Consequence prediction for dust explosions involving interconnected vessels using computational fluid dynamics modeling

Combustible dust explosions continue to present a significant threat toward operating personnel and pneumatic conveyance equipment in a wide variety of processing industries. Following ignition of suspended fuel within a primary enclosure volume, propagation of flame and pressure fronts toward upstream or downstream interconnected enclosures can result in devastating secondary explosions if not impeded through an appropriate isolation mechanism. In such occurrences, an accelerated flame front may result in flame jet ignition within the secondary vessel, greatly increasing the overall explosion severity. Unlike an isolated deflagration event with quantifiable reduced pressures (vent sizing according to NFPA 68 guidance), oscillation of pressure between primary and secondary process vessels leads to uncertain overpressure effects. Dependent on details of the application such as relative enclosure volumes, relief area, fuel type, suspended concentration, duct size, and duct length, the maximum system pressure in both interconnected vessels can be unpredictable. This study proposes the use of FLame ACceleration Simulator (FLACS) computational fluid dynamics (CFD) modeling to provide reliable consequence predictions for specific case scenarios of dust deflagrations involving interconnected equipment. Required minimum supplement to the originally calculated relief area (A_v) was determined through iterative simulation, allowing for reduced explosion pressures (P_red) to be maintained below theoretical enclosure design strengths (P_es).