Dust explosions-cases, causes, consequences, and control

Self-ignition behaviour of corn cob, wheat bran and rice husk residues in ambient air from biomass gasification

The possibility of different agrowastes to self-ignite under ambient condition, due to exothermic reactions between their surface molecules and air or other oxidizing agents which are conveyed into the void volume between the particles, exists. It is imperative to investigate the self-ignition ability of these harzadous waste products causing environmental pollution after the milling process to avoid sudden fire outbreaks. In this study, the self-ignition attributes of corn cob, wheat bran and rice husk residues in ambient air from biomass gasification was investigated by evaluating their self-ignition temperatures using DIN EN 15188:2021 standard and Frank-Kamenetzkii's theory of thermal explosion at varying basket volume. The results revealed decrease in the ignition temperature of dust samples as ignition time and dust basket volume were increased. Sample C (rice husk dust residue) was considered to be the most hazardous with respect to its propensity to self-heating possessing the lowest self-ignition temperature of 173 °C at 800 mL cubic mesh. Its moisture content and activation energy of 1.41 % and 46.52 kJ/mol respectively were the lowest. Its thermal conductivity, carbon content, heating value and bulk density of 0.07 W/mK, 78.98 wt%, 26,895 kJ/kg and 255.4 kg/m3 respectively were the highest. Correlation coefficient from the Arrhenius plot showing the self-ignition behaviour of dust samples using the model of Frank-Kamenetzkii were 0.9976, 0.9910 and 0.9962 for corn cob, wheat bran and rice husk residues respectively. In conclusion, the data presented are effective in predicting the self-ignition ability of corn cob, wheat bran and rice husk residues in ambient air from biomass gasification in order to prevent sudden fire attack that may arise based on storage of their dust particles in food processing industries.

Combustion-explosion suppression and environmental protection of typical sulfur-containing hazardous chemicals

Sulfur, as a crucial chemical raw, poses increased combustion-explosion risks when mixed with other hazardous substances due to its dual nature as both an oxidant and a reducing agent. Additionally, sulfur-induced combustion and explosions can result in environmental pollution. Combustion-explosion suppression technology plays a crucial role in industrial production by effectively preventing hazardous chemical explosion incidents. This research investigates the combustion-explosion suppression of black powder, a common hazardous chemical containing sulfur, by utilizing two solid-based blast suppressants, NH4H2PO4 and NaHCO3. On this basis, examining changes in the oxidation states of sulfur and explaining the mechanisms of combustion-explosion suppression through the examination of combustion-explosion products. Additionally, numerical calculations are employed to analyze the evolution patterns of gaseous and solid-phase products throughout the entire combustion-explosion process. Research indicates that NaHCO3 exhibits a more effective combustion-explosion suppression effect on black powder compared to NH4H2PO4, which attributed to the valence state transformation of sulfur and the reduction of carbon oxidation. Furthermore, with the enhancement of combustion-explosion suppression effect, K2S, which a pollutes the environment, is gradually transform converted into potassium fertilizer K2SO4, which benefits plants. These results offer new insights into the research of combustion-explosion suppression of sulfur-containing substances and environmental protection strategies.

Study into the Fire and Explosion Characteristics of Polymer Powders Used in Engineering Production Technologies

Polymers and their processing by engineering production technologies (injection, molding or additive manufacturing) are increasingly being used. Polymers used in engineering production technologies are constantly being developed and their properties are being improved. Granulometry, X-ray, FTIR and TGA were used to characterize polymer samples. Determination of the fire parameters of powder samples of polyamide (PA) 12, polypropylene, and ultra-high molecular weight (UHMW) polyethylene is the subject of the current article. An explosive atmosphere can be created by the powder form of these polymer materials, and introduction of preventive safeguards to ensure safety is required for their use. Although the fire parameters of these basic types of polymers are available in databases (e.g., GESTIS-DustEx), our results showed that one of the samples used (polypropylene) was not flammable and thus is safe for use in terms of explosiveness. Two samples were flammable and explosive. The lower explosive limit was 30 g·m-3 (PA12) and 60 g·m-3 (UHMW polyethylene). The maximum explosion pressure of the samples was 6.47 (UHMW polyethylene) and 6.76 bar (PA12). The explosion constant, Kst, of the samples was 116.6 bar·m·s-1 (PA12) and 97.1 bar·m·s-1 (UHMW polyethylene). Therefore, when using polymers in production technologies, it is necessary to know their fire parameters, and to design effective explosion prevention (e.g., ventilation, explosive-proof material, etc.) measures for flammable and explosive polymers.

