Venting of deflagrations: hydrocarbon–air and hydrogen–air systems

A set of 34 experiments on vented hydrocarbon–air and hydrogen–air deflagrations in unobstructed enclosures of volume up to 4000 m³ was processed with use of the advanced lumped parameter approach. Reasonable compliance between calculated pressure–time curves and experimental pressure traces is demonstrated for different explosion conditions, including high, moderate, low and extremely low reduced overpressures in enclosures of different shape (L_max:L_min up to 6:1) with different type and position of the ignition source relative to the vent, for near-stoichiometric air mixtures of acetone, methane, natural gas and propane, as well as for lean and stoichiometric hydrogen–air mixtures. New data were obtained on flame stretch for vented deflagrations.The fundamental Le Chatelier–Brown principle analog for vented deflagrations has been considered in detail and its universality has been confirmed. The importance of this principle for explosion safety engineering has been emphasized and proved by examples.A correlation for prediction of the deflagration–outflow interaction number, χ/μ, on enclosure scale, Bradley number and vent release pressure is suggested for unobstructed enclosures and a wide range of explosion conditions. Fractal theory has been employed to verify the universality of the dependence revealed of the deflagration–outflow interaction number on enclosure scale.In spite of differences between the thermodynamic and kinetic parameters of hydrocarbon–air and hydrogen–air systems, they both obey the same general regularities for vented deflagrations, including the Le Chatelier–Brown principle analog and the correlation for deflagration–outflow interaction number.     

Medium-scale experiments on vented hydrogen deflagration

A series of medium-scale experiments on vented hydrogen deflagration was carried out at the KIT test side in a chamber of 1 × 1 × 1 m³ size with different vent areas. The experimental program was divided in three series: (1) uniform hydrogen–air mixtures; (2) stratified hydrogen–air mixtures within the enclosure; (3) a layer deflagration of uniform mixture. Different uniform hydrogen–air mixtures from 7 to 18% hydrogen were tested with variable vent areas 0.01–1.0 m². One test was done for rich mixture with 50% H₂. To vary a gradient of concentration, all the experiments with a stratified hydrogen–air mixtures had about 4%H₂ at the bottom and 10 to 25% H₂ at the top of the enclosure. Measurement system consisted of a set of pressure sensors and thermocouples inside and outside the enclosure. Four cameras combined with a schlieren system (BOS) for visual observation of combustion process through transparent sidewalls were used. Four experiments were selected as benchmark experiments to compare them with four times larger scale FM Global tests (Bauwens et al., 2011) and to provide experimental data for further CFD modelling. The nature of external explosion leading to the multiple pressure peak structure was investigated in details. Current work addresses knowledge gaps regarding indoor hydrogen accumulations and vented deflagrations. The experiments carried out within this work attend to contribute the data for improved criteria for hydrogen–air mixture and enclosure parameters to avoid unacceptable explosion overpressure. Based on theoretical analysis and current experimental data a further vent sizing technology for hydrogen deflagrations in confined spaces should be developed, taking into account the peculiarities of hydrogen–air mixture deflagrations in presence of obstacles, concentration gradients of hydrogen–air mixtures, dimensions of a layer of flammable cloud, vent inertia, etc.     

CFD modelling of hydrogen and hydrogen-methane explosions – Analysis of varying concentration and reduced oxygen atmospheres

This paper evaluates the predictive capabilities of the advanced consequence model FLACS-CFD for deflagrations involving hydrogen. Two modelling approaches are presented: the extensively validated model system originally developed for hydrocarbons included in FLACS-CFD 22.1 and a Markstein number dependent model implemented in the in-house version FLACS-CFD 22.1 IH. The ability of the models to predict the overpressure and the flame arrival time for scenarios with different concentrations of hydrogen, and thus different Lewis and Markstein numbers, is assessed. Furthermore, the effect of adding methane or nitrogen on overpressure for different regimes of premixed combustion are investigated. The validation dataset includes deflagrations in the open or in congested open areas and vented deflagrations in empty or congested enclosures. The overpressure predictions by FLACS-CFD 22.1 IH are found to be more accurate than those obtained with FLACS-CFD 22.1 for scenarios with varying hydrogen concentrations and/or added nitrogen or methane in the mixture. The predictions by FLACS-CFD 22.1 IH for lean hydrogen mixtures are within a factor of 2 of the values observed in the experiments. Further development of the model is needed for more accurate prediction of deflagrations involving rich hydrogen mixtures as well as scenarios with other fuels and/or conditions where the initial pressure or temperature deviate significantly from ambient conditions.     

