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.     

Effects of initial temperature and pressure on explosion characteristics of propane–diluent–air mixtures

The explosion characteristics of propane–diluent–air mixtures under various temperatures and pressures were investigated using a 20-L apparatus. The explosion limits of propane diluted with nitrogen or carbon dioxide were measured at high temperatures from 25 to 120 °C. The results showed that the upper explosion limit (UEL) increased, and the lower explosion limit (LEL) decreased with the rising temperature. The explosion limits of propane diluted with nitrogen or carbon dioxide were also measured at high pressures from 0.10 to 0.16 MPa. The results showed that the UEL increased, and the LEL almost remainedunchanged along with increased pressure. Under the same initial operating conditions, the concentration of nitrogen required to reach the minimum inerting concentration (MIC) point was higher than the concentration of carbon dioxide. Finally, the study investigated the limiting oxygen concentration (LOC) of propane under various initial temperatures, initial pressures, and inert gases. The LOC of propane decreased approximately linearly with increased temperature or pressure, and the LOC of propane dilution with carbon dioxide was greater than dilution with nitrogen from 25 to 120 °C or from 0.10 to 0.16 MPa, which indicated that the dilution effect of carbon dioxide was better than that of nitrogen.     

Study of the severity of hybrid mixture explosions and comparison to pure dust-air and vapour-air explosions

The explosion behaviour of heterogeneous/homogeneous fuel-air (hybrid) mixtures is here analysed and compared to the explosion features of heterogeneous fuel-air and homogeneous fuel-air mixtures separately.Experiments are performed to measure the pressure history, deflagration index and flammability limits of nicotinic acid/acetone-air mixtures in a standard 20 L Siwek bomb adapted to vapour-air mixtures. Literature data are also used for comparison.The explosion tests performed on gas-air mixtures in the same conditions as explosion tests of dust-air mixtures, show that the increase in explosion severity of dust/gas-air mixtures has to be addressed to the role of initial level of turbulence prior to ignition.At a fixed value of the equivalence ratio, by substituting the dust to the flammable gas in a dust/gas-air mixture the explosion severity decreases. Furthermore, the most severe conditions of dust-gas/air mixtures is found during explosion of gas-air mixture at stoichiometric concentration.     

Explosion of lycopodium-nicotinic acid–methane complex hybrid mixtures

With the terms “complex hybrid mixtures”, we mean mixtures made of two or more combustible dusts mixed with flammable gas or vapors in air (or another comburent).In this work, the flammability and explosion behavior of selected complex hybrid mixtures was studied. In particular, we investigated mixtures of nicotinic acid, lycopodium and methane. We performed explosion tests in the 20-L explosion vessel at different overall (nicotinic plus lycopodium) dust concentrations, nicotinic acid/lycopodium ratios, and methane concentrations.An exceptional behavior (in terms of unexpected values of rate of pressure rise and pressure) was found for the complex hybrid mixtures containing lycopodium and nicotinic acid in equal amounts. This mixture was found to be much more reactive than all the other dust mixtures, whatever the dust concentration and the methane content.     

Influence of the ignition source location on the determination of the explosion pressure at elevated initial pressures

Explosion pressures are determined for rich methane–air mixtures at initial pressures up to 30 bar and at ambient temperature. The experiments are performed in a closed spherical vessel with an internal diameter of 20 cm. Four different igniter positions were used along the vertical axis of the spherical vessel, namely at 1, 6, 11 and 18 cm from the bottom of the vessel. At high initial pressures and central ignition a sharp decrease in explosion pressures is found upon enriching the mixture, leading to a concentration range with seemingly low explosion pressures. It is found that lowering the ignition source substantially increases the explosion pressure for mixtures inside this concentration range, thereby implying that central ignition is unsuitable to determine the explosion pressure for mixtures approaching the flammability limits.     

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.     

An investigation of flammability limits of gaseous mixtures at reduced pressures

An experimental investigation of flammability limits of hydrogen, methane and propane in air and oxygen at reduced pressures was carried out. A slow influence of sizes of an experimental vessel of a diameter higher than 125 mm on the flammability limits was revealed, but an influence of a type of an oxidizer (air or oxygen) and an ignition energy is significant. Critical values of an initial pressure for a possibility of a flame propagation were determined. The limiting values of the ignition energy were determined, for which an elevation of this parameter does not influence the critical pressure and the flammability region. A qualitative interpretation of obtained experimental results is given, which is based on a peculiarities of a flame initiation.     

