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

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

Effect of scale on freely propagating flames in aluminum dust clouds

The majority of experimental tests done on combustible dusts are performed in constant volume vessels that have limited or no optical access. Over the years, McGill University has been developing alternative experimental techniques based on direct observation of dust flames, yielding reliable fundamental parameters such as flame burning velocity, temperature and structure. The present work describes two new experimental set-ups allowing direct observation of isobaric and freely propagating dust flames at two sufficiently different scales to test the influence of scale on dust flame phenomena. In the laboratory-scale experiments, a few grams of aluminum powder are dispersed in transparent, 30 cm diameter latex balloons that allow for full visualization of the spherical flame propagation. In the field experiments, about 1 kg of aluminum powder is dispersed by a short pulse of air, forming a conical dust cloud with a total volume of about 5 m³. High-speed digital imaging is used to record the particle dispersal and flame propagation in both configurations. In the small-scale laboratory tests, the measured flame speed is found to be about 2.0 ± 0.2 m/s in fuel-rich aluminium clouds. The burning velocity, calculated by dividing the measured flame speed by the expansion factor deduced from thermodynamic equilibrium calculations, correlates well with the previously measured burning velocity of about 22–24 cm/s from Bunsen dust flames. Flame speeds observed in field experiments with large-scale clouds, however, are found to be much higher, in the range of 12 ± 2 m/s. Estimations are presented that show that the presumably greater role of radiative heat transfer in larger-scale aluminium flames is insufficient to explain the six-fold increase in flame speed. The role of residual large-eddy turbulence, as well as the frozen-turbulence effect leading to large-scale dust concentration fluctuations that cause flame folding, are discussed as two possible sources for the greater flame speed.     

Flame propagation behaviors of nano- and micro-scale PMMA dust explosions

Flame propagation behaviors of nano- and micro-polymethyl methacrylate (PMMA) dust explosions were experimentally studied in the open-space dust explosion apparatus. High-speed photography with normal and microscopic lenses were used to record the particle combustion behaviors and flame microstructures. Simple physical models were developed to explore the flame propagation mechanisms. High-speed photographs showed two distinct flame propagation behaviors of nano- and micro-PMMA dust explosions. For nano-particles, flame was characterized by a regular spherical shape and spatially continuous combustion structure combined with a number of luminous spot flames. The flame propagation mechanism was similar to that of a premixed gas flame coupled with solid surface combustion of the agglomerates. In comparison, for micro-particles, flame was characterized by clusters of flames and the irregular flame front, which was inferred to be composed of the diffusion flame accompanying the local premixed flame. It was indicated that smaller particles maintained the leading part of the propagating flame and governed the combustion process of PMMA dust clouds. Increasing the mass densities from 105 g/m³ to 217 g/m³ for 100 nm PMMA particles, and from 72 g/m³ to 170 g/m³ for 30 μm PMMA particles, the flame luminous intensity, scale and the average propagation velocity were enhanced. Besides, the flame front became more irregular for 30 μm PMMA dust clouds.     

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

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

Flame propagation through dust clouds of nano and micron scale aluminum particles

Temperature measurement on propagating flame and minimum explosible concentration are investigated. The dust explosion experiments of nano-particle dust clouds exhibit higher temperature gradient in preheat zone and lower MEC than those of micron particle dust clouds. A heterogeneous model is proposed to describe the oxidation process under two extreme conditions: whether the alumina film is involved in the reaction or not. The new methodology allows the estimation of oxidation kinetics of growing alumina. For micron particle, the model clarifies that the activation energy which has been wrongly considered to be for aluminum oxidation should be for lattice diffusion, and the initial reaction rate is proved to be dominated by the diffusion rate of oxygen through alumina shell as diffusion controlled reaction. For nano-particle, the model explained that why the reported activation energy shows significantly lower than that for micron particle, due to initially ignorable alumina film or considered as kinetically controlled reaction. However, as reaction occurs and alumina builds up on the surface, the interference of alumina somewhat increases the activation energy.     

