Moderation of dust explosions

Inherent safety is a proactive approach to process safety in which hazards are removed or minimized so as to reduce risk without engineered (add-on) or procedural intervention. Four basic principles are available to attain an inherently safer design—minimization, substitution, moderation, and simplification. The subject of the current paper is the principle of moderation as it applies to the prevention and mitigation of dust explosions.

Moderation can be achieved by processing a material under less severe operating conditions or by processing the material in a less hazardous form. With respect to the latter approach, it may be possible to alter the composition of a dust by admixture of solid inertants, or to increase the dust particle size so as to decrease its reactivity. Additionally, avoidance of the formation of hybrid mixtures of explosible dusts and flammable gases is an application of moderation of the material hazard.

Several examples are given for each of the above three forms of moderation. The discussion on admixture of solid inertants includes examples from the following industrial applications: (i) refractory materials manufacturing, (ii) food processing, (iii) power generation, (iv) industrial recycling, and (v) foundry shell mold fabrication. The importance of particle size consideration is explained first from the perspective of engineering tools such as the Dow Fire & Explosion Index, and professional guidance on the definition of a dust and suitable particle sizes for explosibility testing. Industrial examples are then drawn from the following areas: (i) rubber recycling and textile manufacturing, (ii) industrial recycling, (iii) wood processing, (iv) dry additive handling (polyethylene facility), (v) polyethylene production, (vi) carbon block recycling, and (vii) coal mining. The concluding discussion on hybrid mixtures includes brief cases from the process safety literature.     

试论蒸汽采暖系统的安全管理

通过对蒸汽采暖系统的热煤压力选择、工程验收以及减压阀的调整管理等几方面的分析 ,阐述了如何确保蒸汽采暖系统安全运行的有关系统保障措施     

Hybrid H2/Al dust explosions in Siwek sphere

Explosion indices and explosion behaviour of Al dust/H₂/air mixtures were studied using standard 20 l sphere. The study was motivated by an explosion hazard occurring at some accidental scenarios considered now in ITER design (International Thermonuclear Experimental Reactor). During Loss-of-Vacuum or Loss-of-Coolant Accidents (LOCA/LOVA) it is possible to form inside the ITER vacuum vessel an explosible atmosphere containing fine Be or W dusts and hydrogen. To approach the Be/H₂ explosion problem, Be dust is substituted in this study by aluminium, because of high toxicity of Be dusts. The tested dust concentrations were 100, 200, 400, 800, and 1200 g/m3; hydrogen concentrations varied from 8 to 20 vol. % with 2% step. The mixtures were ignited by a weak electric spark. Pressure evolutions were recorded during the mixture explosions. In addition, the gaseous compositions of the combustion products were measured by a quadruple mass-spectrometer. The dust was involved in the explosion process at all hydrogen and dust concentrations even at the combination ‘8%/100 g/m3’. In all the other tests the explosion overpressures and the pressure rise rates were noticeably higher than those relevant to pure H₂/air mixtures and pure Al dust/air mixtures. At lower hybrid fuel concentrations the mixture exploded in two steps: first hydrogen explosion followed by a clearly separated Al dust explosion. With rising concentrations, the two-phase explosion regime transits to a single-phase regime where the two fuel components exploded together as a single fuel. In this regime both the hybrid explosion pressures and pressure rise rates are higher than either H₂ or Al ones. The two fuels compete for the oxygen; the higher the dust concentration, the more part of O2 it consumes (and the more H₂ remains in the combustion products). The test results are used to support DUST3D CFD code developed at KIT to model LOCA or LOVA scenarios in ITER.     

Effects of ignitors and turbulence on dust explosions

The aim of this work is in an attempt to increase the understanding of the acting behaviour of pyrotechnic ignitors and their effects on confined dust explosions. Flame visualization has shown that pyrotechnic ignitors can initiate an explosion by instantaneous jet-like volumetric and/or multipoint ignition. Hence, the rate of pressure rise and also the apparent burning velocity will be increased to some extent, depending on the ignitor energy and the reactivity of the mixtures. The ignitor effect is more important for the early stages of flame propagation and would be more significant in small explosion chambers. Thus, for dust explosion tests with various purposes, use of pyrotechnic ignitors should be made carefully, and the ignitor effect must be accounted for in the data interpretation. Turbulence induced by dust dispersion is a dominant factor in affecting dust explosions. At different ignition delays, however, the turbulence influence will be coupled with that of ignitors. This complicates further the interpretation of explosion data measured under turbulent conditions.     