Study of the explosion parameters of vapor–liquid diethyl ether/air mixtures

The knowledge of the vapor–liquid two-phase diethyl ether (DEE)/air mixtures (mist) on the explosion parameters was an important basis of accident prevention. Two sets of vapor–liquid two-phase DEE/air mixtures of various concentrations were obtained with Sauter mean diameters of 12.89 and 22.90 μm. Experiments were conducted on vapor–liquid two-phase DEE/air mixtures of various concentrations at an ignition energy of 40.32 J and at an initial room temperature and pressure of 21 °C and 0.10 MPa, respectively. The effects of the concentration and particle size of DEE on the explosion pressure, the explosion temperature, and the lower and upper flammability limits were analyzed. Finally, a series of experiments was conducted on vapor–liquid two-phase DEE/air mixtures of various concentrations at various ignition energies. The minimum ignition energies were determined, and the results were discussed. The results were also compared against our previous work on the explosion characteristics of vapor–liquid two-phase n-hexane/air mixtures.     

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.     

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.     

甲烷/空气混合气燃爆特性的实验研究

对不同初始压力和温度条件下的甲烷/空气混合气的爆炸极限进行实验研究,利用最大-最小准则来确定爆炸极限.分析了温度和压力对甲烷/空气混合气燃爆特性的影响.采用氮气作为惰性气体,对其防爆抑爆效果进行了实验研究.     

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.     

Validation of a new formula for predicting the lower flammability limit of hybrid mixtures

A correlation of the lower flammability limit for hybrid mixtures was recently proposed by us. The experimental conditions including ignition energy and turbulence which play a primary role in a gas or dust explosion were at fixed values. The sensitivity of such experimental conditions to the accuracy of the proposed formula was not thoroughly discussed in the previous work. Therefore, this work studied the effect of varying the ignition energy and turbulence intensity to the formula proposed in our previous paper. For ignition energy effect, results from methane/niacin mixture demonstrated that the MEC and LFL will not be affected by changing ignition energy. There is no distinguishable difference among gas explosion index (K_G) and dust explosion index (K_St) derived from tests with every ignition energy (2.5 kJ, 5 kJ and 10 kJ) in a 36 L vessel. The proposed formula is independent of ignition energy. For turbulence effect, the proposed formula can have a good prediction of the explosion and non-explosion zone if the ignition delay time is within a certain range. The formula prediction is good as the ignition delay time increases up to 100 ms in this work. Propane/niacin and propane/cornstarch mixtures are also tested to validate the proposed formula. It has been confirmed that the proposed formula predicts the explosion and non-explosion zone boundary of such mixtures.     

Explosibility of cork dust in methane/air mixtures

Explosibility studies of hybrid methane/air/cork dust mixtures were carried out in a near-spherical 22.7 L explosibility test chamber, using 2500 J pyrotechnic ignitors. The suspension dust burned as methane/air/dust clouds and the uniformity of the cork dust dispersion inside the chamber was evaluated through optical dust probes and during the explosion the pressure and the temperature evolution inside the reactor were measured. Tested dust particles had mass median diameter of 71.3 μm and the covered dust cloud concentration was up to 550 g/m³. Measured explosions parameters included minimum explosion concentration, maximum explosion pressures and maximum rate of pressure rise. The cork dust explosion behavior in hybrid methane/air mixtures was studied for atmospheres with 1.98 and 3.5% (v/v) of methane. The effect of methane content on the explosions characteristic parameters was evaluated. The conclusion is that the risk and explosion danger rises with the increase of methane concentration characterized by the reduction of the minimum dust explosion concentration, as methane content increases in the atmosphere. The maximum explosion pressure is not very much sensitive to the methane content and only for the system with 3.5% (v/v) of methane it was observed an increase of maximum rate of pressure rise, when compared with the value obtained for the air/dust system.     

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.     

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.     

Determination of explosion limits – Criterion for ignition under non-atmospheric conditions

Many industrial processes are run at non-atmospheric conditions (elevated temperatures and pressures, other oxidizers than air). To judge whether and if yes to what extent explosive gas(vapor)/air mixtures will occur or may be generated during malfunction it is necessary to know the safety characteristic data at the respective conditions. Safety characteristic data like explosion limits, are depending on pressure, temperature and the oxidizer. Most of the determination methods are standardized for ambient conditions. In order to obtain determination methods for non-atmospheric conditions, particularly for higher initial pressures, reliable ignition criteria were investigated. Ignition tests at the explosion limits were carried out for mixtures of methane, propane, n-butane, n-hexane, hydrogen, ammonia and acetone in air at initial pressures up to 20 bar. The tests have been evaluated according to different ignition criteria: visual flame propagation, temperature and pressure rising. It could be shown that flame propagation and occasionally self-sustained combustion for several seconds occurred together with remarkable temperature rise, although the pressure rise was below 3%. The results showed that the combination of a pressure rise criterion of 2% and a temperature rise criterion of 100 K seems to be a suitable ignition criterion for the determination of explosion limits and limiting oxidizer concentration at higher initial pressures and elevated temperatures. The tests were carried out within the framework of a R&D project founded by the German Ministry of Economics and Technology.     