Experimental investigation on explosion flame propagation of wood dust in a semi-closed tube

In order to explore flame propagation characteristics during wood dust explosions in a semi-closed tube, a high-speed camera, a thermal infrared imaging device and a pressure sensor were used in the study. Poplar dusts with different particle size distributions (0–50, 50–96 and 96–180 μm) were respectively placed in a Hartmann tube to mimic dust cloud explosions, and flame propagation behaviors such as flame propagation velocity, flame temperature and explosion pressure were detected and analyzed. According to the changes of flame shapes, flame propagations in wood dust explosions were divided into three stages including ignition, vertical propagation and free diffusion. Flame propagations for the two smaller particles were dominated by homogeneous combustion, while flame propagation for the largest particles was controlled by heterogeneous combustion, which had been confirmed by individual Damköhler number. All flame propagation velocities for different groups of wood particles in dust explosions were increased at first and then decreased with the augmentation of mass concentration. Flame temperatures and explosion pressures were almost similarly changed. Dust explosions in 50–96 μm wood particles were more intense than in the other two particles, of which the most severe explosion appeared at a mass concentration of 750 g/m³. Meanwhile, flame propagation velocity, flame propagation temperature and explosion pressure reached to the maximum values of 10.45 m/s, 1373 °C and 0.41 MPa. In addition, sensitive concentrations corresponding to the three groups of particles from small to large were 500, 750 and 1000 g/m³, separately, indicating that sensitive concentration in dust explosions of wood particles was elevated with the increase of particle size. Taken together, the finding demonstrated that particle size and mass concentration of wood dusts affected the occurrence and severity of dust explosions, which could provide guidance and reference for the identification, assessment and industrial safety management of wood dust explosions.     

Ignition temperatures and flame velocities of metallic nanomaterials

The production of materials with dimensions in the nanometre range has continued to increase in recent years. In order to ensure safety when handling these products, the hazard potential of such innovative materials must be known. While several studies have already investigated the effects of explosions (such as maximum explosion pressure and maximum pressure rise) of powders with primary particles in the nanometre range, little is known about the ignition temperatures and flame velocities. Therefore, the minimum ignition temperature (MIT) of metallic nano powders (aluminium, iron, copper and zinc) was determined experimentally in a so called Godbert-Greenwald (GG) oven. Furthermore, the flame velocities were determined in a vertical tube. In order to better classify the test results, the tested samples were characterised in detail and the lower explosion limits of the tested dust samples were determined. Values for the burning velocity of aluminium nano powders are higher compared to values of micrometre powders (from literature). While MIT of nanometre aluminium powders is within the range of micrometre samples, MIT of zinc and copper nano powders is lower than values reported in literature for respective micrometre samples.     

Quantifying the effect of strong ignition sources on particle preconditioning and distribution in the 20-L chamber

Computational fluid dynamics is used to investigate the preconditioning aspect of overdriving in dust explosion testing. The results show that preconditioning alters both the particle temperature and distribution prior to flame propagation in the 20-L chamber. A parametric study gives the fluid pressure and temperature, and particle temperature and concentration at an assumed flame kernel development time (10 ms) for varying ignitor size and particle diameter. For the 10 kJ ignitor with 50% efficiency, polyethylene particles under 50 μm reach 400 K and may melt prior to flame propagation. Gases from the ignitor detonation displace the dust from the center of the chamber and may increase local particle concentration up to two times the nominal value being tested. These effects have important implications for explosive testing of dusts in the 20-L chamber and comparing to larger 1-m³ testing, where these effects may be negligible.     

Experimental and numerical investigation of constant volume dust and gas explosions in a 3.6-m flame acceleration tube

This paper describes an experimental investigation of turbulent flame propagation in propane-air mixtures, and in mechanical suspensions of maize starch dispersed in air, in a closed vessel of length 3.6 m and internal cross-section 0.27 m × 0.27 m. The primary motivation for the work is to gain improved understanding of turbulent flame propagation in dust clouds, with a view to develop improved models and methods for assessing explosion risks in the process and mining industries. The study includes computational fluid dynamics (CFD) simulations with FLACS and DESC, for gas and dust explosions respectively. For initially quiescent propane-air mixtures, FLACS over-predicts the rate of combustion for fuel-lean mixtures, and under-predicts for fuel-rich mixtures. The simulations tend to be in better agreement with the experimental results for initially turbulent gaseous mixtures. The experimental results for maize starch vary significantly between repeated tests, but the subset of tests that yields the highest explosion pressures are in reasonable agreement with CFD simulations with DESC.     

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.     

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.     

Ignitability characteristics of aluminium and magnesium dusts that are generated during the shredding of post-consumer wastes

The authors investigated the ignitability of aluminium and magnesium dusts that are generated during the shredding of post-consumer waste. The relations between particle size and the minimum explosive concentration, the minimum ignition energy, the ignition temperature of the dust clouds, etc. the relation between of oxygen concentration and dust explosion, the effect of inert substances on dust explosion, etc. were studied experimentally.

