The Boiling Liquid Expanding Vapour Explosion (BLEVE): A bibliometric review and futur trends

The phenomenon “Boiling Liquid Expanding Vapor Explosion” (BLEVE) is one of the most common accidental events in the chemical industry and in the transport of dangerous goods. A bibliographic search in the Web of Science Core Collection reported 375 publications related to BLEVEs from 1979 to the present (August 10, 2022). A bibliometric analysis was conducted using the VOSviewer tool to allow a better understanding of the scientific knowledge on this phenomenon. A comprehensive overview of BLEVE research is presented in terms of annual publication, top journals, countries/regions with the highest productivity, authors and their cooperation networks, key terms, and co-citation analysis. The 375 publications cover 691 authors, 83 journals, 44 countries or territories and 290 institutions. The key publication (highest number of citations and co-citations) for understanding the BLEVE phenomenon is. The results obtained constitute a snapshot of the current state of the art on BLEVEs and can be applied to improve the understanding of research on this topic and establish new trends of research.     

BLEVE火球热辐射及其影响评价模型介绍

高压液化易燃、易爆化学品储罐易发生BLEVE,引起热辐射,会造成周围人员伤亡和设备损坏.介绍了BLEVE火球热辐射及其影响模型,通过该模型可以计算BLEVE火球的尺寸、持续时间、升空高度、热辐射通量及预测暴露在BLEVE火球热辐射通量下人的致死概率.     

扑救液化石油气储罐爆炸火灾安全距离的确定

液化石油气储罐爆炸火灾是一类比较难于扑救的特殊火灾，如何根据现场的情况快速评估事故危害，并确定灭火指挥和人员疏散的安全距离，是消防指挥员指挥决策的重要问题，也是难点问题。本文研究了液化石油气储罐发生BLEVE时的热辐射和冲击波计算方法，并导出了安全距离的确定方法。对于消防指挥员快速决策具有十分重要的意义。     

Fired equipment combustion chamber accidents: A historical survey

A historical analysis was carried out on 189 accidents that occurred in gas and oil fuel fired equipment. The variation of frequency as a function of time, the main causes leading to a fire or an explosion, as well as the consequences of the accidents were studied. Explosion was the most frequent accident, followed by fire; in a few cases the final outcome was a release. Accidents in gas fired combustion equipment were significantly more frequent than those in the liquid fired ones. The main causes were tube rupture and/or error in ignition/reignition sequences, followed by loss of flame in the combustion chamber and, with a minor frequency, entrance of non-expected fuel and presence of non-combusted materials. The consequences on people were much more important in case of explosions than in case of fires. Even though the equipment involving combustion chambers can be considered essentially safe, this historical analysis has shown that accidents continue to occur with certain frequency because the number of existing units is quite high and the possibility of human error during its operation and maintenance is still significant.     

On the mechanism of a BLEVE occurrence due to fire engulfment of tanks with overheated liquids

The BLEVE (boiling liquid expanding vapor explosion) effect that involves the formation of a fireball occurs at the engulfment by fire of a tank with a highly flammable liquid or a liquid gas. Heating of the tank causes elevation of the liquid phase temperature and pressure inside the tank. A partial rupture of the dry tank walls is possible, with the formation of a rarefaction wave propagating into the liquid phase. An evaporation wave moves after the rarefaction wave and cause a rapid increase of pressure, exceeding the initial pressure before depressurization. Rapid violent destruction of the tank occurs. The mechanism of a BLEVE initiation is considered using Van der Waals isotherms. The following criterion for the possibility of a BLEVE was formulated. If the final state is located on an unstable part of the Van der Waals isotherm, a BLEVE takes place. Limiting values of the temperatures for overheating of certain highly flammable liquids and liquid gases (propane, n-butane, n-pentane, isopentane) were calculated using the proposed method, and were found to be in good agreement with experimental data available in the literature.     

Assessing the hazards from a BLEVE and minimizing its impacts using the inherent safety concept

Many worlds' major process industry accidents are due to BLEVE such as at Feyzin, France, 1966 and San Juan Ixhuatepec, Mexico City, 1984. One of the approaches to eliminate or minimize such accidents is by the implementation of inherently safer design concept. This concept is best implemented where the consequence of BLEVE can be evaluated at the preliminary design stage, and necessary design improvements can be done as early as possible. Thus, the accident could be avoided or minimized to as low as reasonably practicable (ALARP) without resorting to a costly protective system. However, the inherent safety concept is not easy to implement at the preliminary design stage due to lack of systematic technique for practical application. To overcome these hurdles, this paper presents a new approach to assess process plant for the potential BLEVE at the preliminary design stage and to allow modifications using inherent safety principles in order to avoid or minimize major accidents. A model known as Inherent Fire Consequence Estimation Tool (IFCET) is developed in MS Excel spreadsheet to evaluate BLEVE impacts based on overpressure, radiation heat flux and missile effects. In this study, BLEVE impacts are the criteria used as the decision-making for the acceptability of the design. IFCET is integrated with iCON process design simulator for ease of data transfer and quick assessment of potential BLEVE during the design simulation stage. A case study was conducted to assess of potential BLEVE from a propane storage vessel at the design simulation stage using this new approach. The finding shows promising results that this approach has a potential to be developed as a practical tool.     