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

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

Suppression effects of powder suppressants on the explosions of oxyhydrogen gas

Suppression tests of oxyhydrogen gas explosions were performed in an explosion tube with five types of dry powder used as the suppressants. The experimental results showed that the powder with large dust cloud density and small radius has better suppression effect, which agrees well with previous correlative results. Moreover, our results also showed that particles with chemical activity and light material density, their suppression effect are more prominent than that of the inert particles with heavy density. To discover the detailed suppression process of dust powder, governing equations were developed based on the homogeneous reactive two-phase flow. The TVD scheme and the Lax–Wendroff–Rubin scheme were adopted to solve the reactive gas phase and particle phase, respectively. The time splitting technique was employed to handle the stiffness of the coupled equations. Our calculated results showed that the dust cloud has the suppression effect on the explosion of oxyhydrogen gas, and with the increase of dust cloud density or the decrease of particle diameter, its suppression effect become more evident, which is in good agreement with our experimental results, in addition, the numerical results showed that with the same particle diameter, the suppression performance is enhanced with the reduction in particle material density.     

Influence of thermal radiation on layered dust explosions

Multidimensional unsteady numerical simulations were carried out to explore the influence of thermal radiation on the propagation and structure of layered coal dust explosions. The simulation solved the reactive compressible Navier-Stokes equations coupled to an Eulerian kinetic-theory-based granular multiphase model. The radiation heat transfer is modeled by solving the radiation transfer equation using the third-order filtered spherical harmonics approximation. The radiation was assumed to be gray and all boundaries of the domain are black at 300 K. The reaction mechanism is based on global irreversible reactions for each physical process including devolatilization, char burning, moisture vaporization, and methane combustion. The governing equations were solved using a high-order Godunov method. Several simulation configurations were considered: layer volume fractions of 47% and 1%, channel lengths of 10 m and 40 m, and radiative and non-radiative cases. The results show that gray radiation has a significant influence on the propagation and structure of a layered dust explosion. However, radiation can have opposite effects on different scenarios. For example, radiation promotes the propagation of the dust flame when the layer volume fraction was 1% and in the short-channel cases where reflected shock-flame interactions are important. However, radiation enhances quenching for the 47% volume fraction dust layer in the longer channel.     

蒸汽系统安全阀泄漏原因分析及改进措施

从技术及管理两方面分析了蒸汽系统安全阀泄漏的原因,提出了预防措施。     

空气中爆炸对巷道稳定性影响模拟研究

以西北某铀矿矿床某巷道为依托,针对巷道稳定性及巷道内爆炸问题,运用ANSYS软件对自重应力场下的巷道衬砌及围岩进行静力分析,得出巷道围岩有效应力分布情况及巷道断面上几个典型位置的位移量和等效应力值。在此基础上,再利用LS-DYNA显式分析功能模拟自重应力场下爆炸对计算,获得衬砌结构最大主应力和加速度时程曲线,分析爆炸波在巷道中传播规律,为巷道抗爆性设计提供参考。结果表明,巷道中的爆炸波会产生强烈的多次反射现象,并且在自重应力场下,直墙拐角处往往最先出现破坏。     

Assessing the influence of real releases on explosions: Selected results from large-scale experiments

The research activities in the project Assessing the Influence of Real Releases on Explosions (AIRRE) included a unique series of large-scale explosion experiments with high-momentum jet releases directed into congested geometries with subsequent ignition. The primary objective for the AIRRE project was to gain improved understanding of the effect that realistic releases and turbulent flow conditions have on the consequences of accidental gas explosions in the petroleum industry. A secondary objective was to develop a methodology that can facilitate safe and optimal design of process facilities. This paper presents selected results from experiments involving ignition of a highly turbulent gas cloud, generated by a large-scale, pressurised release of natural gas. The paper gives an overview of the effect on maximum explosion overpressures of varying the ignition position relative to the release point of the jet and a congested region placed inside the flammable cloud, with either a high or a medium level of congestion. For two of the tests, involving a jet release and the medium congestion rig, the maximum overpressures significantly exceeded those obtained in a quiescent reference test. The paper presents detailed results for selected tests and discusses the effect of the initial flow field generated by realistic releases – including turbulence, net flow and concentration gradients – on relevant explosion phenomena.     