Flame acceleration in unconfined hydrogen/air deflagrations using infrared photography

Flame behavior and blast waves generated during unconfined hydrogen deflagrations were experimentally studied using infrared photography. Infrared photography enables expanding spherical flame behaviors to be measured and flame acceleration exponents to be evaluated. In the present experiments, hydrogen/air mixtures of various concentrations were filled in a plastic tent of thin vinyl sheet of 1 m³ and ignited by an electric spark. The onset of accelerative dynamics on the flame propagation was analyzed by the time histories of the flame radius and the stretched flame speed. The results demonstrated that the self-acceleration of the flame, which was caused by diffusional-thermal and hydrodynamic instabilities of the blast wave, was influenced by hydrogen deflagrations in unconfined areas. In particular, it was demonstrated that the overpressure rapidly increased with time. The burning velocity acceleration was greatly enhanced with spontaneous-turbulization.     

Unified correlations for vent sizing of enclosures at atmospheric and elevated pressures

Innovative vent sizing technology is presented for explosion safety design of equipment at atmospheric and elevated initial pressures. Unified correlations for vent sizing are suggested. They are modifications of previously reported correlations verified thoroughly for experimental data on vented gaseous deflagrations under different conditions but only at initial atmospheric pressure. Suggested correlations are based on experimental data on vented deflagrations of quiescent and turbulent propane–air mixtures at initial pressures up to 0.7 MPa. Typical values of turbulence factor and deflagration–outflow interaction number are obtained for experimental vented deflagrations at initial pressures higher than atmospheric.

“Blind” examination of new vent sizing technology on another set of experiments with methane–air and propane–air mixtures has shown that predictions by suggested vent sizing technology are better than by the NFPA 68 guide for “Venting of Deflagrations”.

In the development of recently reported results for initial atmospheric pressure it has been concluded that the innovative vent sizing technology is more reliable compared to the NFPA 68 guide at elevated initial pressures as well. Moreover it is crucial that the calculation procedure remains the same for arbitrary deflagration conditions.     

The nature and large eddy simulation of coherent deflagrations in a vented enclosure-atmosphere system

The nature of coherent deflagration phenomena in a vented enclosure-atmosphere system is analysed. The study is based on experimental observations of SOLVEX programme in the empty 547-m³ vented enclosure and consequent analysis of the same test by large eddy simulations (LES). A comparison between simulated and experimental pressure transients and dynamics of flame front propagation inside and outside the enclosure gave an insight into the nature of the complex simultaneous interactions between flow, turbulence and combustion inside the enclosure and in the atmosphere. It is revealed through LES processing of experimental data that the substantial intensification of premixed combustion occurs only outside the empty SOLVEX enclosure and this leads to steep coherent pressure rise in both internal and external deflagrations. The external explosion does not affect burning rate inside the enclosure. There is only one ad hoc parameter in the LES model, which is used to account for unresolved subgrid scale increase of flame surface density outside the enclosure. The model allows reaching an excellent match between theory and experiment for coherent deflagrations in the empty SOLVEX facility. The mechanism of combustion intensification in the atmosphere is discussed and the quantitative estimation of the model ad hoc parameter is given.     

Numerical analysis of hydrogen deflagration mitigation by venting through a duct

This paper presents a model and simulation results for the mitigation of a hydrogen–air deflagration by venting through a duct. A large eddy simulation (LES) model, applied previously to study both closed-vessel, and open atmosphere hydrogen–air deflagrations, was developed further to model a hydrogen–air explosion vented through a duct. Sub-grid scale (SGS) flame wrinkling factors were introduced to model major phenomena which contribute to the increase of flame surface area in vented deflagrations. Simulations were conducted to validate the model against 20% hydrogen–air mixture deflagrations (vent diameters 25 and 45 cm) and 10% hydrogen–air mixture deflagration (vent diameter 25 cm). There was reasonable correlation between the simulations and the experimental data. The comparative importance of different physical phenomena contributing to the flame wrinkling is discussed.     

