Thermo-kinetic modelling of dust explosions

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

Influence of dustiness on small-scale vented dust explosions

A new safety characteristic the “dustiness” according to VDI 2263 – part 9 (Verein Deutscher Ingenieure, 2008) is investigated. Dustiness means the tendency of a dust to form clouds. The paper deals with the physical reasons for the different behavior of dusts, even if they have similar properties such as particle size and density and the influence of the dustiness on dust explosions. In order to study the effects of the dustiness on dust cloud formation for different dispersion methods experiments in a vertical dust dispersion glass tube apparatus were carried out. Furthermore vented dust explosion experiments were done for two different dispersion methods and two static activation pressures.Experiments show that particle size and density are not the only factors which influence dispersibility. Particle shape, specific surface area, flow and dispersion method have an influence which can outweigh size and density. Preliminary explosion experiments showed that the dustiness has an influence on the reduced explosion pressure and flame speed in a vented 75 L test apparatus. In order to verify the results for applications in the process industries further tests with industrial scale experiments are planned.     

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

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

Evaluating the overall efficiency of a flameless venting device for dust explosions

Results from cornstarch explosion tests using a flameless venting device (mounted over a burst disc) on an 8 m³ vessel are presented and used to determine the overall efficiency of the device, which is defined as the ratio between its effective vent area and the nominal vent area. Because these devices are comprised of an arrestor element mounted over an impulsively-actuated venting device (such as a burst disc), the functional form of the overall efficiency is taken as the product of the area efficiency (i.e., the ratio between the effective vent area of the entire assembly to that of the venting device without the arrestor element) and the burst efficiency (i.e., the ratio of the effective vent area of the venting device without the arrestor element to the nominal vent area). The effective vent areas are calculated from measured overpressures using three different empirical correlations (FM Global 2001, NFPA 2007, and VDI 2002). Furthermore, due to significant variations in the effective reactivity from test to test, a correction factor proportional to the initial flame speed is applied when determining the area efficiency. In general, it was found that the FM Global and NFPA methodologies yield consistent results with less scatter than VDI 3673.     

Flame propagation mechanisms in dust explosions

To reveal the effects of particle characteristics, including particle thermal characteristics and size distributions, on flame propagation mechanisms during dust explosions clearly, the flame structures of dust clouds formed by different materials and particle size distributions were recorded using an approach combining high-speed photography and a band-pass filter. Two obviously different flame propagation mechanisms were observed in the experiments: kinetics-controlled regime and devolatilization-controlled regime. Kinetics-controlled regime was characterized by a regular shape and spatially continuous combustion zone structure, which was similar to the premixed gas explosions. On the contrary, devolatilization-controlled regime was characterized by a complicated structure that exhibited heterogeneous combustion characteristics, discrete blue luminous spots appeared surrounding the yellow luminous zone. It was also demonstrated experimentally that the flame propagation mechanisms transited from kinetics-controlled to devolatilization-controlled while decreasing the volatility of the materials or increasing the size of the particles. Damköhler number was defined as the ratio of the heating and devolatilization characteristic time to the combustion reaction characteristic time, to reflect the transition of flame propagation mechanisms in dust explosions. It was found that the kinetics-controlled regime and devolatilization-controlled regime can be categorized by whether Damköhler number was less than 1 or larger than 1.     

Efficiency of triggered barriers in dust explosion suppression in galleries

The paper describes large-scale tests of triggered barriers of different design. Main stress was put on examining suitability of the flame detector developed in US Bureau of Mines to work as a trigger for the barriers. It was found that the detector works satisfactorily with the barriers of different design providing a suitable mean to suppress explosions in galleries, either in mines or in other industries.     

Some aspects in testing and assessment of metal dust explosions

The dust explosion committee of the Association of Powder Process Industry and Engineering, Japan recently established two testing standards for dust explosions. In the investigations for the standardization, many experimental data have been obtained for the dusts currently used in Japanese industries. Data for zirconium, tantalum and silicone dusts are presented to discuss the use of test methods, which have been accepted internationally. The test methods for dust explosions have to consider a variety of kinds and forms of dusts to be tested.     

