Limiting oxygen concentration for coal dusts for explosion hazard analysis and safety

Investigation of explosion characteristics of coal dust was undertaken as a part of regular research program at CSIR-CBRI, Roorkee, India, for designing explosion safety measures for coal dust handling installations. This paper presents results of detailed experimental work on determination of Limiting Oxygen Concentration (LOC) and influence of reduced oxygen levels on explosion severity data for two types of coals with varying volatile matter as 27.18% (coal A) and 19.69% (coal B) from Jharia coalfield of India determined at ambient conditions with 20-L Spherical Vessel established at CSIR-CBRI. The effects of coal particle size and moisture content were evaluated. Data presented will be used for hazard analysis, designing explosion preventive measures, and explosion severity reduction by involving the use of inert gases for installations handling pulverized coal with similar nature. The importance of ignition source energy in determining LOC data is highlighted. The data collected lead to an extension of the current data for coal dusts as found in the literature. Limiting oxygen concentrations were found as 7% for coal A and 8% for coal B for the size representative to that used in pulverized coal boilers and moisture content ～4%.     

储、转运粮食系统除尘粉尘回流安全性分析

对储存及转运粮食系统除尘粉尘回流问题进行了回顾和评述 ,对天津港散粮站日常处理主要粮食品种伴生粉尘进行了物性分析和粉尘爆炸性测试 ,并结合生产工艺过程进行了设备内部实际粉尘浓度的测试 ,在此基础上得出 :除尘粉尘具有爆炸的危险性 ;爆炸下限较高 ,有利于控制粉尘浓度在爆炸下限以下来预防粉尘爆炸 ;除尘粉尘回流工艺在无粉尘沉积的情况下是安全的。     

Thermo-kinetic modelling of dust explosions

The guidelines for protection and mitigation against hazard coming from dust explosion require the knowledge and then the evaluation either experimentally or theoretically of the thermo-kinetic parameters (i.e. K_St, P_max). We developed a numerical tool for the evaluation of the thermo-kinetic parameters of dust explosion. This model is based on the simulations of the combustion reaction by means of a detailed reaction mechanism assuming that the pyrolysis/devolatilization step is very fast and then gas combustion is controlling dust explosion. The model allows then the determination of the most conservative values of K_St, S_l, P_max. In the present paper we calculated the deflagration index and the laminar burning velocity for dusts utilized in various process industries (i.e. cornstarch, polyethylene, cellulose) as function of dust concentration. The obtained data were successfully compared with the available experimental results.     

Does your facility have a dust problem: Methods for evaluating dust explosion hazards

The hazards of dust explosions prevailing in plants are dependent on a large variety of factors that include process parameters, such as pressure, temperature and flow characteristics, as well as equipment properties, such as geometry layout, the presence of moving elements, dust explosion characteristics and mitigating measures. A good dust explosion risk assessment is a thorough method involving the identification of all hazards, their probability of occurrence and the severity of potential consequences. The consequences of dust explosions are described as consequences for personnel and equipment, taking into account consequences of both primary and secondary events.While certain standards cover all the basic elements of explosion prevention and protection, systematic risk assessments and area classifications are obligatory in Europe, as required by EU ATEX and Seveso II directives. In the United States, NFPA 654 requires that the design of the fire and explosion safety provisions shall be based on a process hazard analysis of the facility, process, and the associated fire or explosion hazards. In this paper, we will demonstrate how applying such techniques as SCRAM (short-cut risk analysis method) can help identify potentially hazardous conditions and provide valuable assistance in reducing high-risk areas. The likelihood of a dust explosion is based on the ignition probability and the probability of flammable dust clouds arising. While all possible ignition sources are reviewed, the most important ones include open flames, mechanical sparks, hot surfaces, electric equipment, smoldering combustion (self-ignition) and electrostatic sparks and discharges. The probability of dust clouds arising is closely related to both process and dust dispersion properties.Factors determining the consequences of dust explosions include how frequently personnel are present, the equipment strength, implemented consequence-reducing measures and housekeeping, as risk assessment techniques demonstrate the importance of good housekeeping especially due to the enormous consequences of secondary dust explosions (despite their relatively low probability). The ignitibility and explosibility of the potential dust clouds also play a crucial role in determining the overall risk.Classes describe both the likelihood of dust explosions and their consequences, ranging from low probabilities and limited local damage, to high probability of occurrence and catastrophic damage. Acceptance criteria are determined based on the likelihood and consequence of the events. The risk assessment techniques also allow for choosing adequate risk reducing measures: both preventive and protective. Techniques for mitigating identified explosions risks include the following: bursting disks and quenching tubes, explosion suppression systems, explosion isolating systems, inerting techniques and temperature control. Advanced CFD tools (DESC) can be used to not only assess dust explosion hazards, but also provide valuable insight into protective measures, including suppression and venting.     