Explosion prevention and weighting analysis on the inerting effect of methane via grey entropy model

Explosion prevention is vital for process safety and daily life. In practice, inerting is viewed as an ideal method to reach basic explosion prevention as well as to diminish flammability risk in normal operation, storage, and transportation of materials. This study deals with the inerting effect on the explosion range for methane via grey entropy model, comparatively detected under the different inert gases of nitrogen (N₂), argon (Ar), and carbon dioxide (CO₂), which have various loading inerting concentrations: 10 (90 vol% air), 20 (80 vol% air) and 25 vol% (75 vol% air). The inert influences were determined via the experimental 20-L-apparatus investigations under 1 atm, 30 ^OC, combined with the grey entropy model, which is one of the most prevailingly used grey system theories for weighting analysis and decision-making of the fire and explosion assessment for practical operations. The results indicated that CO₂ had better inerting capacity than the others, as derived from our grey entropy theoretical soft computing calculations. Through the combination of the grey entropy weighting analysis model and the flammability investigations in this study, the concluded decision-making was feasible and useful for the practical applications of inert gases for preventing fire and explosion hazards in relevant processes.     

Theoretical evaluation of lower explosion limit of hybrid mixtures

Lower explosion limits of hybrid fuel mixtures are usually determined through time consuming and expensive experiments. Although, mathematical expressions like Le-Chatelier's Law and Bartknecht curve have been used by many researchers to predict the LEL of hybrid mixtures, significant deviations remain unexplained. This research work, presents a more sophisticated and general approach for the determination of LEL of hybrid mixtures.Assuming that the combustion kinetics of pure species are independent and unchanged by the presence of other combustible species, complete conversion of the reactants and no heat losses, a simple mathematical model has been derived from the enthalpy balance of the whole system. For the experimental validation of the modelled values, modified version of 20L sphere has been employed, following the European standard (EN 14034-3: 2011) as experimental protocol. Hybrid mixtures of three dusts with two gases were selected for the scope of this publication. By analyzing the modelled as well as the experimental values, it can be concluded that the LEL values of the individual components in the hybrid mixture set the upper and lower limit for the LEL of the hybrid mixture provided the total amount of fuel in the system is considered as the concentration of the hybrid mixture. Moreover, the amount of dust or gas required to render the hybrid mixture flammable mainly depends on the energy contribution upon combustion of the individual species to raise the temperature of the whole system from ambient to the flame temperature.Le-Chatelier's Law and Bartknecht curve are empirical relations, which might hold true for a first-order approximation of LEL of hybrid mixtures, but do not represent the most conservative values of LEL reported in literature. This implies that there is a non-zero probability of occurrence of an explosible mixture in the non-explosible concentrations ranges defined by these relations. Considering these arguments, the authors suggest to employ the model presented in this paper – which presents reasonably conservative values of LEL of hybrid mixtures – for theoretical calculation of LEL of hybrid mixtures, when no precise experimental data is available.     

Flammability envelopes for methanol,ethanol, acetonitrile and toluene

The flammability envelope was experimentally determined up to the point of vapor saturation for four flammable liquids: methanol, ethanol, acetonitrile, and toluene. The experimental apparatus consisted of a 20-L spherical chamber with a centrally located 10 J fuse wire igniter. The liquid was injected and vaporized into the chamber via a septum and a precision syringe. Nitrogen and oxygen were mixed from pure components using a precision pressure gauge. Pressure versus time data were measured for each ignition test. Flammability was defined as any ignition resulting in an increase in pressure of 7% over the initial pressure, as per ASTM E 918–83. All data were obtained at an initial temperature of 298 K and 1 atm. The experimental values of the LFL agreed well with published values. Limiting oxygen concentrations (LOC) were also determined—although these were somewhat lower than published values.The calculated adiabatic flame temperature (CAFT) method was used to model the data using a threshold temperature of 1200 K. A reasonable fit of the flammability envelope was obtained, although this could be improved with a higher threshold temperature.