LPG球罐BLEVE过程中超压与热耦合效应模拟研究

为评估LPG球罐发生BLEVE过程中超压与热耦合效应对化工企业抗爆控制室和避难所选址的影响,采用TNO多能法数学模型计算冲击波超压,采用多源数学模型计算火球热辐射。编写MATLAB计算程序,并应用ANSYS模拟二者破坏效应的耦合作用。LPG球罐发生BLEVE过程中,爆炸冲击波的传播速度、持续时间和火球的传播速度、持续时间不同,爆炸冲击波主要在燃料高速抛散的初期形成,之后基本与火球脱离。分别模拟计算冲击波超压和火球热辐射对抗爆控制室和避难所的影响,结果表明：抗爆控制室选址只需考虑爆炸冲击波的影响;避难所选址需要考虑冲击波超压和火球热辐射作用双重影响。在研究基础上提出,LPG球罐附近人员逃生的避难所应设置在球罐防火堤外紧邻防火堤处的地下,应具有抗震、防渗、防火、防中毒窒息等功能。人员应在BLEVE发生前进入避难所才能逃生。     

Study of the severity of industrial accidents with hazardous substances by historical analysis

This paper studies the levels of risk in industrial facilities where hazardous substances are used, evaluating the influence of certain variables on the severity of the accidents that have occurred until now. It makes use of the incidents recorded in the July 2001 version of the MHIDAS database. This study reveals that accidents in developed countries are less severe than those that occur in other geographical areas. Also, it establishes the influence on the severity (number of fatalities) of this kind of incident of certain factors: the type of incident and the type and amount of substance involved. Lastly, the extent to which current facilities comply to the risk tolerance criteria in various countries is evaluated with regards to incidents involving explosions.     

Predicting the frequency of accidents in port areas by developing event trees from historical analysis

The historical analysis of 828 accidents in port areas, which have been selected from a database, has been used to identify the sequences of the accidents. Processing these data has allowed the event trees and the probability of the various accident scenarios to be determined. By using these event trees and figures detailing the frequency of the events that initiated the accidents, as taken from various authors, the frequency of the accidents has been determined.     

Steam cavity and explosion intensity of molten copper column interaction with water

The steam explosion is one of the most serious accidents in the metallurgical industry. In this paper, an experimental study on the interaction of molten copper column with cooling water was carried out using high-speed camera and transient pressure measurement system. The effects of temperature, falling height, diameter and mass of molten copper column on the interaction were investigated. The steam cavity phenomenon was observed in the interaction and the percentage of steam cavity volume affects the probability of fragmentation of molten copper column. The maximum percentage of steam cavity volume increases firstly and then decreases with the increase of temperature and falling height. It increases with the increase of diameter of molten copper column, but the mass has a weak effect. The pressure wave generated by the interaction of molten copper column with cooling water gradually increases with an increase in the temperature of molten copper column. The energy conversion rate in the interaction of molten copper column with cooling water was calculated. The rate of energy conversion from the thermal energy of molten copper column to the energy of pressure wave is low because most of the thermal energy is dissipated into the cooling water by heat transfer.     

The significance of domino effect in chemical accidents

A historical survey was performed on 330 accidents involving domino effect, occurred in process/storage plants and in the transportation of hazardous materials; only accidents occurred after 1st-January-1961 have been considered. The main features – geographical location, type of accident, materials involved, origin and causes, consequences, domino sequences – were analyzed, with special consideration to the situation in the developing countries and compared to those from other previous surveys. Among the involved substances, LPG was the most frequent one, followed by liquid hydrocarbons. Process plants (38.5% of cases) and storage areas (33%) were the most common settings; 10.6% of past domino accidents occurred in transfer operations. The ratio between “two-step” and “three-step” domino accidents was found to be 6. A specific analysis of the accidents (84) occurred in the 21st century was performed, comparing them with the total set of accidents. Finally, a set of specific recommendations inferred from the results is provided.     

