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.     

超细CaCO3惰化剂对铝合金抛光伴生粉尘爆炸的防控效果*

为探究超细粉体惰化剂对铝合金抛光伴生粉尘爆炸特性的影响规律,利用标准化实验装置及自行搭建的实验平台,在对爆炸基本参数进行测试的基础上,分别研究超细CaCO3粉体对抛光废弃物粉尘点燃敏感度的钝化作用以及对爆炸火焰传播进程的惰化效果,并在相同条件下与同等粒径高纯度铝粉的实验效果进行比对。研究结果表明:铝合金抛光废弃物粉尘最小点火能量为280 mJ,而同等粒径高纯度铝粉最小点火能量为35 mJ;在铝合金抛光废弃物粉尘质量浓度为300 g/m3条件下,发生爆炸的火焰传播速度峰值为7.4 m/s,约为高纯度铝粉的57%,铝合金抛光废弃物粉尘的爆炸敏感度及猛烈度均低于高纯度铝粉;当超细CaCO3粉体的惰化比为30%时,可将铝合金抛光废弃物粉尘的最小点火能量钝化至约1 J,爆炸火焰失去持续传播能力,惰化作用效果充分显现。     

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.     

混合金属粉尘爆炸最小点火能量影响因素研究*

为探究混合金属粉尘爆炸危险性及与单一粉体爆炸特性差异，确保车间安全生产，采用粉尘云点火能量测试系统对车间混合金属粉尘及铝粉最小点火能量在不同影响因素下的变化规律及2种粉尘火焰变化特征进行测试。研究结果表明:混合金属粉尘和铝粉最小点火能量在一定范围内（38~96 μm）与粒径呈正相关性，当混合金属粉尘粒径大于75 μm时，所需最小点火能量大于1 000 mJ，其爆炸敏感性迅速降低，此时铝粉仍有较强爆炸敏感性；2种粉尘最小点火能量随质量浓度增加呈先降低后升高的趋势，最小点火能分别为295，15 mJ，对应的敏感质量浓度为600，1 000 g/m3，混合金属粉尘在质量浓度为500~700 g/m3时具有较大爆炸危险性；同铝粉相比，混合金属粉尘点火能量更高、火焰燃烧时间更短、火焰高度更低、爆炸剧烈程度更弱。     

Explosion temperatures and pressures of metals and other elemental dust clouds

The Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) conducted a study of the explosibility of various metals and other elemental dusts, with a focus on the experimental explosion temperatures. The data are useful for understanding the basics of dust cloud combustion, as well as for evaluating explosion hazards in the minerals and metals processing industries. The dusts studied included boron, carbon, magnesium, aluminum, silicon, sulfur, titanium, chromium, iron, nickel, copper, zinc, niobium, molybdenum, tin, hafnium, tantalum, tungsten, and lead. The dusts were chosen to cover a wide range of physical properties—from the more volatile materials such as magnesium, aluminum, sulfur, and zinc to the highly “refractory” elements such as carbon, niobium, molybdenum, tantalum, and tungsten. These flammability studies were conducted in a 20-L chamber, using strong pyrotechnic ignitors. A unique multiwavelength infrared pyrometer was used to measure the temperatures. For the elemental dusts studied, all ignited and burned as air-dispersed dust clouds except for nickel, copper, molybdenum, and lead. The measured maximum explosion temperatures ranged from 1550 K for tin and tungsten powders to 2800 K for aluminum, magnesium, and titanium powders. The measured temperatures are compared to the calculated, adiabatic flame temperatures.     