The minimum explosive concentration increased exponentially with particle size. The minimum explosive concentrations of the sample dusts were about 170 g/m³ (aluminium: 0–8 μm) and 90 g/m³ (magnesium: 0–20 μm). The minimum ignition energy tended to increase with particle size. It was about 6 mJ for the aluminium samples and 4 mJ for the magnesium samples. The ignition temperature of dust clouds was about 750 °C for aluminium and about 520 °C for magnesium. The lowest concentrations of oxygen to produce a dust explosion were about 10% for aluminium and about 8% for magnesium. A large mixing ratio (more than about 50%) of calcium oxide or calcium carbonate was necessary to decrease the explosibility of magnesium dust. The experimental data obtained in the present investigation will be useful for evaluating the explosibility of aluminium and magnesium dusts generated in metal recycling operations and thus for enhancing the safety of recycling plants.     

Behavior of flames propagating through lycopodium dust clouds in a vertical duct

The structure of flame propagating through lycopodium dust clouds has been investigated experimentally. Upward propagating laminar flames in a vertical duct of 1800 mm height and 150×150 mm square cross-section are observed, and the leading flame front is also visualized using by a high-speed video camera. Although the dust concentration decreases slightly along the height of duct, the leading flame edge propagates upwards at a constant velocity. The maximum upward propagating velocity is 0.50 m/s at a dust concentration of 170 g/m³. Behind the upward propagating flame, some downward propagating flames are also observed. Despite the employment of nearly equal sized particles and its good dispersability and flowability, the reaction zone in lycopodium particles cloud shows the double flame structure in which isolated individual burning particles (0.5–1.0 mm in diameter) and the ball-shaped flames (2–4 mm in diameter; the combustion time of 4–6 ms) surrounding several particles are included. The ball-shaped flame appears as a faint flame in which several luminous spots are distributed, and then it turns into a luminous flame before disappearance. In order to distinguish these ball-shaped flames from others with some exceptions for merged flames, they are defined as independent flames in this study. The flame thickness in a lycopodium dust flame is observed to be 20 mm, about several orders of magnitude higher than that of a premixed gaseous flame. From the microscopic visualization, it was found that the flame front propagating through lycopodium particles is discontinuous and not smooth.     

Study of dust cloud behaviour in the modified Hartmann tube using the image subtraction method (ISM)

A dispersion of fine particles in the air is needed for a dust explosion to occur since an explosion is the fast combustion of particles in the air. When particles are poorly dispersed, agglomerated, or their concentration is low, the combustion velocity decreases, and deflagration would not occur. The combustion rate is strictly related to dust concentration. Therefore, the maximum explosion pressure rise occurs at dust concentration close to stoichiometric. Conversely, Minimum Explosion Concentration (MEC) is the lower limit at which self-sustained combustion and a pressure rise are possible. Dust explosion tests are designed to reproduce the dispersion and generation of dust clouds in industrial ambiences by using dispersion devices activated by pressurised air pulses. The resulting dust cloud, which has a marked transient character, is considered representative of real clouds by current standards. Over time, several studies have been carried out to optimise these devices (e.g. to reduce the inhomogeneity of the cloud in the 20 L sphere). The Minimum Ignition Energy (MIE) of dust is measured using the Mike3 modified Hartmann tube, where the ignition attempt is made 60–180 ms after dust dispersion regardless of dust characteristics.This work investigates the dust clouds’ actual behaviour inside the modified Hartmann tube before ignition using high-velocity video movies and a new image post-treatment method called Image Subtraction Method (ISM). Movies are recorded with high-speed cameras at a framerate of 2000 fps and elaborated with an on-purpose developed LabVIEW® code. Concentration (mass per volume) and dispersion pressure are varied to evaluate their effect on dust clouds. Maise starch, iron powder and silica powder are chosen to investigate the effect of particle density and size on the cloud structure and turbulence. This approach will help to investigate the structure of the dust cloud, the shape and size of the particle lumps and the change in dust concentration over time. In addition, information on the actual concentration and cloud turbulence at the ignition location and delay time were obtained, which may help identify the local turbulence scale and widen the characterisation of the cloud generated in the Hartmann tube.     

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.     

Detailed analysis of flame propagation during dust explosions by UV band observations

It is important to sufficiently understand the phenomena during the dust explosions in order to take appropriate measures preventing dust explosion accidents. However, at present basic knowledge on flame propagation mechanisms during dust explosions is not enough. In this study, therefore, the flame propagation mechanisms during dust explosions are examined by detailed analyses using a special observation at UV band. Small scale experiments were performed to analyze flame propagating processes in detail. In the experiments, the stearic acid was used as the combustible particle, suspended particles were ignited by an electric spark, and flame propagation through the combustible dust was observed by using a special observation system at UV band. The leading combustion zone is observed to consist of discrete burning blue spot flames by the observation using ordinary photograph system. It is questionable how the leading flame of such discrete structure propagates. In this study, high-speed video images at UV band through a band-pass filter were taken to detect OH emission from combustion reaction zone. Using this method, the propagating flame could be detected clearly and the flame propagation mechanism could be examined in detail. In the conditions performed in this study, discrete flame propagation was not observed and the leading flame was observed to propagate continuously. This result is of importance for understanding the flame propagation phenomena during dust explosion.     