Characteristics of work-related injuries involving forklift trucks

Industrial lift trucks or forklift trucks are a common source of occupational injuries. In 1983, over 13,000 workers' compensation claims for lost-workday injuries involving forklift trucks were filed in 30 states. An estimated 24,000 forklift-related injuries were treated in U.S. emergency rooms in 1983, and an estimated 34,000 in 1985. This paper presents the results of an analysis of forklift injuries reported in two occupational injury databases — the National Electronic Injury Surveillance System (NEISS) and the Bureau of Labor Statistics (BLS) Supplementary Data System (SDS). Characteristics of these injuries (e.g., type of injury, diagnosis, body part affected) and of the injury victims (e.g., age, sex, occupation) are described, and scenarios of typical forklift injuries in various occupations are presented. Trends in forklift injuries from 1983–1985 are also discussed.     

Effect of ignition position on vented hydrogen–air deflagration in a 1 m3 vessel

This study investigates the effect of the ignition position on vented hydrogen-air deflagration in a 1 m³ vessel and evaluates the performance of the commercial computational fluid dynamics (CFD) code FLACS in simulating the vented explosion of hydrogen-air mixtures. First, the differences in the measured pressure-time histories for various ignition locations are presented, and the mechanisms responsible for the generation of different pressure peaks are explained, along with the flame behavior. Secondly, the CFD software FLACS is assessed against the experimental data. The characteristic phenomena of vented explosion are observed for hydrogen-air mixtures ignited at different ignition positions, such as Helmholtz oscillation for front ignition, the interaction between external explosion and combustion inside the vessel for central ignition, and the wall effect for back-wall ignition. Flame-acoustic interaction are observed in all cases, particularly in those of front ignition and very lean hydrogen-air mixtures. The predicted flame behavior agree well with the experimental data in general while the simulated maximum overpressures are larger than the experimental values by a factor of 1.5–2, which is conservative then would lead to a safe design of explosion panels for instance. Not only the flame development during the deflagration was well-simulated for the different ignition locations, but also the correspondence between the pressure transients and flame behavior was also accurately calculated. The comparison of the predicted results with the experimental data shows the performance of FLACS to model vented mixtures of hydrogen with air ignited in a lab scale vessel. However, the experimental scale is often smaller than that used in practical scenarios, such as hydrogen refueling installations. Thus, future large-scale experiments are necessary to assess the performance of FLACS in practical use.     

Suppression of metal dust deflagrations

Dust explosions continue to pose a serious threat to the process industries handling combustible powders. According to a review carried out by the Chemical Safety Board (CSB) in 2006, 281 dust explosions were reported between 1980 and 2005 in the USA, killing 119 workers and injuring 718. Metal dusts were involved in 20% of these incidents. Metal dust deflagrations have also been regularly reported in Europe, China and Japan.The term “metal dusts” encompasses a large family of materials with diverse ignitability and explosibility properties. Compared to organic fuels, metal dusts such as aluminum or magnesium exhibit higher flame temperature (T_f), maximum explosion pressure (P_max), deflagration index (K_St), and flame speed (S_f), making mitigation more challenging. However, technological advances have increased the efficiency of active explosion protection systems drastically, so the mitigation of metal dust deflagrations has now become possible.This paper provides an overview of metal dust deflagration suppression tests. Recent experiments performed in a 4.4 m³ vessel have shown that aluminum dust deflagrations can be effectively suppressed at a large scale. It further demonstrates that metal dust deflagrations can be managed safely if the hazard is well understood.     

Effects of hydrogen addition on the confined and vented explosion behavior of methane in air

