A theoretical model for the prediction of the minimum ignition energy of dust clouds

In this study, a physical model of the dust cloud ignition process is developed for both cylindrical coordinates with a straight-line shaped ignition source and spherical coordinates with a point shaped ignition source. Using this model, a numerical algorithm for the calculation of the minimum ignition energy (MIE) is established and validated. This algorithm can evaluate MIEs of dusts and their mixtures with different dust concentrations and particle sizes. Although the average calculated cylindrical MIE (MIE_cylindrical) of the studied dusts only amounts to 63.9% of the average experimental MIE value due to reasons including high idealization of the numerical model and possible energy losses in the experimental tests, the algorithm with cylindrical coordinates correctly predicts the experimental MIE variation trends against particle diameter and dust concentration. There is a power function relationship between the MIE and particle diameter of the type MIE ∝ d_p^k with k being approximately 2 for cylindrical coordinates and 3 for spherical coordinates. Moreover, as dust concentration increases MIE(conc) first drops because of the decreasing average distance between particles and, at fuel-lean concentrations the increasing dust cloud combustion heat; however, after the dust concentration rises beyond a certain value, MIE(conc) starts to increase as a result of the increasingly significant heat sink effect from the particles and, at fuel-rich concentrations the no longer increasing dust cloud combustion heat.     

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.     

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.     

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.     

Study of the influence of melamine polyphosphate and aluminum hydroxide on the flame propagation and explosion overpressure of aluminum magnesium alloy dust

When aluminum magnesium alloy dust floats in the air, a certain ignition energy can easily cause an accidental explosion. To prevent and control the occurrence of accidental explosions and reduce the severity of accidents, it is necessary to carry out research on the explosion suppression of aluminum magnesium alloy dust. This paper uses a vertical glass tube experimental device and a 20 L spherical explosive experimental device to carry out experimental studies on the suppression of the flame propagation and explosion overpressure of aluminum magnesium alloy dust with melamine polyphosphate (MPP) and Al(OH)₃. With increasing MPP and Al(OH)₃ concentrations, the flame brightness darkened, the flame velocity and propagation distance gradually decreased, and P_max and (dp/dt)_max decreased significantly. When the amount of MPP added reached 60%, the flame propagation distance decreased to 188 mm, which is a decrease of 68%, and the explosion overpressure decreased to 0.014 MPa, effectively suppressing the explosion of aluminum magnesium alloy dust. The experimental results showed that MPP was more effective than Al(OH)₃ in inhibiting the flame propagation and explosion overpressure of the aluminum magnesium alloy dust. Finally, the inhibitory mechanisms of the MPP and Al(OH)₃ were further investigated. The MPP and Al(OH)₃ endothermic decomposition produced an inert gas, diluted the oxygen concentration and trapped active radicals to terminate the combustion chain reaction.     

Study on explosion characters of HDPE dust inerted by CaCO3 and NaHCO3

To prevent high density polyethylene (HDPE) dust explosions, this study evaluated HDPE's explosive sensitivity characteristics, and comparatively examined two inert dust types (CaCO₃ and NaHCO₃) to mitigate the explosive sensitivity of HDPE dust. In the serials of experiments, the 1.2 L Hartmann tube and Godbert-Greenwald furnace were used respectively to measure the minimum ignition energy (MIE) and minimum ignition temperature (MIT) of HDPE dust. The findings demonstrated that the MIE and MIT of HDPE are 56.8 mJ and 320 °C under the most sensitive situation. Second, both CaCO₃ and NaHCO₃ can inhibit the explosive sensitivity of HDPE with the variation of several parameters (i.e., quality percentage and particle sizes). Specially, as the quality percentage of 38–48 μm NaHCO₃ come to 70%, the HDPE/NaHCO₃ will not be explosive. Finally, NaHCO₃ had a better inerting effect than CaCO₃ in the reduction of explosive sensitivity of HDPE.     