Visualization and analysis of dispersion process of combustible dust in a transparent Siwek 20-L chamber

Dust explosion severities are closely associated with dust dispersion behaviors. To characterize the dispersion process of dust cloud, visualization experiments were conducted by using a transparent Siwek 20-L chamber. Dispersion processes of typical carbonaceous dust were recorded by a high-speed camera and, with the image processing technique, the qualitative analysis based on the transmission of dust cloud was carried out. Results have evidenced the three consecutive stages of dust dispersion process: the fast injection stage of dust particles, the stabilization stage and the sedimentation stage of dust cloud. The motion of dust particles and the variations of dust cloud in space and time can be clearly distinguished. In the stabilization stage, the good uniformity of dust dispersion is achieved when the deviation of transmission data at different locations reaches to the minimum value. Under different nominal dust concentrations, the time periods for dust dispersion stabilization are found to be significantly different, suggesting that different dust concentrations should correspond to different ignition delay in order to accurately measure the explosion characteristics in the Siwek 20-L chamber. Moreover, it is found that the decrease trend of transmission with increasing nominal dust concentration will become gradually leveling off, different from the inversely proportional relationship according to the Bouguer's law, and this indicates that the actual dust concentration will be lower than the nominal concentration or the dust cannot be fully dispersed at the case of high dust concentration. According to the experiment, when the nominal dust concentration exceeds to 1000 g/m³, the transmission will no longer vary visibly.     

Numerical modelling of the effects of vessel length-to-diameter ratio (L/D) on pressure piling

Pressure piling presents a major explosion hazard in interconnected process vessels. Pressure enhancement in the secondary vessel due to the acceleration of the flame through the connecting pipe can generate a disproportionately more violent explosion than would have been expected based on the concentration of dust in the secondary vessel. Pressure piling is a very complex phenomenon that is difficult to investigate through experimentation. Advanced computational fluid dynamics (CFD) modelling is a promising route to accurately account for all the complexities associated with pressure piling.In this paper, the current state of knowledge concerning pressure piling is presented. Further, the effects of varying the length-to-diameter ratio (L/D) of the primary vessel (Vessel 1) on pressure piling was investigated using numerical modelling. The volumes and volume ratio of the interconnected vessels were kept constant while the L/D of Vessel 1 was varied from 0.5 to 15. The simulations of coal dust explosion were performed using the coalChemistryFoam solver from OpenFOAM version 5.0.1. It is hoped that the findings from this study provide insight into the effects of the geometrical design of interconnected vessels, particularly L/D, on pressure piling. Additionally, this work has implications for the optimal placement of explosion isolation devices intended to actuate before the flame front and pressure escape to downstream vessels.     