Study on explosion risk of aluminum powder under different dispersions

This paper mainly studied the influence of particle size distribution on the explosion risk of aluminum powder under the span of large particle size distribution. The measurement was carried out with the 20 L explosion ball and the Hartmann tube. The statistical analysis was used to analyze the relevance between the parameters of explosion risk and the particle size parameters. Test results showed that with the increase of particle size, the sensitivity parameter increases and the intensity parameter deceleration decreases. The effect of particle size change on MEC and MIE of small particle size aluminum powder is relatively small but greater impact on Pm and (dP/dt)m. The small particle size components greatly increasing the sensitivity of the explosion and accelerating the rate of the explosion reaction; while the large particle size component contributes to the maximum explosion pressure. D_3,2 particle size dust determines the risk of aluminum powder explosion.     

Does the dust explosion risk increase when moving from μm-particle powders to powders of nm-particles?

Based on experience with powders of particle sizes down to the 1–0.1 μm range one might expect that dust clouds from combustible nm-particle powders would exhibit extreme ignition sensitivities (very low MIEs) and extreme explosion rates (very high K_St-values). However, there are two basic physical reasons why this may not be the case. Firstly, complete transformation of bulk powders consisting of nm-particles into dust clouds consisting of well-dispersed primary particles is extremely difficult to accomplish, due to very strong inter-particle cohesion forces. Secondly, should perfect dispersion nevertheless be achieved, the extremely fast coagulation process in clouds of explosive mass concentrations would transform the primary nm-particles into much larger agglomerates within fractions of a second. Furthermore, for organic dusts and coal the basic mechanism of flame propagation in dust clouds suggests that increased cloud explosion rates would not be expected as the particle size decreases into the <1 μm range. An overall conclusion is that dust clouds consisting of nm primary particles are not expected to exhibit more severe K_St-values than clouds of μm primary particles, in agreement with recent experimental evidence. In the case of the ignition sensitivity recently published evidence indicates that MIEs of clouds in air of some metal powders are significantly lower for nm particles than for μm particles. A possible reason for this is indicated in the paper.     

Friction spark generation and incendivity of several metal alloys

When metal alloys are used as mechanical equipment or tools in explosive atmospheres, the occurrence and incendivity of mechanically generated sparks as ignition sources should be taken into consideration. The formation of mechanically generated sparks was investigated for seven metals, including Q235 steel, 304 stainless steel, TC4 titanium alloy, 6061 aluminum alloy, H62 bronze alloy, AMAK3 zinc alloy, and AZ31B magnesium alloy. The relationship between the physical-chemical properties and generation and incendivity of friction sparks was evaluated. For 6061 aluminum alloy, H62 bronze alloy, AMAK3 zinc alloy, and AZ31B magnesium alloy, no bright friction sparks were observed in the maximum friction velocity of 12 m/s and maximum surface pressure of 3.75 N/mm², because of low hardness, high thermal conductivity, low melting point, and the absence of carbon content. Ignition testing indicated that nano titanium dust layers with MIEL (minimum ignition energy of dust layer) of 1 mJ were not ignited by friction particles from the four metal alloys. However, bright particles were clearly observed for 304 stainless steel, Q235 steel, and TC4 titanium alloy. Friction sparks at the maximum power densities showed incendivity with micro titanium layers having an MIEL of 17.5–25 mJ but not with PMMA, corn starch, and wood dust having MIELs greater than 1 J. Two different particle burning behaviors with different fragmentation mechanisms during the friction process were determined, namely the micro explosion phenomenon for TC4 titanium alloy and particle burst for Q235 steel. Results indicate that the physical-chemical properties of friction metal rods are useful for preliminary evaluation of spark generation. Powder layers with known MIEL can be considered as indicator testing materials to evaluate spark incendivity.     