Minimum ignition energy theoretical model for flammable gas based on flame propagation layer by layer

To achieve the rapid prediction of minimum ignition energy (MIE) for premixed gases with wide-span equivalence ratios, a theoretical model is developed based on the proposed idea of flame propagation layer by layer. The validity and high accuracy of this model in predicting MIE have been corroborated against experimental data (from literature) and traditional models. In comparison, this model is mainly applicable to uniform premixed flammable mixtures, and the ignition source needs to be regarded as a punctiform energy source. Nevertheless, this model can exhibit higher accuracy (up to 90%) than traditional models when applied to premixed gases with wide-span equivalence ratios, such as C₃H₈-air mixtures with 0.7–1.5 equivalence ratios, CH₄-air mixtures with 0.7–1.25 equivalence ratios, H₂-air mixtures with 0.6–3.15 equivalence ratios et al. Further, the model parameters have been pre-determined using a 20 L spherical closed explosion setup with a high-speed camera, and then the MIE of common flammable gases (CH₄, C₂H₆, C₃H₈, C₄H₁₀, C₂H₄, C₃H₆, C₂H₂, C₃H₄, C₂H₆O, CO and H₂) under stoichiometric or wide-span equivalence ratios has been calculated. Eventually, the influences of model parameters on MIE have been discussed. Results show that MIE is the sum of the energy required for flame propagation during ignition. The increase in exothermic and heat transfer efficiency for fuel molecules can reduce MIE, whereas prolonging the flame induction period can increase MIE.     

A numerical model for the prediction of the minimum ignition temperature of dust clouds

This paper presents a numerical model for the prediction of the minimum ignition temperature (MIT) of dust clouds. First, a physical model is developed for the dust cloud ignition in the Godbert-Greenwald furnace. A numerical approach is then applied for the MIT prediction based on the physical model. The model considers heat transfer between the air and dust particles, the dust particle reaction kinetics, and the residence times of dust clouds in the furnace. In general, for the 13 dusts studied, the calculated MIT data are in agreement with the experimental values. There is also great accordance between the experimental and numerical MIT variation trends against particle size. Two different ignition modes are discovered. The first one consists in ignition near the furnace wall for bigger particles characterized by rather short residence times. In the second mode, the ignition starts from the center of the furnace by self-heating of the dust cloud for smaller particles with longer residence times. For magnesium, as dust concentration increases, the lowest ignition temperature of the dust cloud IT(conc) decreases first, then transits to increase at a certain point. The transition happens at different dust concentrations for different particle sizes. Moreover, the MIT of the magnesium dust cloud generally increases as particle size increases, but the increasing trend stagnates within a certain medium particle size range.     

The effects of phosphorus-free inhibitors on the ignition of lycopodium dust

The minimum ignition temperature of dust suspension (MIT) and the hot surface ignition temperature of the dust layer (LIT) are essential safety parameters for the process industry. However, the knowledge of the ignition behavior when solid mixtures of flammable fuels and phosphorous-free inhibitors are considered is still scarce and further experimental and theoretical analyses are requested. In this work, the ignition temperature of phosphorous-free inhibitors (coal fly ash and calcium carbonate) mixed with lycopodium dust have been studied in terms of LIT analysis (hot plate thickness: 5 mm, 12.5 mm and 15 mm), and by the Godbert-Greenwald test for the MIT. Both coal fly ash and calcium carbonate have been tested at different concentrations and particle sizes.Results show that the effects of the inhibitor can be counter-productive when layer ignition temperature is considered even if the minimum ignition temperature of the dust suspension shows a positive effect from the safety point of view. This behavior has been analyzed in the terms of thermal conductivity and diffusivity of the mixture, by using Maxwell's equation for two-phase solid mixtures. Standard empirical correlations for the ignition temperature of solid mixtures have been also tested, showing their weakness in reproducing mixture behavior.     

Testing of dust clouds for the electrostatic-spark ignition hazard in industry. Need for a modified approach?