粉尘爆炸事故模式及其预防研究

随着粉体工业的发展,粉尘爆炸发生的危险性也随之增大。为了探讨粉尘爆炸发生的规律,笔者对粉尘爆炸发生的点火源类型、事故原因进行了统计、排序;在对已发生的典型的粉尘爆炸事故分析的基础上,总结、归纳了影响粉尘爆炸发生的,诸如粉尘自身的可燃性、粉尘所处的状态、粉尘所处的外部环境等因素;提炼出了7种粉尘爆炸事故模式,并对各种模式下粉尘爆炸发生的条件、机理进行了初步研究分析,然后提出了相应的事故预防措施。笔者所研究的成果,对粉体工业的安全生产具有实际的指导作用,对今后防灾决策的深入研究也具有一定的参考价值。     

Methods for more accurate determination of explosion severity parameters

Accurate determination of explosion severity parameters (p_max, (dp/dt)_max, and K_St) is essential for dust explosion assessment, identification of mitigation strategy, and design of mitigation measure of proper capacity. The explosion severity parameters are determined according to standard methodology however variety of dust handled and operation circumstances may create practical challenge on the optimal test method and subsequent data interpretation. Two methods are presented: a statistical method, which considers all test results in determination of explosion severity parameters and a method that corrects the results for differences of turbulence intensity. The statistical method also calculates experimental error (uncertainty) that characterises the experimental spread, allows comparison to other dust samples and may define quality determination threshold. The correction method allows to reduce discrepancies between results from 1 m³ vessel and 20-l sphere caused by difference in the turbulence intensity level. Additionally new experimental test method for difficult to inject samples together with its analysis is described. Such method is a versatile tool for explosion interpretation in test cases where different dispersion nozzle is used (various turbulence level in the test chamber) because of either specific test requirements or being “difficult dust sample”.     

Effect of ignition delay on explosion parameters of corn dust/air in confined chamber

This paper presents the explosion parameters of corn dust/air mixtures in confined chamber. The measurements were conducted in a setup which comprises a 5 L explosion chamber, a dust dispersion sub-system, and a transient pressure measurement sub-system. The influences of the ignition delay on the pressure and the rate of pressure rise for the dust/air explosion have been discussed based on the experimental data. It is found that at the lower concentrations, the explosion pressure and the rate of pressure rise of corn dust/air mixtures decrease as the ignition delay increases from 60 ms; But at the higher concentrations, the explosion pressure and the rate of pressure rise increase slightly as the ignition delay increases from 60 ms to 80 ms, and decrease beyond 80 ms. The maximum explosion pressure of corn dust/air mixtures reaches its highest value equal to 0.79 MPa at the concentration of 1000 gm⁻³.     

Development of an organizational framework for studying dust explosion phenomena

To develop a predictive dust explosion model or theory many considerations of the interaction between several complex multiscale processes are required. Due to practical considerations only some of the processes may be fully resolved, while the rest must be approximated or neglected. The current study focuses on constructing an organizational framework for dust explosion model development. The framework is organized based on progression of the explosion in time and geometric scale of the important features. Suggested methodologies are given to investigate the small-scale features and develop feed-forward approximations for predictive models at the larger system-scale. The concepts developed through constructing the organizational framework are applied to closed volume dust explosion testing and classification of several sources of experimental variance for this system is given.     

Biomass explosion testing: Accounting for the post-test residue and implications on the results

This work uses the ISO 1 m³ dust explosion equipment to study the explosion properties and combustion characteristics of pulverized biomass dust clouds. An unreported feature of this apparatus is that in rich concentrations only about half the dust injected is burned in the explosion, while the overpressures remain high. This work was undertaken to try to understand the mechanisms of these phenomena, through the accounting of the debris at the end of the explosion, some of which was found in the form of impacted “cake” against the vessel wall. One possible explanation is that the residue material was biomass dust blown ahead of the flame by the explosion induced wind, impacted on the walls where then the flame side underwent flame impingement pyrolysis and the metal (wall) side material was compacted but largely chemically unchanged. The results also show that the heat transfer insulation provided by the powder wall layer contributes to the higher observed pressures. The risk of explosion with significant overpressures remains at 100% in very rich environments (equivalence ratios of up to 6) although these environments are leaner than thought due to material sequestration within the “cake”. There was little indication that a rich combustion limit was approached, this was determined in standard testing equipment that has been modified and calibrated to handle larger quantities of powder than normal.     