Multi-component gas mixture explosion accidents occur and recur frequently, while the safety issues of multi-component gas mixture explosion for hydrogen–methane mixtures have rarely been addressed.Numerical simulation study on the confined and vented explosion characteristics of methane-hydrogen mixture in stoichiometric air was conducted both in the 5 L vessel and the 64 m³ chamber, involving different mixture compositions and initial pressures. Based on the results and analysis, it is shown that the addition of hydrogen has a negative effect on the explosion pressure of methane-hydrogen mixture at adiabatic condition. While in the vented explosion, the addition of the hydrogen has a significant positive effect on the explosion hazard degree. Additionally, the addition of hydrogen can induce a faster reactivity and enhance the sensitivity of the mixture by reducing the explosion time and increasing the rate of pressure rise both in confined and vented explosion. Both the maximum pressure and the maximum rate of pressure rise increase with initial pressure as a linear function, and also rise with the increase of hydrogen content in fuel. The increase in the maximum rate of pressure rise is slight when hydrogen ratio is lower than 0.5, however, it become significant when hydrogen ratio is higher than 0.5. The maximum rate of pressure rise for stoichiometric hydrogen-air is about 10 times the one of stoichiometric methane-air.Furthermore, the vent plays an important role to relief pressure, causing the decrease in explosion pressure and rate of pressure rise, while it can greatly enhance the flame speed, which will extend the hazard range and induce secondary fire damages. Additionally it appears that the addition of hydrogen has a significant increasing effect on the flame speed. The propagation of flame speed in confined explosion can be divided into two stages, increase stage and decrease stage, higher hydrogen content, higher slope. But in the vented explosion, the flame speed keeps increasing with the distance from the ignition point.     

Propane-air mixture deflagration hazard with different ignition positions and restraints in large-scale venting chamber

In order to better assess the hazards of explosion accidents, propane-air mixture deflagrations were conducted in a large-scale straight rectangular chamber (with a cross-section of 1.5 m × 1.5 m, length of 10 m, and total volume of 22.5 m³). The effect of initial volume, ignition position, and initial restraints on the explosion characteristics of the propane-air mixtures was investigated. The explosion overpressure, flame propagation, and flame speed were obtained and the computational fluid dynamics (CFD) software was used to simulate the flame-propagation process and field flow for auxiliary analysis. The hazards of large-scale propagation explosion under weak and strong constraints were evaluated and the different phases of flame propagation under weak and strong constraints were discriminated. Results indicate that the hazards caused by propane deflagration under weak constraint are mainly caused by flame spread. And the maximum overpressure under strong constraint appeared at the front part of the chamber under the large-scale condition, which is consistent with the previous small-scale test. Moreover, the simulations of flame structures under weak and strong constraint are in good agreement with experimental results, which furthers the understanding of large-scale propane deflagration under different initial conditions in large-scale spaces and provides basic data for three-dimensional CFD model improvement.     

Validation of CFD-model for hydrogen dispersion

To be able to perform proper consequence modelling as a part of a risk assessment, it is essential to be able to model the physical processes well. Simplified tools for dispersion and explosion predictions are generally not very useful. CFD tools have the potential to model the relevant physics and predict well, but without proper user guidelines based on extensive validation work, very mixed prediction capability can be expected. In this article, recent dispersion validation effort for the CFD tool FLACS–HYDROGEN is presented. A range of different experiments is simulated, including low-momentum releases in a garage, subsonic jets in a garage with stratification effects and subsequent slow diffusion, low momentum and subsonic horizontal jets influenced by buoyancy, and free jets from high-pressure vessels. LH₂ releases are also considered. Some of the simulations are performed as blind predictions.     

Occupational Exposure to Polycyclic Aromatic Hydrocarbons During Diesel Combustion

Identification and determination of polycyclic aromatic hydrocarbons (PAHs) in Diesel exhaust in the working environment and assessment of workers’ occupational exposure to these suspected human carcinogens were the aim of this experimental investigation.

The range of exposure factors calculated on the basis of 9 individual PAH concentrations determined in personal air samples shows that time-averaged concentration of these compounds did not exceed the Polish Maximum Admissible Concentration (MAC) value for PAHs, that is, 2 μg·m^–3. The highest concentrations of PAHs were determined in the breathing zone of forklift operators. The maximum exposure factor was 0.427 μg·m^–3 (about 1/4 of MAC).     

Modelling the mitigation of a hydrogen deflagration in a nuclear waste silo ullage with water fog

During the decommissioning of certain legacy nuclear waste storage plants it is possible that significant releases of hydrogen gas could occur. Such an event could result in the formation of a flammable mixture within the silo ullage and, hence, the potential risk of ignition and deflagration occurring, threatening the structural integrity of the silo. Very fine water mist fogs have been suggested as a possible method of mitigating the overpressure rise, should a hydrogen–air deflagration occur. In the work presented here, the FLACS CFD code has been used to predict the potential explosion overpressure reduction that might be achieved using water fog mitigation for a range of scenarios where a hydrogen–air mixture, of a pre-specified concentration (containing 800 L of hydrogen), uniformly fills a volume located in a model silo ullage space, and is ignited giving rise to a vented deflagration. The simulation results suggest that water fog could significantly reduce the peak explosion overpressure, in a silo ullage, for lower concentration hydrogen–air mixtures up to 20%, but would require very high fog densities to be achieved to mitigate 30% hydrogen–air mixtures.     