Flame acceleration in tube explosions with up to three flat-bar obstacles with variable obstacle separation distance

The effect of obstacle separation distance on the severity of gas explosions has received little methodical study. It was the aim of this work to investigate the influence of obstacle spacing of up to three flat-bar obstacles. The tests were performed using methane-air (10% by vol.), in an elongated vented cylindrical vessel 162 mm internal diameter with an overall length-to-diameter, L/D, of 27.7. The obstacles had either 2 or 4 flat-bars and presenting 20% blockage ratio to the flow path. The different number of flat-bars for the same blockage achieved a change of the obstacle scale which was also part of this investigation. The first two obstacles were kept at the established optimum spacing and only the spacing between the second and third obstacles was varied. The profiles of maximum flame speed and overpressure with separation distance were shown to agree with the cold flow turbulence profile determined in cold flows by other researchers. However, the present results showed that the maximum effect in explosions is experienced at 80 to 100 obstacle scales about 4 times further downstream than the position of maximum turbulence determined in the cold flow studies. Similar trends were observed for the flames speeds. In both cases the optimum spacing between the second and third obstacles corresponded to the same optimum spacing found for the first two obstacles demonstrating that the optimum separation distance does not change with number of obstacles. In planning the layout of new installations, the worst case separation distance needs to be avoided but incorporated when assessing the risk to existing set-ups. The results clearly demonstrate that high congestion in a given layout does not necessarily imply higher explosion severity as traditionally assumed. Less congested but optimally separated obstructions can lead to higher overpressures.     

Coupling effects of venting and inerting on explosions in interconnected vessels

The coupling effects of venting and CO₂ inerting on stoichiometric methane-air mixture explosions were investigated in an isolated vessel and interconnected vessels. The results indicate that venting mitigates the explosion intensity, especially for small vessels. For vessels connected by pipes, a venting design following EN 14994 (2007) and NFPA 68 (2013) could not meet the venting requirements. For an isolated big vessel and interconnected vessels, increasing the CO₂ volume fraction (Φ) from 0 to 15.0 vol% decreased the maximum explosion overpressure (P_max) and maximum rate of overpressure rise ((dP/dt)_max) and delayed t_max. For closed interconnected vessels, P_max varied approximately linearly with Φ. For both isolated vessel and interconnected vessels, the coupling effects of venting and CO₂ inerting on methane-air explosion were more efficient than those of individual mitigative method (that is, venting alone or CO₂ inerting alone).     

Influence of different ignition delay times on the pressure rise rate in hybrid mixture explosions in the 20-L sphere

For the development of a standardized method for measuring the explosion safety characteristics of combustible hybrid dust/vapor mixtures, the influence of the ignition delay time needs to be investigated. The ignition delay time, defined as the time between the injection of dust and the activation of the ignition source, is related to the turbulence of the mixture and thus to the pressure rise rate. The ignition source for pure vapors, however, has to be activated in a quiescent atmosphere according to the standards. Nevertheless, when measuring the explosion safety characteristics of hybrid mixtures, it is important that the dust be in suspension around the igniter. Like pure dust/air mixtures, hybrid dust/vapor/air mixtures need to be ignited in a turbulent atmosphere to keep the dust in suspension.This work will therefore investigate the influence of ignition delay times on the severity of hybrid explosions. It was generally found that at shorter ignition delay times, (dp/dt)_ex increased due to higher turbulence and decreases as the dust sinks to the bottom of the 20 L-sphere. This effect is more pronounced for hybrid mixtures with higher vapor content compared to dust content.     