Explosibility and thermal decomposition behavior of nitrile rubber dust in industrial processes

The formation of nitrile rubber (NBR) dust clouds during processing can lead to a potential dust explosion under certain conditions. However, the potential explosion hazard posed by NBR dust is usually overlooked by enterprises. In this paper, the explosive properties of NBR dust are investigated using a Hartmann tube, a G-G furnace, and a 20 L explosion chamber. The results showed that NBR dust could cause explosions severe enough to be classified as St-1. In addition, the thermal decomposition behavior of NBR dust under combustion conditions was investigated using a combination of thermogravimetric analysis coupled with Fourier transform infrared spectroscopy (TGA-FTIR). The results indicated that in the early stage, NBR dust mainly undergoes self-thermal decomposition to produce a large amount of combustible gas, which combines with oxygen to form a mixed gas and cause a gas-phase explosion. In addition, the participation of oxygen could lower the initial temperature of NBR dust thermal decomposition. As a result, decomposition occurred more quickly and a large amount of combustible gas was produced, thus expanding the range of dust explosions. Furthermore, these combustible gases exhibit varying degrees of toxicity, seriously affecting the life and health safety of relevant personnel. This work provides theoretical guidance for the development of safe procedures to prevent and address problems during NBR dust processing in enterprises.     

CFD modeling and simulation of turbulent fluid flow and dust dispersion in the 20-L explosion vessel equipped with the perforated annular nozzle

A three-dimensional CFD model was developed to simulate the turbulent flow field induced by dust feeding and the associated dust dispersion within the 20-L explosion vessel equipped with the perforated annular nozzle. The model was validated against experimental data for pressure and root mean square velocity.Simulation results have shown that the turbulent kinetic energy is rather uniformly distributed and its values are significantly lower than those attained with the rebound nozzle. Furthermore, the perforated annular nozzle is able to generate a uniform dust/air cloud. However, a consistent fraction of the dust remains trapped inside the nozzle and, thus, it does not contribute to the explosion process.     

Some myths and realities about dust explosions

The necessary conditions for a dust explosion to occur are well-expressed by the explosion pentagon: (i) fuel, (ii) oxidant, (iii) ignition source, (iv) mixing of the fuel and oxidant, and (v) confinement of the resulting mixture. While it might seem relatively straightforward to prevent or mitigate a dust explosion by simply removing one of the pentagon elements, the field of dust explosion risk reduction is more complex. Building upon previous work by the author and other dust explosion researchers, the theme of the current paper is that this complexity is partially rooted in several erroneous beliefs. These beliefs ignore the realities found with full consideration of appropriate scientific and engineering principles. Several such myths and their factual counterparts are presented with an illustrative example.     

Determination of the maximum effective burning velocity of dust–air mixtures in constant volume combustion

The reactivity of a combustible dust cloud is traditionally characterized by the so-called K_St value, defined as the maximum rate of pressure rise measured in constant volume explosion vessels, multiplied with the cube root of the vessel volume. The present paper explores the use of an alternative parameter, called the maximum effective burning velocity (u_eff,max), which also is derived from pressure–time histories obtained in constant volume explosion experiments. The proposed parameter describes the reactivity of fuel–air mixtures as a function of the dispersion-induced turbulence intensity. Procedures for estimating u_eff,max from tests in both spherical and cylindrical explosion vessels are outlined, and examples of calculated values for various fuel–air mixtures in closed vessels of different sizes and shapes are presented. Tested fuels include a mixture of 7.5% methane in air, and suspensions of 500 g/m³ cornstarch in air and 500 g/m³ coal dust in air. Three different test vessels have been used: a 20-l spherical vessel and two cylindrical vessels, 7 and 22 l. The results show that the estimated maximum effective burning velocities are less apparatus dependent than the corresponding K_St values.     