Experimental investigation of the complex deflagration phenomena of hybrid mixtures of activated carbon dust/hydrogen/air

This paper aims to develop quantitative insights based on measured deflagration parameters of hybrid mixtures of activated carbon (AC) dust and hydrogen (H₂) gas in air. The generated experimental evidence is used to reject the claim of the null hypothesis (H₀) that severity of deflagrations of H₂/air mixtures always bound the severity of deflagrations of heterogenous combustible mixtures of AC dust/H₂/air containing the same H₂ concentrations as in the H₂/air binaries. The core insights of this investigation show that the maximum deflagration pressure rise (ΔP_MAX) and maximum rate of pressure rise ((dP/dt)_MAX) of this hybrid mixture are greater than those corresponding to deflagrations of H₂/air mixtures for all the dust and H₂ concentrations being examined. The deflagration severity indices (K_St and ES) of the hybrid mixture containing 29 mol% H₂ are found to be greater than those of the H₂/air mixture containing 29 mol% H₂. Also, the minimum explosible concentration (MEC) of the hybrid mixture is lower than that of the AC dust in air only. The insights gained should lead to better realization of the severity of a postulated safety-significant accident scenario associated with on-board cryoadsorption H₂ storage systems for fuel-cell (FC) powered light-duty vehicles. The identified insights could also be relevant to other industrial processes where combustible dusts are generated in the vicinity of solvent vapors. Moreover, these insights should be useful for supporting quantitative risk assessment (QRA) of on-board H₂ storage systems, designing improved safety measures for cryoadsorption H₂ storage tanks, and guiding H₂ safety standards and transportation regulations.     

Turbulent deflagrations of mildly flammable refrigerant-air mixtures

With current concerns around global climate change, new hydrofluorocarbons with low Global Warming Potential (GWP) are being evaluated as alternative refrigerants. These alternative refrigerants, however, may be mildly flammable (as defined by the A2L safety group classification) and pose safety concerns for the heating, ventilation, air conditioning, and refrigeration (HVAC/R) industry. Consequently, careful assessments of different flammability characteristics and risks for these refrigerants are essential for their safe use in actual applications. In this study, deflagration propagation measurements for different mildly flammable refrigerants, including difluoromethane (R-32) and 2,3,3,3-tetrafluoropropene (R-1234yf), were undertaken in different geometries including a 9.1-m long conduit test rig and a closed cubical 12.5 m³ volume. Different tests were conducted for full volume deflagrations as well as with and without obstructions. Turbulent deflagration speeds for well-mixed, refrigerant-air mixtures have been shown to be orders of magnitude larger than their corresponding laminar flame speed values that are used in classifying flammable refrigerants in safety standards. Testing has also quantified the resulting severity as measured by the event overpressure which was shown to worsen with increased congestion or confinement as a consequence of increased induced turbulence. This work illustrates the importance for severity evaluations for actual large-scale or congested geometries of concern in practical applications. Even for mildly flammable refrigerants characterized by laminar flame speeds <2 cm/s, which is lower than the 10 cm/s limit for A2L refrigerants, relatively fast deflagrations can be generated for very congested geometries where downstream turbulence is generated as the flame front passes over obstacles in these situations.     

Experimental data and CFD performance for cloud dispersion analysis: The USP-UPC project

Forecasting the behaviour of a flammable or toxic cloud is a critical challenge in quantitative risk analysis. Recent literature shows that empirical and integral models are unable to model complex dispersion scenarios, like those occurring in semi-confined spaces or with the presence of physical barriers. Although CFD simulators are promising tools in this regard, they still need to be fully validated with comprehensive datasets coming from experimental campaigns designed ad-hoc. In this paper, we present an experimental campaign carried out by a joint venture between University of São Paulo and Universitat Politècnica de Catalunya to investigate CFD tools performance when used to analyse clouds dispersion. The experiments consisted on propane cloud dispersion field tests (unobstructed and with the presence of a fence obstructing the flow) of releases up to 0.5 kg s⁻¹ of 40 s of duration in a discharge area of 700 m². We provide a full 1-s averaged propane concentration evolution dataset of two experiments, extracted from 29 points located at different positions within the cloud, with which we have tested FLACS^® CFD-software performance. FLACS reproduces successfully the presence of complex geometry, showing realistic concentration decreases due to cloud dispersion obstruction by the existence of a fence. However, simulated clouds have not represented the whole complex accumulation dynamics due to wind variation.     