Experimental investigation and modelling of aluminum dusts explosions in the 20 L sphere

An experimental investigation was carried out on the influences of dust concentration, particle size distribution and humidity on aluminum dust explosion. Tests were mainly conducted thanks to a 20 L explosion sphere. The effect of humidity was studied by storing the aluminum particles at constant relative humidity until the sorption equilibrium or by introducing water vapour in the explosion vessel. The tested particles sizes ranged from a volume median diameter of 7 to 42 μm and the dust concentrations were up to 3000 g m^?3.Among other results, the strong influence of the particle size was pointed out, especially when the Sauter mean diameter is considered. These results stressed the predominance of the specific surface area on the mass median particle diameter.The effect of water on aluminum dust explosion was decoupled: on the one hand, when water adsorption occurs, hydrogen generation leads to an increase of the explosion severity; on the other hand, when the explosion of dried aluminum powder occurs in a humid atmosphere, the inhibiting effect of humidity is put forward.A model based on mass and heat balances, assuming a shrinking core model with chemical reaction limitation, leads to a satisfactory representation of the pressure evolution during the dust explosion.     

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.     

Propane-air mixture deflagration hazard with different ignition positions and restraints in large-scale venting chamber

In order to better assess the hazards of explosion accidents, propane-air mixture deflagrations were conducted in a large-scale straight rectangular chamber (with a cross-section of 1.5 m × 1.5 m, length of 10 m, and total volume of 22.5 m³). The effect of initial volume, ignition position, and initial restraints on the explosion characteristics of the propane-air mixtures was investigated. The explosion overpressure, flame propagation, and flame speed were obtained and the computational fluid dynamics (CFD) software was used to simulate the flame-propagation process and field flow for auxiliary analysis. The hazards of large-scale propagation explosion under weak and strong constraints were evaluated and the different phases of flame propagation under weak and strong constraints were discriminated. Results indicate that the hazards caused by propane deflagration under weak constraint are mainly caused by flame spread. And the maximum overpressure under strong constraint appeared at the front part of the chamber under the large-scale condition, which is consistent with the previous small-scale test. Moreover, the simulations of flame structures under weak and strong constraint are in good agreement with experimental results, which furthers the understanding of large-scale propane deflagration under different initial conditions in large-scale spaces and provides basic data for three-dimensional CFD model improvement.     

Coloured powder potential dust explosions

The use of Coloured powder (Holi powder orcolour dust) has been largely used in India for their festivities. Due to their popularity is extensive around the world since the popularity of the parties and events with this kind of show is increasing considerably. Despite the fact of its extensive use, its highly flammable nature is poorly known. Currently, some serious accidents related to the Coloured powder have been registered. Coloured powder organic nature implies a significant increase in the probability to form an explosive atmosphere as their use includes dust dispersion, leading to explosion hazards as has been previously reported. Moreover, it is important to take into account the effects on the flammability of the additives and the colorings existing in the Coloured powder as they might increase the hazard. To properly understand Coloured powder potential for producing an explosive atmosphere, and the attached risk of dust explosions, several samples were tested. Coloured powder from 6 different manufacturers were gathered. Each manufacturer provided several colours (between 5 and 8) which were characterized through moisture content and particle size determination. Once each sample was characterized, screening tests were performed on each sample determining whether ignition was produced or not. Those screening tests were carried out under certain conditions using the equipment for minimum ignition temperature on cloud determination (0.5 g set at 500 °C and 0.5 bar), and minimum ignition energy determination (using 100 and 300 mJ energies and 900 and 1200 mg). From those test results, important differences were seen between manufacturers, but most important, differences between colours of the same manufacturer were observed. The screening tests allowed the selection of 11 samples that were fully characterized through thermogravimetric analysis, maximum pressure of explosion, K_st, minimum ignition temperature on cloud, and minimum ignition energy. When carrying out thermogravimetric analysis, some samples increased mass at temperatures close to 300 °C and unexpectedly absorbed energy, followed by the expected combustion reaction at higher temperatures. From the obtained results it was noticed that the colour powders that included talcum in its composition did not produce explosion. Flammability and explosion tests, again, showed important differences between manufacturers and colours, and so it was possible to determine the relative flash fire and explosion risks of the various tested powders.     

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.     