Fire and explosion hazard analysis during surface transport of liquefied petroleum gas (LPG): A case study of LPG truck tanker accident in Kannur,Kerala, India

This paper presents an analysis and simulation of an accident involving a liquefied petroleum gas (LPG) truck tanker in Kannur, Kerala, India. During the accident, a truck tanker hit a divider and overturned. A crack in the bottom pipe caused leakage of LPG for about 20 min forming a large vapor cloud, which got ignited, creating a fireball and a boiling liquid expanding vapor explosion (BLEVE) situation in the LPG tank with subsequent fire and explosion. Many fatalities and injuries were reported along with burning of trees, houses, shops, vehicles, etc. In the present study, ALOHA (Area Locations of Hazardous Atmospheres) and PHAST (Process Hazard Analysis Software Tool) software have been used to model and simulate the accident scenario. Modeling and simulation results of the fireball, jet flame radiation and explosion overpressure agree well with the actual loss reported from the site. The effects of the fireball scenario were more significant in comparison to that of the jet fire scenario.     

Predicting the ejection velocities of fragments from explosions cylindrical pressure vessels: Uncertainty and sensitivity analysis

The purpose of this study was a refinement of knowledge on predicting the ejection velocities of fragments generated by explosions of cylindrical horizontal pressure vessels. A procedure is proposed for assessing these velocities by means of the stochastic simulation. The procedure is used to quantify uncertainties related to the ejection velocities and to carry out a simulation-based sensitivity analysis. The main finding is that the currently available information on phenomena related to the vessel fragmentation is sparse and, therefore, predicting ejection velocities will require a substantial amount of subjective judgement. It was found that ejection velocities are functions of a relatively large number of random input variables, many of which must be modelled subjectively. The study revealed also the need to choose subjectively between several alternative mathematical models used to specify input variables that influence the ejection velocities. The most critical choice must be made between several models used for an assessment of the energy liberated during vessel explosions. Results of the sensitivity analysis indicate that the ejection velocities are influenced mainly by input variables used to express energies involved in the prediction problem. Increased sensitivity to filling ratio of a two-phase pressure vessel was also detected. Results of the study can be used for an improvement of estimation of fragment impact probabilities and design of protective barriers that are built close to the pressure vessels posing explosion hazard.     

An innovative and comprehensive approach for the consequence analysis of liquid hydrogen vessel explosions

Hydrogen is one of the most suitable solutions to replace hydrocarbons in the future. Hydrogen consumption is expected to grow in the next years. Hydrogen liquefaction is one of the processes that allows for increase of hydrogen density and it is suggested when a large amount of substance must be stored or transported. Despite being a clean fuel, its chemical and physical properties often arise concerns about the safety of the hydrogen technologies. A potentially critical scenario for the liquid hydrogen (LH₂) tanks is the catastrophic rupture causing a consequent boiling liquid expanding vapour explosion (BLEVE), with consequent overpressure, fragments projection and eventually a fireball. In this work, all the BLEVE consequence typologies are evaluated through theoretical and analytical models. These models are validated with the experimental results provided by the BMW care manufacturer safety tests conducted during the 1990's. After the validation, the most suitable methods are selected to perform a blind prediction study of the forthcoming LH₂ BLEVE experiments of the Safe Hydrogen fuel handling and Use for Efficient Implementation (SH₂IFT) project. The models drawbacks together with the uncertainties and the knowledge gap in LH₂ physical explosions are highlighted. Finally, future works on the modelling activity of the LH₂ BLEVE are suggested.     

氨分解装置中液氨储罐火灾爆炸危险性分析

以某金属处理企业氨分解装置中液氨储罐罐区为例,对液氨泄漏后火灾爆炸事故及其伤害范围进行了研究,用池火、蒸气云爆炸和沸腾液体扩展蒸气爆炸模型进行计算分析,给出火灾、爆炸事故的人员伤害和财产损失范围。结果表明:围堤堤内池火或罐内池火时,罐区建构筑物内的汽化器、管道等设备会因直接过火或热辐射导致损坏,建筑内人员死亡,但难以波及罐区之外;蒸气云爆炸产生相当于1192.72kgTNT爆炸的当量,爆炸的后果严重,应重点防范,防范的重点为液氨泄漏、点火源;沸腾液体扩展蒸气爆炸的火球半径56.1m,持续时间8.7s,死亡半径27.2m,其源于储罐受热或系统突然失效,液体瞬时泄漏汽化并遇点火源而发生,具有突发性且后果严重,企业应高度重视并严格储罐及系统的定期检验与校验、密切关注系统的有效运行。     

