass-spectrometer. The dust was involved in the explosion process at all hydrogen and dust concentrations even at the combination ‘8%/100 g/m3’. In all the other tests the explosion overpressures and the pressure rise rates were noticeably higher than those relevant to pure H₂/air mixtures and pure Al dust/air mixtures. At lower hybrid fuel concentrations the mixture exploded in two steps: first hydrogen explosion followed by a clearly separated Al dust explosion. With rising concentrations, the two-phase explosion regime transits to a single-phase regime where the two fuel components exploded together as a single fuel. In this regime both the hybrid explosion pressures and pressure rise rates are higher than either H₂ or Al ones. The two fuels compete for the oxygen; the higher the dust concentration, the more part of O2 it consumes (and the more H₂ remains in the combustion products). The test results are used to support DUST3D CFD code developed at KIT to model LOCA or LOVA scenarios in ITER.     

Explosion limits of mixtures relevant to the production of 1,2-dichloroethane (ethylene dichloride)

A simple method exists to estimate the limiting oxygen concentration (LOC) based upon the lower explosion limit (LEL) by assuming (1) that the LOC lies at the apex of the explosion area, (2) that the LEL is unaffected by nitrogen addition and (3) that the apex of the explosion area lies on the stoichiometric line. This estimation method is assessed for mixtures relevant to the production of 1,2-dichloroethane. To this end, the explosion areas of ethylene/hydrogen/nitrogen/air, ethylene/nitrogen/air and ethylene/1,2-dichloroethane/hydrogen chloride/nitrogen/air mixtures are determined at typical process conditions. The experiments are performed in a closed spherical 8 l vessel. The mixtures are ignited by fusing a coiled tungsten wire, placed at the centre of the vessel. A 5% pressure rise criterion is used to determine the explosion limits. The experimental procedure is based upon EN 14756. It is found that a safe estimate of the LOC of ethylene/hydrogen/nitrogen/air mixtures can be found based upon the LEL of these mixtures.     

Fast and tiny: A model for the flame propagation of nanopowders

To avoid the influence of external parameters, such as the vessel volume or the initial turbulence, the explosion severity should be determined from intrinsic properties of the fuel-air mixture. Therefore, the flame propagation of gaseous mixtures is often studied in order to estimate their laminar burning velocity, which is both independent of external factors and a useful input for CFD simulation. Experimentally, this parameter is difficult to evaluate when it comes to dust explosion, due to the inherent turbulence during the dispersion of the cloud. However, the low inertia of nanoparticles allows performing tests at very low turbulence without sedimentation. Knowledge on flame propagation concerning nanoparticles may then be modelled and, under certain conditions, extrapolated to microparticles, for which an experimental measurement is a delicate task. This work focuses on a nanocellulose with primary fiber dimensions of 3 nm width and 70 nm length. A one-dimensional model was developed to estimate the flame velocity of a nanocellulose explosion, based on an existing model already validated for hybrid mixtures of gas and carbonaceous nanopowders similar to soot. Assuming the fast devolatilization of organic nanopowders, the chemical reactions considered are limited to the combustion of the pyrolysis gases. The finite volume method was used to solve the mass and energy balances equations and mass reactions rates constituting the numerical system. Finally, the radiative heat transfer was also considered, highlighting the influence of the total surface area of the particles on the thermal radiation. Flame velocities of nanocellulose from 17.5 to 20.8 cm/s were obtained numerically depending on the radiative heat transfer, which proves a good agreement with the values around 21 cm/s measured experimentally by flame visualization and allows the validation of the model for nanoparticles.     

甲烷煤尘燃烧爆炸试验研究

为揭示甲烷煤尘空气混合物爆炸波的传播规律,采用试验分析的方法,建立甲烷煤尘空气混合物燃烧爆炸的3种试验方案,分析不同体积分数的甲烷和不同质量浓度的煤尘消耗不同体积空气时的爆压和爆速等参数的发展趋势,探究爆轰波传播的稳定性,阐明了甲烷煤尘燃烧爆炸的基本特征。试验结果表明,在最优配比条件下,与单一甲烷空气、煤尘空气混合物相比,甲烷煤尘空气混合物的爆压、爆速明显增加。甲烷煤尘空气混合物爆轰比单一的气相、固相混合物爆轰的爆炸压力、爆速明显增加、爆轰更稳定。     

关于粉尘云爆炸下限浓度的讨论

运用Ｓｉｗｅｋ２０升球形粉尘爆炸装置，通过对几种工业粉尘测试研究，发现粉尘最低爆炸下限浓度与燃烧持续时间有关。对于不同的粉尘，从压力一时间曲线中得出的最大持续时间与利用ＩＥＣ标准测定的爆炸下限浓度相接近。依据实验结果，提出了一种新的判据。     

Experiment-based investigations of magnesium dust explosion characteristics

An experimental investigation was carried out on magnesium dust explosions. Tests of explosion severity, flammability limit and solid inerting were conducted thanks to the Siwek 20 L vessel and influences of dust concentration, particle size, ignition energy, initial pressure and added inertant were taken into account. That magnesium dust is more of an explosion hazard than coal dust is confirmed and quantified by contrastive investigation. The Chinese procedure GB/T 16425 is overly conservative for LEL determination while EN 14034-3 yields realistic LEL data. It is also suggested that 2000-5000 J is the most appropriate ignition energy to use in the LEL determination of magnesium dusts, using the 20 L vessel. It is essential to point out that the overdriving phenomenon usually occurs for carbonaceous and less volatile metal materials is not notable for magnesium dusts. Trends of faster burning velocity and more efficient and adiabatic flame propagation are associated with fuel-rich dust clouds, smaller particles and hyperbaric conditions. Moreover, Inerting effectiveness of CaCO₃ appears to be higher than KCl values on thermodynamics, whereas KCl represents higher effectiveness upon kinetics. Finer inertant shows better inerting effectiveness.