Current standard test methods for electric-spark minimum ignition energies (MIEs) of dust clouds in air require that a series inductance of at least 1–2 mH be included in the electric-spark discharge circuit. The reason is to prolong the spark discharge duration and thus minimize the spark energy required for ignition. However, when assessing the minimum electrostatic energy ½CU² for dust cloud ignition by accidental electrostatic-spark discharges, current testing standards require that the series inductance of at least 1–2 mH be removed from the spark discharge circuit. No other changes of apparatus and test procedure are required. The present paper questions whether this simple approach is always adequate. The reason is that in practice in industry accidental electrostatic-spark discharge circuits may contain large ohmic resistances due to corrosion, poor electrical grounding connections, poorly electrically conducting construction materials etc. The result is increased spark discharge durations and reduced mechanical disturbance of the dust cloud by the blast wave emitted by the spark. Therefore, testing for minimum ½CU² for ignition by accidental electrostatic spark discharges may not only require removal of the series inductance of 1–2 mH from the standard MIE spark discharge circuit. Additional tests may be needed with one or more quite large series resistances R_s inserted into the spark discharge circuit. The present paper proposes a modified standard test procedure for measurement of the minimum electrostatic-spark ignition energy of dust clouds that accounts for these effects.     

Explosibility of polyamide and polyester fibers

The current research is aimed at investigating the explosion behavior of hazardous materials in relation to aspects of particulate size. The materials of study are flocculent (fibrous) polyamide 6.6 (nylon) and polyester (polyethylene terephthalate). These materials may be termed nontraditional dusts due to their cylindrical shape which necessitates consideration of both particle diameter and length. The experimental work undertaken is divided into two main parts. The first deals with the determination of deflagration parameters for polyamide 6.6 (dtex 3.3) for different lengths: 0.3 mm, 0.5 mm, 0.75 mm, 0.9 mm and 1 mm; the second involves a study of the deflagration behavior of polyester and polyamide 6.6 samples, each having a length of 0.5 mm and two different values of dtex, namely 1.7 and 3.3. (Dtex or decitex is a unit of measure for the linear density of fibers. It is equivalent to the mass in grams per 10,000 m of a single filament, and can be converted to a particle diameter.) The explosibility parameters investigated for both flocculent materials include maximum explosion pressure (P_max), size-normalized maximum rate of pressure rise (K_St), minimum explosible concentration (MEC), minimum ignition energy (MIE) and minimum ignition temperature (MIT). ASTM protocols were followed using standard dust explosibility test equipment (Siwek 20-L explosion chamber, MIKE 3 apparatus and BAM oven). Both qualitative and quantitative analyses were undertaken as indicated by the following examples. Qualitative observation of the post-explosion residue for polyamide 6.6 indicated a complex interwoven structure, whereas the polyester residue showed a shiny, melt-type appearance. Quantitatively, the highest values of P_max and K_St were obtained at the shortest length and finest dtex for a given material. For a given length, polyester displayed a greater difference in P_max and K_St at different values of dtex than polyamide 6.6. Long ignition delay times were observed in the BAM oven (MIT measurements) for polyester, and video framing of explosions in the MIKE 3 apparatus (MIE measurements) enabled observation of secondary ignitions caused by flame propagation after the initial ignition occurring at the spark electrodes.     

Inhibiting effects by Fe2O3 on combustion and explosion characteristics of ABS resin

The global increase in the use of, and reliance on, plastics has prompted the demand for acrylonitrile-butadiene-styrene (ABS) resin in various fields. With this increased requirement, numerous failures have occurred in the ABS process. Those incidents, resulting from electrostatic discharge, powder accumulation, heat accumulation, construction sparks, and plant fires, have caused dust fire and explosions.In this study, the ABS resin was gleaned from the site and tested for its explosion parameters, including minimum ignition temperature of dust cloud (MIT_C), minimum ignition energy (MIE), and minimum explosion concentration (MEC). To improve loss prevention in the manufacturing process, ferric oxide (Fe₂O₃) as an inert additive was added in the ABS powder. According to the MIE test, Fe₂O₃ has an apparent inhibiting effect on dust explosion for the ABS dust. With the proportion of Fe₂O₃ increased from 25 to 50 mass% in ABS, the MIE increased from 67 to 540 mJ. The explosion tests via 20-L apparatus indicated that Fe₂O₃ mixed with ABS could not increase the MEC significantly. However, the explosion pressure dropped by increasing in the ratio of Fe₂O₃ in ABS. This inerting strategy of ABS was deemed to substantially lessen the probability and severity of fire and explosion.     