Duct-venting of dust explosions in a 20 L sphere at elevated static activation overpressures

Ducts are often recommended in the design of dust explosion venting in order to discharge materials to safe locations. However, the maximum reduced overpressure increases in a duct-vented vessel rather than in a simply vented vessel. This needs to be studied further for understanding the duct-venting mechanism. Numerous duct-vented dust explosion experiments were conducted, using a 20 L spherical chamber at elevated static activation overpressures, ranging from 1.8 bar to 6 bar. Duct diameters of 15 mm and 28 mm, and duct lengths of 0 m (simply venting), 1 m and 2 m, were selected. Explosion pressures both in the vessel and in the duct were recorded by pressure sensors, with a frequency of 5 kHz. Flame signals in the duct were also obtained by phototransistors. Results indicate that the secondary explosion occurring in the duct increases the maximum reduced overpressure in the vessel. The secondary explosion is greatly affected by the duct diameter and static activation overpressure, and hence influences the amplification of the maximum reduced overpressure. Larger static activation overpressure decreases the severity of the secondary explosion, and hence decreases the increment in the maximum reduced overpressure. The secondary pressure peak is more obvious as the pressure accumulation is easier in a duct with a smaller diameter. However, the increment of the maximum reduced overpressure is smaller because blockage effect, flame front distortion, and turbulent mixing due to secondary explosion are weaker in a narrow duct. The influence of duct length on the maximum reduced overpressure is small at elevated static activation overpressures, ranging from 1.8 bar to 6 bar at 15 mm and 28 mm duct diameters.     

Flame behaviors and pressure characteristics of vented dust explosions at elevated static activation overpressures

Dust explosion venting experiments were performed using a 20-L spherical chamber at elevated static activation overpressures larger than 1 bar. Lycopodium dust samples with mean diameter of 70 μm and electric igniters with 0.5 KJ ignition energy were used in the experiments. Explosion overpressures in the chamber and flame appearances near the vent were recorded simultaneously. The results indicated that the flame appeared as the under-expanded free jet with shock diamonds, when the overpressure in the chamber was larger than the critical pressure during the venting process. The flame appeared as the normal constant-pressure combustion when the pressure venting process finished. Three types of venting processes were concluded in the experiments: no secondary flame and no secondary explosion, secondary flame, secondary explosion. The occurrence of the secondary explosions near the vent was related to the vent diameter and the static activation overpressure. Larger diameters and lower static activation overpressures were beneficial to the occurrence of the secondary explosions. In current experiments, the secondary explosions only occurred at the following combinations of the vent diameter and the static activation overpressure: 40 mm and 1.2 bar, 60 mm and 1.2 bar, 60 mm and 1.8 bar.     

Modelling of the effect of size on flocculent dust explosions

The effect of size on the severity of explosions involving flocculent materials has been simulated by means of a model previously developed for spherical particles and here extended to the cylindrical geometry of flock. The model consists of the identification of the regime (internal and external heating, pyrolysis/devolatilization reaction, and volatiles combustion) controlling the explosion by the evaluation of dimensionless numbers (Bi, Da, Th and Pc) and then of the estimation of the deflagration index as a function of flocculent size. The model has been validated by means of explosion data of polyamide 6.6 (nylon) at varying diameter and length. The comparison between model and experimental data show a fairly good agreement.     

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.     

Prevention and suppression of explosions in gas-air and dust-air mixtures using powder aerosol-inhibitor

The prevention and suppression of explosions is a very topical field of research because annually hundreds of coal mine workers became their victims. In this research a very effective powder “powder for suppression of explosions” (“PSE”) for the suppression of explosions has been developed and tested. The experiments on suppression of explosions of a methane–air mixture (MAM) at a laboratory conditions using “PSE”-powder have been carried out. The possibility of lowering the power of coal-dust explosion with the help of a “PSE”-powder has been investigated. The feasibility of almost instantaneous disperse of powders using intentionally created mini-explosions (ammonal) was investigated. The barrel-suppressor of explosion in the experimental adit (tunnel) was studied and the large-scale tests for suppression of MAM-explosions in experimental adit were also subjects of study.     