Analysis of the dust-methane two-phase coupling blowdown effect at different air duct positions in an excavation anchor synchronous tunnel

Bolter miners are being increasingly used. Unfortunately, this mining technology causes a considerable amount of air pollution (especially by methane and dust) during excavation. In this study, the multiphase coupling field of airflow-dust-methane for different distances between the pressure air outlet and the working face (Lp) was simulated by using the FLUENT software. The migration law of pollutants in the multiphase coupling field was analyzed, and the distance parameters between the pressure air outlet and the working face were optimized. Finally, the simulation results were verified based on the field measurement results. We found that the blowdown effect was more obvious when 14 m ≤ Lp < 16 m compared with other conditions. The peak value of dust concentration within this distance range was the smallest (44.4% lower than the highest peak value, which was verified when Lp = 18 m), while the methane concentration was < 0.6%. A high-concentration area (where methane concentration > 0.75%), identified near the walking part of the bolter miner, was 13 m shorter than the largest (when Lp = 18 m). Therefore, we determined that the optimal blowdown distance would be 14 m ≤ Lp < 16 m. Within this range, the dust removal and methane dilution effects are optimal, effectively improving the tunnel air quality and providing a safe and clean environment for mine workers.

FRAM-based causal analysis and barrier measures to mitigate dust explosions: A case study

Both the number of dust explosion accidents and the resulting number of casualties have increased dramatically in recent years. To reduce this risk of dust explosions, we use the functional resonance analysis method (FRAM) to analyze the cause of the dust explosion accident at the Kunshan factory and propose barrier measures to prevent such accidents. The functional units that changed in the production system during the accident and how these functional units coupled to eventually cause the dust explosion were examined and explained. In addition, barrier measures were developed for functional units that changed during production and emergency systems defined to block the propagation of changes between functions and prevent resonance. Through case study, the identification of key functional parameters in both triggering the initial explosion and in then allowing its spread are key to define barriers to prevent a recurrence of such an event. FRAM uses system function coupling instead of traditional linear causality to explain the accident process, and develops barrier measures for changing function units, providing a novel thinking strategy and method for the analysis of accidents and their prevention.

Single-Collision Statistics Reveal a Global Mechanism Driven by Sample History for Contact Electrification in Granular Media

Models for same-material contact electrification in granular media often rely on a local charge-driving parameter whose spatial variations lead to a stochastic origin for charge exchange. Measuring the charge transfer from individual granular spheres after contacts with substrates of the same material, we find instead a "global" charging behavior, coherent over the sample's whole surface. Cleaning and baking samples fully resets charging magnitude and direction, which indicates the underlying global parameter is not intrinsic to the material, but acquired from its history. Charging behavior is randomly and irreversibly affected by changes in relative humidity, hinting at a mechanism where adsorbates, in particular, water, are fundamental to the charge-transfer process.

Study of Explosion Characteristics and Mechanism of Sucrose Dust

In order to investigate the explosion mechanism of sucrose in the air atmosphere, the explosion intensity under different ignition delay times (IDT), powder input pressures (PIP), and concentrations were studied using a 20L-sphere. The sucrose particles were analyzed in a synchronized thermal analyzer (STA) and scanning electron microscope (SEM). The results are as follows: 1. The DSC curve has two endothermic peaks and one exothermic peak, respectively at T = 180.5 ℃, 510.2 ℃ and 582.6 ℃. 2. The explosion intensity varies with the experiment conditions. The maximum explosion pressure (Pmax) appears when IDT = 90 ms, PIP = 1.5 MPa and concentration = 625 g/m3. 3. The explosive mechanism is a homogeneous combustion mechanism based on particle surface pyrolysis and volatilization. Because of the decomposition, H2, CO, furfural, and other flammable gas-phase products are released, then surface burn appears, which leads to the crystal rupture on account of thermal imbalance, resulting in multiple flame points and a chain explosion. As the temperature of the 20L-sphere rises, more explosive products are released, which causes a rapidly expanding explosion and eventually forms the explosion. This paper can be used as a reference for the prevention of explosion accidents in sucrose production processing.