Explosion behaviour of metallic nano powders

This paper describes experiences and results of experiments with several metallic dusts within the nanometer range. The nano dusts (aluminium, iron, zinc, titanium and copper) were tested in a modified experimental setup for the test apparatus 20 L-sphere (also known as 20-L Siwek Chamber), that enables the test samples to be kept under inert atmospheric conditions nearly until ignition. This setup was already introduced in earlier papers by the authors. It was designed to allow the determination of safety characteristics of nano powders under most critical circumstances (e.g. minimisation of the influence of oxidation before the test itself). Furthermore the influence of passivation on explosion behaviour is investigated and additional tests with deposited dust were carried out to describe the burning behaviour of all dusts. For a better characterisation all samples were tested with a simultaneous thermal analysis (STA). To minimise the influence of oxidation all samples were handled at inert conditions until shortly before ignition or start of the test respectively.     

Explosion characteristics of micron- and nano-size magnesium powders

Explosion characteristics of micron- and nano-size magnesium powders were determined using CSIR-CBRI 20-L Sphere, Hartmann apparatus and Godbert-Greenwald furnace to study influence of particle size reduction to nano-range on these. The explosion parameters investigated are: maximum explosion pressure (P_max), maximum rate of pressure-rise (dP/dt)_max, dust explosibility index (K_St), minimum explosible concentration (MEC), minimum ignition energy (MIE), minimum ignition temperature (MIT), limiting oxygen concentration (LOC) and effect of reduced oxygen level on explosion severity. Magnesium particle sizes are: 125, 74, 38, 22, 10 and 1 μm; and 400, 200, 150, 100, 50 and 30 nm. Experimental results indicate significant increase in explosion severity (P_max: 7–14 bar, K_St: 98–510 bar·m/s) as particle size decreases from 125 to 1 μm, it is maximum for 400 nm (P_max: 14.6 bar, K_St: 528 bar·m/s) and decreases with further decrease of particle size to nano-range 200–30 nm (P_max: 12.4–9.4 bar, K_St: 460–262 bar·m/s) as it is affected by agglomeration of nano-particles. MEC decreases from 160 to 30 g/m³ on decreasing particle size from 125 to 1 μm, its value is 30 g/m³ for 400 and 200 nm and 20 g/m³ for further decrease in nano-range (150–30 nm). MIE reduces from 120 to 2 mJ on decreasing the particle size from 125 to 1 μm, its value is 1 mJ for 400, 200, 150 nm size and <1 mJ for 50 and 30 nm. Minimum ignition temperature is 600 °C for 125 μm magnesium, it varies between 570 and 450 °C for sizes 38–1 μm and 400–350 °C for size range 400–30 nm. Magnesium powders in nano-range (30–200 nm) explode less violently than micron-range powder. However, likelihood of explosion increases significantly for nano-range magnesium. LOC is 5% for magnesium size range 125–38 μm, 4% for 22–1 μm, 3% for 400 nm, 4% for 200, 150 and 100 nm, and 5% for 50 and 30 nm. Reduction in oxygen levels to 9% results in decrease in P_max and K_St by a factor of 2–3 and 4–5, respectively, for micron as well as nano-sizes. The experimental data presented will be useful for industries producing or handling similar size range micron- and nano-magnesium in order to evaluate explosibility of their magnesium powders and propose/design adequate safety measures.     

MIE determination and thermal degradation study of PA12 polymer powder used for laser sintering