Inhibition effects of aluminum dust explosions by various kinds of ammonium polyphosphate

In this work, vinyltriethoxysilane (A151) and 3-aminopropyltriethoxysilane (KH550) were used to modify ammonium polyphosphate (APP), showing that the dispersibility of APP could be improved remarkably by A151 and KH550. The maximum explosion pressure of aluminum dust explosion decreased with the addition of APP, A151-APP (APP-A) and KH550-APP (APP-B), with the exception of the case where the inerting ratio (α) of APP-A was less than 0.4. After the addition of APP-B, there was little difference in flame propagation behavior and explosion pressure compared with that of adding APP, indicating that APP-B could retain the inhibition performance of APP compared with APP-A. When the inerting ratios of APP, APP-A and APP-B were 1.2, 1.4 and 1.4, respectively, the aluminum dust explosion could be completely inhibited. The explosion residues of aluminum dust/APP mainly consisted of Al₂O₃, P-containing and N-containing compounds. It could be analyzed that APP exerted the inhibition effect through both chemical and physical effects.     

Study on the effect of explosion suppression equipment on hydrogen explosions

Hydrogen safety is a critical component of modern industrial safety production. In this study, a set of hydrogen explosion suppression equipment is designed independently. The suppression effects of the equipment on hydrogen explosions are studied at normal room temperature and pressure. The experimental results show that the actuation time of the equipment and the spraying mode of the suppressant are the main factors leading to the failure of the hydrogen explosion suppression equipment. The flame, with a hydrogen equivalence ratio of 0.7 and 1.0, spreads out of control when the suppressant touches the flame front. At this time, the addition of the suppressant enhances flame propagation and increases pressure. In addition, because the suppressant does not fully cover the developing flame, the hydrogen flame with the equivalence ratio of 0.5 eventually breaks through the suppressant cloud, and the explosion happens. However, when the initial flame is completely covered by the suppressant, the hydrogen explosion is suppressed by hydrogen explosion suppression equipment. This research provides a solid and reliable foundation for hydrogen explosion suppression equipment in industrial safety and production protection.     

Investigations into the influence of dustiness on dust explosions

A new safety characteristic the “dustiness” according to VDI 2263 – part 9 (Verein Deutscher Ingenieure, 2008) is investigated. Dustiness means the tendency of a dust to form clouds. The paper deals with the influence of the dustiness on vented dust explosions. In order to look into the effects of the dustiness on dust cloud formation and explosion properties experiments and simulations in a vertical dust dispersion glass tube apparatus were carried out.Preliminary explosion experiments showed that the dustiness has an influence on the reduced explosion pressure in a vented 75 L test apparatus. Dusts with comparable p_max and K_St values and different dustiness were tested. Dusts with higher dustiness produced higher overpressures, despite comparable safety characteristics. In order to verify the results for applications in the process industries further tests with different settings are planned as well as industrial scale experiments. Characteristics of the dust such as particle size, density, specific surface area and particle shape, which influence the dispersibility, have been determined experimentally.The Euler/Lagrange and the Euler/Euler approaches are compared for simulating an exemplary dust/air mixture. Especially sedimentation and the ability of the approaches to simulate the tendency of dust to stay airborne were investigated. The Euler/Lagrange approach is better suited for simulating local dust concentrations, particle size distributions and particle forces. It could be used to point out regions of high dust concentrations in a vessel. With the Euler/Euler method it is possible to achieve fast solutions for one specified diameter, but the simulated dust/air mixtures are always more homogenous than in reality. ANSYS CFX version 13 was used in all simulations.     

Determination of heterogeneous reaction mechanisms: A key milestone in dust explosion modelling

Reaction kinetics is fundamental for modelling the thermal oxidation of a solid phase, in processes such as dust explosions, combustion or gasification. The methodology followed in this study consists in i) the experimental identification of the reaction mechanisms involved in the explosion of organic powders, ii) the proposal of simplified mechanisms of pyrolysis and oxidation, iii) the implementation of the model to assess the explosion severity of organic dusts. Flash pyrolysis and combustion experiments were carried out on starch (22 μm) and cellulose (53 μm) at temperatures ranging from 973 K to 1173 K. The gases generated were collected and analyzed by gas chromatography. In this paper, a semi-global pyrolysis model was developed for reactive systems with low Damköhler number. It is in good agreement with the experimental data and shows that both carbon monoxide and hydrogen are mainly generated during the pyrolysis of the solid, the generation of the latter compound being greatly promoted at high temperature. A simplified combustion model was also proposed by adding two oxidation reactions of the pyrolysis products. In parallel, flame propagation tests were performed in a semi open tube in order to assess the burning velocity of such compounds. The laminar burning velocity of cellulose was determined to be 21 cm s⁻¹. Finally, this model will be integrated to a predictive model of dust explosions and its validation will be based on experimental data obtained using the 20 L explosion sphere. The explosion severity of cellulose was determined and will be used to develop and adjust the predictive model.     