Analysis of the boiling liquid expanding vapor explosion (BLEVE) of a liquefied natural gas road tanker: The Zarzalico accident

The road accident of a tanker transporting liquefied natural gas (LNG) originated a fire and, finally, the BLEVE of the tank. This accident has been analyzed, both from the point of view of the emergency management and the explosion and fireball effects. The accidental sequence is described: fire, LNG release, further safety valves release, flames impingement on vessel unprotected wall, vessel failure mode, explosion and fireball. According to the effects and consequences observed, the thermal radiation and overpressure are estimated; a mathematical model is applied to calculate the probable mass contained in the vessel at the moment of the explosion. The peak overpressure predicted from two models is compared with the values inferred from the accident observed data. The emergency management is commented.     

Carbon dioxide pipelines: A statistical analysis of historical accidents

Carbon dioxide pipeline is an essential carrier in carbon capture, utilization, and storage (CCUS). Statistically revealing the accident rate and risk of carbon dioxide pipelines is conducive to integrity management. Based on 112 accident records collected from Pipeline & Hazardous Materials Safety Administration, this work analyzes the frequency, rate, and risk of accidents. In addition, the impact of relevant factors on risk is further discussed. Some primary conclusions are as follows: (1) For carbon dioxide pipelines, the leak is the leading form of accident. Most carbon emissions are generated in the form of leakage, but economic losses are mainly generated in other forms. (2) The pipelines that have been in service for 0–10 years have the highest frequency of accidents and the highest proportion of carbon emissions, but the pipelines that have been in service for 11–20 years have caused the most economic losses. (3) Among the accident causes, the number of accidents caused by equipment failure is the highest, while the economic loss caused by natural force damage is the highest, and the carbon emission caused by material failure is the highest.     

Effect of separation distance on gas dispersion and vapor cloud explosion in a storage tank farm determined using computational fluid dynamics

Storage tank separation distance, which considerably affects forestalling and mitigating accident consequences, is principally determined by thermal radiation modeling and meeting industry safety requirements. However, little is known about the influence of separation distance on gas dispersion or gas explosion, which are the most destructive types of accidents in industrial settings. This study evaluated the effect of separation distance on gas dispersion and vapor cloud explosion in a storage tank farm. Experiments were conducted using Flame Acceleration Simulator, an advanced computational fluid dynamics software program. Codes governing the design of separation distances in China and the United States were compared. A series of geometrical models of storage tanks with various separation distances were established. Overall, increasing separation distance led to a substantial reduction in vapor cloud volume and size in most cases. Notably, a 1.0 storage diameter separation distance appeared to be optimal. In terms of vapor cloud explosion, a greater separation distance had a marked effect on mitigating overpressure in gas explosions. Therefore, separation distance merited consideration in the design of storage tanks to prevent gas dispersion and explosion.     

Historical evolution of process safety and major-accident hazards prevention in Spain. Contribution of the pioneer Joaquim Casal

This paper aims at presenting the evolution of process safety in Spain from various points of view. In first place, a study of the accidents occurred in this country in the process industry and in the transportation of chemical substances is presented. After this, the starting point of the process safety research in Spain and its evolution during the years are explained. The importance of this topic has also been reflected in the chemical engineering studies in some Spanish universities. Therefore, the current status of the studies on process safety in Spain is analyzed in this paper. A section has also been devoted to the process safety in the Spanish industry. An analysis of the related legislation and its implementation in the Spanish process industry is also presented in this paper. Finally, the professional career of Prof. Joaquim Casal, the pioneer in Spain in process safety and risk assessment, is summarized.     

Performance evaluation of integrated resilience engineering factors by data envelopment analysis: The case of a petrochemical plant

Petrochemical units are potentially prone to incidents that have catastrophic consequences such as explosion, leakage of toxic materials, and the stoppage of the production process. Resilience engineering (RE) is a new method that can control incidents and limit their consequences. It includes top-level commitment, reporting culture, learning, awareness, preparedness, and flexibility. However, this study introduces a new concept of RE (referred to as integrated RE or IRE) which includes the above factors in addition to self-organization, teamwork, redundancy and fault-tolerant. This study evaluates performance of IRE in a petrochemical plant through considering the obtained data from questionnaires and data envelopment analysis (DEA) approach. Moreover, the performance of RE and the new IRE are compared and discussed. The results show that although there is a strong direct correlation between the DEA results in two frameworks, the mean scores of efficiency in IRE is slightly higher than RE. This is the first study that introduces an integrated approach for RE. In addition, this study is amongst the first ones that examine the behavior of resilience engineering by DEA. Moreover, the superiority of IRE is shown through robust statistical analysis.