Effects of ignition energy on fire and explosion characteristics of dilute hybrid fuel in ventilation air methane

Deflagration explosions of coal dust clouds and flammable gases are a major safety concern in coal mining industry. Accidental fire and explosion caused by coal dust cloud can impose substantial losses and damages to people and properties in underground coal mines. Hybrid mixtures of methane and coal dust have the potential to reduce the minimum activation energy of a combustion reaction. In this study the Minimum Explosion Concentration (MEC), Over Pressure Rise (OPR), deflagration index for gas and dust hybrid mixtures (K_st) and explosive region of hybrid fuel mixtures present in Ventilation Air Methane (VAM) were investigated. Experiments were carried out according to the ASTM E1226-12 guideline utilising a 20 L spherical shape apparatus specifically designed for this purpose.Resultsobtained from this study have shown that the presence of methane significantly affects explosion characteristics of coal dust clouds. Dilute concentrations of methane, 0.75–1.25%, resulted in coal dust clouds OPR increasing from 0.3 bar to 2.2 bar and boosting the K_st value from 10 bar m s⁻¹ to 25 bar m s⁻¹. The explosion characteristics were also affected by the ignitors’ energy; for instance, for a coal dust cloud concentration of 50 g m⁻³ the OPR recorded was 0.09 bar when a 1 kJ chemical ignitor was used, while, 0.75 bar (OPR) was recorded when a 10 kJ chemical ignitor was used.For the first time, new explosion regions were identified for diluted methane-coal dust cloud mixtures when using 1, 5 and 10 kJ ignitors. Finally, the Le-Chatelier mixing rule was modified to predict the lower explosion limit of methane-coal dust cloud hybrid mixtures considering the energy of the ignitors.     

Wire-mesh inhibition of jet fire induced by explosion venting

Explosion venting is widely applied in industrial explosion-proof designs due to the convenient, economical and practical features of this method. Natural gas is usually stored in storage tanks. If the gas in the vessel is mixed with air and encounters an ignition source, explosion venting might occur, producing jet fire, generating new secondary derivative accidents and causing casualties and property losses. In this paper, a set of test platforms including wire-mesh suppression devices is established to study the inhibition of jet fire induced by explosion venting by wire mesh. The experimental research shows that a wire mesh significantly inhibits the jet fire induced by explosion venting. The flame propagation velocity and pressure clearly decrease with increasing numbers of wire-mesh layers. The wire-mesh structure significantly affects the flame propagation, and the more layers of mesh there are, the better the suppression effect is. The flame temperature gradually decreases with the addition of the wire mesh. The mesh size significantly affects the pressure propagation of explosion venting. The explosion pressure gradually decreases with the addition of the wire mesh. With increasing distance between the wire mesh and the explosion vent, the maximum temperature first increases and then decreases, and the maximum explosion pressure first decreases and then increases. In the case of single gas cloud, the flame suppression effect is the most obvious when the wire mesh is 0.2 m away from the explosion vent. In the case of double gas clouds, the flame suppression effect is the most significant when the distance between the wire mesh and the first gas cloud is 0.4 m.     

Overpressure characteristics of aluminium dust explosion vented through a relief pipe

A parametric experimental study of an aluminium dust explosion, initiated in a vessel and vented through a relief pipe, was performed. The aim is to clarify the overpressure characteristics in a vessel and relief pipe, during aluminium dust explosion venting, especially when a burn-up phenomenon occurs. For a vessel of fixed size, the influence of pipe diameter and pipe length on burn-up was discussed. Results demonstrate that burn-up occurs shortly after flame only enters the initial part of the relief pipe when the original dust concentration in the vessel is at relatively high level, which is usually higher than the optimum concentration obtained from the confined vessel. When burn-up occurs, the maximal overpressure continues to increase rather than to decay along the initial part of the relief pipe. If burn-up is vigorous, a second peak on overpressure-time curve in the vessel could appear. By adding 0.1 g aluminium powders on the membrane, the second overpressure peak may even surpass the first peak. Extending pipe lengths can strengthen the overpressures around the position where burn-up occurs in the relief pipe. Reducing the pipe diameter can increase the burn-up severity in the relief pipe owing to the increased dust concentration and the pressure accumulation.     

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.