Inerting effect of CaCO3 powder on flame spread of wood dust layer

The effect of CaCO₃ powder, a typical inert dust, on the flame spread characteristics of wood dust layers was studied using an experimental device to understand the ignition characteristics of and develop inert explosion-proof technology for deposited wood dust. The results showed that the flame spread velocity (FSV) of the mixed dust layer was affected by the dispersion effect of CaCO₃ powder and physical heat absorption. As the CaCO₃ powder mass fraction increased, the FSV of the dust layer first increased and then decreased, reaching a peak at a 50% mass fraction. Moreover, the front-end temperature of the flame gradually decreased, and the red spark faded. The combustion reaction of the mixed dust layer could be more completed, and the colour of the combustion residue changed from charcoal black to charcoal grey. The coupling effect of the initial temperature and wind speed can promote an increase in the FSV in the mixed dust layer. The Gauss–Amp model of the FSV of the wood dust layer and mass fraction of CaCO₃ powder showed that the peak of the FSV occurred when the mass fraction of CaCO₃ powder was between 40 and 50%. Thus, a good inerting and explosion-proof effect can be achieved by using CaCO₃ powder with a mass fraction of more than 50%; it can improve the whole inerting process. Inert explosion-proof technology should be considered when assessing fire and explosion risk of dust in real process industry situations.     

抛光铝粉爆炸及ABC粉体抑爆特性的实验研究

为研究抛光铝粉的爆炸危险和ABC粉体的抑爆特性,在对实验粉体粒径分布进行分析的基础上,采用20 L粉尘爆炸特性实验装置,分别对不同铝粉尘浓度、不同抑爆剂浓度条件下的爆炸特性参数进行测试。研究结果表明:在实验条件下,铝粉的爆炸下限为45 g/m3＜C＜60 g/m3;随铝粉浓度增加,爆炸烈度呈现出先增强后减弱的变化趋势,在浓度为400 g/m3时爆炸烈度最大。ABC抑爆剂能够有效抑制铝粉爆炸超压和爆炸反应进程,随着惰性粉体浓度的增加,抑制效果愈加明显,爆炸逐渐减弱。当ABC惰性粉体的质量占比增加到50%时,相较单一铝粉爆炸,反应过程时间由72 ms增加至785 ms,爆炸最大压力、最大压力上升速率分别下降了61.7%,89.5%;当ABC粉体质量占比为53%时,铝粉被完全惰化,未发生爆炸。     

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

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

小苏打对红色彩跑粉粉尘云爆炸极限氧浓度的影响

为研究彩跑粉的爆炸强度和爆炸敏感性,采用20 L球形爆炸实验系统和热重-差热分析仪开展实验,在分析红色彩跑粉爆炸压力和爆炸极限氧浓度(LOC)的基础上,进一步揭示小苏打对红色彩跑粉爆炸极限氧浓度的影响规律。研究结果表明:在玉米粉中添加红色食用色素后形成的彩跑粉会增加爆炸风险,爆炸猛烈度属于St1级;在50~400 g/m³粉尘浓度范围内,红色彩跑粉的LOC值先减小后增大,在200 g/m³时LOC值达到最低9%;当添加不同比例小苏打对红色彩跑粉爆炸风险进行抑制时,发现LOC值随着红色彩跑粉与小苏打混合性粉尘掺混比的增大而增大,在掺混比为50%时,红色彩跑粉与小苏打混合性粉尘的LOC值为21%。研究结果可为彩跑粉加工厂的抑爆和惰化防爆技术提供基础数据参考。