Pulverized materials such as metallic or polymer powders play a considerable role in many industrial processes. Their use requires the introduction of preventive safeguards to control the plant's safety.PA12 polymer powder processing by laser sintering is characteristic of this tendency. The present work concerns PA12 powder (bimodal particle size distribution: 10 μm and 55 μm) and relates to explosion sensitivity and the thermal degradation of this powder, which can occur during laser sintering. Minimum Ignition Energy is determined using a modified Hartmann tube combined with the Langlie method developed in the PRISME Laboratory. This study shows the influence of parameters such as distance between the electrodes, powder concentration and arc power on MIE values. Theses parameters vary in the range of 3–6 A for the current intensity of the spark and the electrode gap in the range of 2.5–4 mm. The MIE is obtained for a spark gap of 3 mm and current intensity of the 4 A spark in our device. It shows that the MIE is less than 40 mJ for concentrations approaching 1000 g/m³. At lower concentrations (under 150 g/m³) the MIE increases but discrepancies in measurements appear, probably because of the static electricity that creates strong irregularities in dust dispersion. The second part of this study concerns the thermal degradation of the PA12 which is performed by thermogravimetric experiments coupled with mass spectrometric (MS) analysis for gas investigation. The mass loss measurement combined with the gas analysis allows the principal stages of degradation to be determined so as to calculate the kinetics parameter PA12. Experiments have been performed for different heating rates between 1 and 30 K min^?1 and the reproducibility of experiments has been verified. The activation energy is determined using two methods: Freidman and KAS. For a reaction rate of between 0.2 and 0.6, the activation energy is nearly constant. The KAS method gives a value of E_a = 250 kJ mol^?1 and the Friedman method gives E_a = 300 kJ mol^?1. The gas analysis by MS shows that oxidation begins at over 350 °C and finishes at under 650 °C with the formation of CO₂ and H₂O. Other major peaks with an m/z ratio of 29, 28 and 30 are noticed in this range of temperature. They show the presence of intermediate species such as C₂H₆, NO or CH₂O. The presence of HCN is also detected (m/z ratio of 27).     

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.     

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.     

Structural response for vented methane–air deflagrations: Effects of volumetric blockage ratio

To investigate the effects of cylinders placed parallel to the venting direction on the structural response of the vessel walls to an explosion, 25 batches of vented explosion tests were conducted in a 1 m³ rectangular vessel. Two types of structural response with different amplitudes and frequency distributions were observed and evaluated by comparing the vibration data with both the pressure data and high-speed videos. A low-amplitude structural response of approximately 150–250 m/s², which increased slightly as VBR increased, was triggered by a combination of the initial flame propagation, external explosion, Helmholtz oscillations, and the Taylor instability. A high-amplitude structural response of approximately 9500 m/s² was also observed, which decreased sharply as VBR increased. Additionally, the high amplitude response was never observed when more than two cylinders were present in the vessel. The high amplitude response was triggered due to the coupling between the acoustic wave, the flame, and the resonance of the vessel. The presence of obstacles did not increase the severity of the structural responses under the current experimental conditions. To the contrary, the presence of obstacles in the container attenuated or even inhibited the high-amplitude vibration of the container caused by the explosion.     

Effect of Al2O3 particle size reduction on aluminium dust explosion

To investigate the effect of Al₂O₃ particle size on an aluminum explosion, the overpressure and flame velocity in a vertical duct were evaluated. The results show that the inhibitory effect of submicron Al₂O₃ is best, while the inhibitory effect increases with increasing inerting ratio. However, the inhibitory effect of micron Al₂O₃ does not increase significantly after the inerting ratio exceeds 40%. For high-concentration aluminum powder, 0.8 μm Al₂O₃ with an inerting ratio less than 20% promotes aluminum explosion. As the inerting ratio increases beyond 20%, however, the overpressure decreases. Furthermore, Al₂O₃ inhibits the formation of the intermediate product AlO and decreases the flame brightness. As the inerting ratio of 0.8 μm Al₂O₃ reaches 50%, the white patches in the flame image disappear. The results of scanning electron microscopy showed that the explosion products agglomerate and some dot-like protrusions appear on the surface of the unburned aluminum particles. The inhibition mechanism was qualitatively investigated. Physical heat absorption is proven to play a limited role. Thermal radiation and chemical inhibition play a key role. The chemical effect mainly influences the surface reaction energy source.