Study of Parameters and Theory of Sucrose Dust Explosion

To investigate the parameters of sucrose dust explosion, the minimum ignition energy (MIE) and minimum ignition temperature (MIT) were evaluated. The experiments tested the MIE of sucrose dust under different conditions of dust quantity, ignition delay time (IDT), and powder injection pressure (PIP). The experiments tested the MIT of different particle sizes. The results demonstrate that the MIE of sucrose powder under three conditions was an open-up quadratic polynomial. When the dust quantity, the IDT, and PIP were 0.5 g (417 g/m3), 90 ms, and 150 kPa, respectively, the MIE was 58.9 mJ, 62.6 mJ, and 52.4 mJ. The MIT was positively correlated with the particle size of sucrose dust, and the MIT was 340 °C. At the molecular level, the “O–H” bonds of the sucrose molecule hydroxyl groups were broken by the discharge of electrodes or high temperature to generate H2. The combustion of H2 caused the explosion to spread to the surrounding sucrose dust and made the deposited dust rise, forming an interlocking explosion. The explosion would not stop until the dust concentration dropped below the lowest explosion limit. The results of this study can provide guidance for sucrose enterprises to prevent dust explosion accidents.

Assessment of Destructive Impact of Different Factors on Concrete Structures Durability

The durability of concrete structure members is dependent on several factors that should be analyzed at each stage of the construction process. Omitting any of these factors might lead to the augmentation of harmful interactions and, as an effect, to safety hazards and the degradation of a structure or its parts. The article, based on several years of studies on exploited concrete structures, presents the effects of an incorrect analysis of selected factors resulting in the occurrence of faults significantly influencing the possibility of safe use of the objects. The described cases include, but are not limited to, the consequences of an improper assessment of building conditions after a biogas explosion in a fermentation chamber, the effect of a wood dust explosion, fire temperature and firefighting action on the prestressed girders, the stages of degradation of bearing structures supporting gas tanks exploited in an aggressive environment, and the consequences of omitting the temperature load in relation to the upper surface of a plate covering the fire pond. In each case, methods of restoration of the damaged elements were proposed, and their application to engineering practice was described. The practical aspects of the conducted research and implemented interventions were indicated.

Experimental Investigations of the Ignitability of Several Coal Dust Qualities

The ignition characteristics of coal dust is of high importance for the flame stability in coal-fired power plants. We investigate the ignitability of six lignite dust qualities and one hard coal using dust explosion tests and an ignitability characteristic number. The paper aims to identify the degree of impact of the properties of coals, such as the moisture content, the ash content etc., on the ignition characteristics and ultimately to compare the identified relevant ignition parameters to the ignition performance of the dust qualities in an industrially relevant environment. The minimum cloud ignition temperature (MCIT), the maximum rate of pressure rise ((dp/dt)max), the maximum explosion pressure (pmax), the deflagration index (Kst-value) and the modified ignitability characteristic number (ZWZmod.) were determined and were attributed to the moisture content, the ash content and the median particle size. The MCIT was largely influenced by the volatile content, whereas the variations of moisture and ash contents within the range of 10% to 20% did not have a significant impact on the MCIT. The maximum explosion pressure did not differ considerably and stayed in a narrow range among the tested dust qualities. The deflagration index showed a higher sensitivity to the dust properties. The deflagration index and the modified ignitability characteristics number dropped as the moisture content increased and the volatile content reduced. The Kst and ZWZmod. values showed the highest susceptibility to the coal dust properties. Hence, they were used as representative parameters for further comparison with the ignition performance of coal dust in a pilot-scale testing. The results showed that both parameters predicted the ignition performance relatively well and can be used as indicators for the prediction of the ignition performance.

Electric car battery: An overview on global demand, recycling and future approaches towards sustainability

Li-ion batteries are daily present in our electronic devices. These batteries are used in electric and hybrid vehicles supporting the current agreements to decrease greenhouse gas emissions. As a result, the electric vehicle demand has increased in the world. As Li-ion batteries are composed of critical metals in which there is a risk of interruption of supply in the medium term, recycling is the key to a sustainable future without internal combustion vehicles. Understanding the current scenario and future perspectives is important for strategies of new battery design, recycling routes and reverse logistics, as well as policies for sustainable development. This paper presents an overview of current and future vehicles used worldwide. An increase from 1.3 to 2 billion vehicles is expected worldwide until 2030; an outstanding demand will occur mainly in BRICS countries. The data demonstrated a correlation between the number of vehicles in use and GDP. Patents and processes designed for recycling Li-ion batteries and the new developments on pyro-, hydro-, and bio-metallurgical routes have been revised. The manuscript describes the importance and benefits of recycling as regards the supply of critical metals and future trends towards a circular economy.