Scaling of dust explosion violence from laboratory scale to full industrial scale – A challenging case history from the past

The standardized K_St parameter still seems to be widely used as a universal criterion for ranking explosion violence to be expected from various dusts in given industrial situations. However, this may not be a generally valid approach. In the case of dust explosion venting, the maximum pressure P_max generated in a given vented industrial enclosure is not only influenced by inherent dust parameters (dust chemistry including moisture, and sizes and shapes of individual dust particles). Process-related parameters (degree of dust dispersion, cloud turbulence, and dust concentration) also play key roles. This view seems to be confirmed by some results from a series of large scale vented dust explosion experiments in a 500 m³ silo conducted in Norway by CMI, (now GexCon AS) during 1980–1982. Therefore, these results have been brought forward again in the present paper. The original purpose of the 500 m³ silo experiments was to obtain correlations between P_max in the vented silo and the vent area in the silo top surface, for two different dusts, viz. a wheat grain dust collected in a Norwegian grain import silo facility, and a soya meal used for production of fish farming food. Both dusts were tested in the standard 20-L-sphere in two independent laboratories, and also in the Hartmann bomb in two independent laboratories. P_max and (dP/dt)_max were significantly lower for the soya meal than for the wheat grain dust in all laboratory tests. Because the available amount of wheat grain dust was much larger than the quite limited amount of available soya meal, a complete series of 16 vented silo experiments was first performed with the wheat grain dust, starting with the largest vent area and ending with the smallest one. Then, to avoid unnecessary laborious changes of vent areas, the first experiment with soya dust was performed with the smallest area. The dust cloud in the silo was produced in exactly the same way as with the wheat grain dust. However, contrary to expectations based on the laboratory-scale tests, the soya meal exploded more violently in the large silo than the wheat grain dust, and the silo was blown apart in the very first experiment with this material. The probable reason is that the two dusts responded differently to the dust cloud formation process in the silo on the one hand and in the laboratory-scale apparatuses on the other. This re-confirms that a differentiated philosophy for design of dust explosion vents is indeed needed. Appropriate attention must be paid to the influence of the actual dust cloud generation process on the required vent area. The location and type of the ignition source also play important roles. It may seem that tailored design has to become the future solution for tackling this complex reality, not least for large storage silos. It is the view of the present author that the ongoing development of CFD-based computer codes offers the most promising line of attack. This also applies to design of systems for dust explosion isolation and suppression.     

Validation of discharge and atmospheric dispersion for unpressurised and pressurised carbon dioxide releases

This paper discusses the validation of discharge and subsequent atmospheric dispersion for both unpressurised and pressurised carbon dioxide releases using the consequence modelling package Phast.The paper first summarises the validation of the Phast dispersion model (UDM) for unpressurised releases. This includes heavy gas dispersion from either a ground-level line source (McQuaid wind-tunnel experiments) or an area source (Kit-Fox field experiments). For the McQuaid experiments minor modifications of the UDM were made to support line sources. For the Kit Fox experiments steady-state and 20-s finite-duration releases were simulated for both neutral and stable conditions. Most accurate predictions of the concentrations for finite duration releases were obtained using the UDM Finite Duration Correction method.Using experiments funded by BP and Shell and made available via DNV's CO2PIPETRANS JIP, the paper secondly summarises the validation of the Phast discharge and dispersion models for pressurised CO₂ releases. This modelling accounted for the possible presence of the solid CO₂ phase following expansion to atmospheric pressure. These experiments included both high-pressure steady-state and time-varying cold releases (liquid storage) and high-pressure time-varying supercritical hot releases. Both the flow rate and the concentrations were found to be predicted accurately.The above validation was carried out with no fitting whatsoever of the Phast extended discharge and dispersion models.