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.     

Post-explosion observations of experimental mine and laboratory coal dust explosions

The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted joint research on dust explosions by studying post-explosion dust samples. The samples were collected after full-scale explosions at the PRL Lake Lynn Experimental Mine (LLEM), and after laboratory explosions in the PRL 20-L chamber and the Fike 1 m³ chamber. The dusts studied included both high- and low-volatile bituminous coals. Low temperature ashing for 24 h at 515 °C was used to measure the incombustible content of the dust before and after the explosions. The data showed that the post-explosion incombustible content was always as high as, or higher than the initial incombustible content. The MSHA alcohol coking test was used to determine the amount of coked dust in the post-explosion samples. The results showed that almost all coal dust that was suspended within the explosion flame produced significant amounts of coke. Measurements of floor dust concentrations after LLEM explosions were compared with the initial dust loadings to determine the transport distance of dust during an explosion. All these data will be useful in future forensic investigations of accidental dust explosions in coal mines, or elsewhere.     

Minimum ignition energy of mixtures of combustible dusts

Most industrial powder processes handle mixtures of various flammable powders. Consequently, hazard evaluation leads to a reduction of the disaster damage that arises from dust explosions. Determining the minimum ignition energy (MIE) of flammable mixtures is critical for identifying possibility of accidental hazard in industry. The aim of this work is to measure the critical ignition energy of different kinds of pure dusts with various particle sizes as well as mixtures thereof.The results show that even the addition of a modest amount of a highly flammable powder to a less combustible powder has a significant impact on the MIE. The MIE varies considerably when the fraction of the highly flammable powder exceeds 20%. For dust mixtures consisting of combustible dusts, the relationship between the ignition energy of the mixture and the minimum ignition energy of the components follows the so-called harmonic model based upon the volume fraction of the pure dusts in the mixture. This correlation provides results which show satisfactory agreement with the experimental values.     

A simple design method of dust explosion venting size at elevated static activation pressure

To develop the application of explosion venting technology in high-pressure vessels, a new model for the design of dust explosion venting size was presented, which took the physicochemical phenomenon deriving from the elevation of the static activation pressure into account. Firstly, for confined pressure rise, the wall quenching effect originating from the dust flame thickness was considered by adopting the three-zone model. Secondly, for the venting pressure rise, the energy loss due to the discharge of high-energy burnt mixture (quantified as the specific surface area loss of the flame) was taken into account and the induced turbulence factor was introduced. Thirdly, for the venting pressure drop, a dynamic pressure relief capability evaluation model which takes into account the flame morphology evolution (tear-shaped flame) and the proportion of discharged mixture (relative volume ratio) at elevated activation pressure was proposed. The predicted maximum reduced pressure and venting size were checked against the PMMA explosion experiments and a more great performance was obtained compared with standards.     

Current status and expected future trends in dust explosion research

In spite of extensive research and development for more than 100 years to prevent and mitigate dust explosions in the process industries, this hazard continues to threaten industries that manufacture, use and/or handle powders and dusts of combustible materials. Lack of methods for predicting real dust cloud structures and flame propagation processes has been a major obstacle to prediction of course and consequences of dust explosions in practice. However, work at developing comprehensive numerical simulation models for solving these problems is now on its way. This requires detailed experimental and theoretical studies of the physics and chemistry of dust cloud generation and combustion. The present paper discusses how this kind of work will promote the development of means for prevention and mitigation of dust explosions in practice. However, progress in other areas will also be discussed, e.g. ignition prevention. The importance of using inherently safe process design, building on knowledge in powder science and technology, and of systematic education/training of personnel, is also emphasized.