氢气爆炸特性研究

本文研究、总结了氢气与空气(氢气与氧气)的混合物的爆炸特性.即氢气在空气中,在比较低燃烧界限的情况下,只有向上的传播和非常少的超压可以观测得到.正因为氢气的这种特性,将氢应用于科技将极大地推进社会进步,氢燃料将成为一种主要的能源.然而,氢技术应用的成功与否主要取决于氢使用的安全性.所以,必须掌握实际使用时氢气燃烧的性能.本文在日本过去十年实验数据的基础上,通过实验研究了氢气与空气混合物的燃点.研究了氢气、氧气混合物经氮气稀释后,按化学当量比例将不同浓度的氢气与空气进行混合,并得出了低温下的爆炸压力特性.随后,分别讨论了在初始压力下一致的情况下,试管直径相同的状况下,氢气与空气混合浓度相同的情况下,这三种爆轰传播限制之间的关系.得出了在空气中直接点燃的发生爆轰的最小试管直径,最小的装药量之间的关系,进行了爆轰危险性分级.最后,文章概括比较了氢与其他燃料的燃烧特性,评估了氢气燃烧过程中的危险与安全因素.     

A quantitative correlation of evaluating the flame speed for the BST method in vapor cloud explosions

In recent decades, vapor cloud explosions (VCEs) have occurred frequently and resulted in numerous personnel injuries and large property losses. As a main concern in the petrochemical industry, it is of great importance to assess the consequence of VCEs. Currently, the TNT equivalency method (TNT EM), the TNO multi-energy method (TNO MEM), and the Baker-Strehlow-Tang (BST) method are widely used to estimate the blast load from VCEs. The TNO MEM and BST method determine the blast load from blast curves based on the class number and the flame speed, respectively. To quantitatively evaluate the flame speed for the BST method, the experimental data is adopted to validate the confinement specific correlation (CSC) for the determination of the class number in the TNO MEM. As a bridge, a quantitative evaluation correlation (QEC) between CSC correlation and the flame speed is established and the blast wave shapes corresponding to different flame speeds are proposed. CFD software FLACS was used to verify the quantitative correlation with the numerical models of three geometrical scales. It is found that the calculated flame speeds by the QEC are in good agreement with the simulated ones. A petrochemical plant is selected as a realistic scenario to analyze the TNT EM, TNO MEM, BST method and FLACS simulations in terms of the positive-phase side-on overpressure and impulse at different distances. Compared with the flame speed table, the predicted overpressure from BST curves determined by the proposed QEC is closer to that from FLACS and more conservative. Furthermore, the predicted results of different methods are compared with each other. It is found that the estimated positive-phase side-on overpressure and impulse by the TNO MEM are the largest, and the estimated impulse by the TNT EM is the smallest. Moreover, the estimated overpressure and impulse are larger in the higher reactivity gas.     

基于STAMP模型的核动力蒸汽发生器水位控制系统安全性分析

核电厂蒸汽发生器(SG)水位控制系统的安全可靠运行是保证核电厂安全性和经济性的关键因素,其控制对象具有高度复杂、非线性的特点。由于复杂系统的安全性是特定环境下由系统相关要素交互作用所产生的一种涌现特性,运用系统理论,以STAMP模型为基础对SG水位控制系统进行安全性分析,以利于在设计早期阶段发现影响该系统安全运行的潜在风险因素,预防危险事故。该方法将系统理论用于核电厂关键系统和设备安全性分析,为核电厂安全运行提供了新的技术手段支持。     

The effect of vent ducts on the reduced explosion pressures of vented dust explosions

An investigation into the effects of vent ducts on reduced explosion pressures is described. Experiments were made using an 18.5m³ explosion vessel and a modified 20 1 sphere, with dusts having K_st values ranging from 144 bar ms⁻¹ to 630 bar ms⁻¹. The vent area/vessel volume ratio bursting pressure of the vent cover, and the length to diameter ratio of the vent duct have been varied. Straight vent ducts, and ducts containing sharp 45° and 90° bends have been used.A simple model to describe the effect of vent ducts on the reduced explosion pressure has been derived and compared with the experimental results. Agreement is shown to be satisfactory in nearly all cases. A comparison between the experimental results and guidance on the effect of vent ducts already available in the literature is discussed.     

Development of a limit state approach for design against gas explosions

The design of topsides against explosions requires the definition of a design over-pressure, however, these values are often treated as deterministic and there is a wide variation within the industry in the treatment and interpretation of the loads.

This paper advocates the adoption of a number of limit state for explosion loading. Events of different magnitudes are differentiated on the basis of frequency and linked to appropriate degree of reliability thus avoiding disproportionate effects from minor events.

The two principal limit states considered are a limit state for all the safety critical systems for relatively high frequency events and a survival condition for low probability events. Parallels are drawn from other branches of engineering where extreme loads have to be designed for.