Minimum ignition energy of LDPE dust/ethylene hybrid mixture

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

湍流对粉尘云电火花点火过程的影响

随着现代工业的发展,粉尘爆炸事故发生的频率也逐年增加,因此,对粉尘云点火敏感程度进行测量和计算就变得十分重要。粉尘云最小点火能是粉尘爆炸重要的特性参数之一,是采取粉尘爆炸防护的基础。最小点火能在测量的过程中受到多个敏感条件的影响,其中湍流则是最复杂的影响因素之一。文中对实验过程中粉尘云的湍流进行了定义,并分析了湍流对粉尘云最小点火能影响的内在原因;同时对通过数值模拟计算粉尘云最小点火能过程中的湍流计算给出了数学模型。从实验和数学模型两个方向对湍流进行了全面描述,对粉尘云电火花点火过程中湍流影响的分析结论,可有效的指导实验。     

Risk assessment method of polyethylene dust explosion based on explosion parameters

The explosion characteristic parameters of polyethylene dust were systematically investigated. The variations in the maximum explosion pressure (P_max), explosion index (K_st), minimum ignition energy (MIE), minimum ignition temperature (MIT), and minimum explosion concentration (MEC) of dust samples with different particle sizes were obtained. Using experimental data, a two-dimensional matrix analysis method was applied to classify the dust explosion severity based on P_max and K_st. Then, a three-dimensional matrix was used to categorize the dust explosion sensitivity based on three factors: MIE, MIT, and MEC. Finally, a two-dimensional matrix model of dust explosion risk assessment was established considering the severity and sensitivity. The model was used to evaluate the explosion risk of polyethylene dust samples with different particle sizes. It was found that the risk level of dust explosion increased with decreasing particle size, which was consistent with the actual results. The risk assessment method can provide a scientific basis for dust explosion prevention in the production of polyethylene.     

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.     

Study of lignocellulosic biomass ignition properties estimation from thermogravimetric analysis

In the last decade, the use of renewable resources has increased significantly in order to reduce the energetic dependence on fossil fuels, as they have an important contribution to the global warning and greenhouse gasses effect. Because of that, research on biofuels has been increased in the last years as its characteristics of use match those of the conventional fuel's: solid biomass can be used instead of coals, and biodiesel could replace diesel. Research on solid biomass ignition properties has been considerably developed because of the amount of industrial accidents related to the treatment and use of solid biomass (self-ignition, dust explosions, etc.). On the other hand, thermogravimetric analysis (TGA) is becoming and important characterization technique as it can be used to determine a wide spectrum of properties, such as kinetics, composition, proximate analysis, etc. This research aims to combine thermal analysis and ignition properties, by using the TGA to obtain the elemental composition of lignocellulosic biomass and compare those results to Minimum Ignition Energy (MIE) values test output, so a relation between composition and MIE can be found.To achieve this aim, biomass samples from different origins have been used: oil palm wastes (empty fruit bunches, mesocarp fiber and palm kernel shell), agricultural wastes (straw chops) and forestry wastes (wood chips and wood powder). Also, raw materials and torrefied biomass were compared. The hemicellulose/cellulose ratio was calculated and compared to different flammability properties, finding out that the greater the ratio and the lower the onset temperature (temperature at which the pyrolysis reaction accelerates), the lower was the minimum ignition energy. From this basis it was possible to define “tendency areas” that grouped the samples whose MIE values were similar. Three tendency areas were found: high minimum ignition energy, medium minimum ignition energy, and low ignition energy.     

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.     

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.