Effect of the Pyrolysis Process Applied to Waste Branches Biomass from Fruit Trees on the Calorific Value of the Biochar and Dust Explosivity

The article discusses the findings related to the calorific value as well as the explosion and combustion parameters of dust from the raw biomass of fruit trees, i.e., apple, cherry, and pear branches, and from biochars produced using this type of biomass during pyrolysis processes conducted under various conditions. The plant biomass was thermally processed at 400, 450, or 500 °C for a duration of 5, 10, or 15 min. The study aimed to identify the calorific value of the biomass obtained from waste produced in orchards and to estimate the explosion hazard during the processing of such materials and during the storage of the resulting solid fuels. Tests were conducted to assess the total contents of carbon, ash, nitrogen, hydrogen, and volatile substances as well as the calorific value. The findings show a significant effect of the thermal transformation of fruit tree branches on the calorific value of the biochars that were produced. It was found that the mean calorific value of all of the biochars was increased by 62.24% compared to the non-processed biomass. More specifically, the mean calorific values of the biochars produced from apple, cherry, and pear branches amounted to 27.90, 28.75, and 26.84 MJ kg−1, respectively. The maximum explosion pressure Pmax measured for the dust from the biomass and for the biochars was in the range 7.56–7.8 and 7.95–11.72 bar, respectively. The maximum rate of pressure rose over time (dp/dt)max in the case of the dust from the biomass, which was in the range of 274.77–284.97 bar s−1, and the dust from biochar amounted to 282.05–353.41 bar s−1. The explosion index Kst max measured for non-processed biomass and biochars was found to range from 74.46 to 77.23 and from 76.447 to 95.77 bar s−1, respectively. It was also shown that a change in the temperature and duration of the pyrolysis process affected the quality of the biochars that were obtained. The findings show that pyrolysis, as a method of plant biomass processing, positively affects the calorific value of the products and does not lead to an increased risk of explosion during the treatment and storage of such materials. It is necessary, however, to continue research on biomass processing in order to develop practices that adequately ensure safety during the production of novel fuels.

Experimental study and mechanism model on the ignition sensitivity of typical organic dust clouds in O2/N2, O2/Ar and O2/CO2 atmospheres

To reveal and improve our understanding of the ignition behavior and mechanism, G-G furnace experiments of three typical organic dusts were performed to investigate the minimum ignition temperature (MIT) in O₂/N₂, O₂/Ar and O₂/CO₂ atmospheres with oxygen mole fraction from 8.4% to 50%. The experimental results were presented in oxygen-lean and oxy-fuel atmospheres to evaluate the ignition sensitivity of dusts in different atmospheres. It was found that CO₂ is the strongest in terms of lowing the ignition sensitivity of the three dusts, and the dust explosion risk increases significantly with increasing O₂ mole fraction for the three dusts through a logarithmically and significantly reducing MIT. However, for different dusts, inert gases show different suppression effects. In addition, a modified steady-state homogeneous ignition model was proposed and successfully applied to oxygen-lean atmospheres, and in oxy-fuel atmospheres, this model has also been improved to estimate the ignition mechanism. This ignition mechanism model could be used to successfully predict the minimum ignition temperature of high volatile dust under different inert atmospheres controlled by homogeneous ignition, which will provide a reference for the ignition hazard assessment of dust on hot surfaces.

Transient reaction process and mechanism of cornstarch/air and CH4/cornstarch/air in a closed container: Quantitative research based on experiments and simulations

Both dust/air explosion and flammable gas/dust/air explosion are common forms of energy release. Experiments and simulation models with a multi-step chemical reaction mechanism were used to study the intensity parameters and mechanism of the CH₄/air explosion, cornstarch/air explosion and CH₄/cornstarch/air explosion in a closed container. Results showed that the peak overpressure, maximum flame temperature, and average flame propagation speed of the stoichiometric CH₄/air explosion reach 0.84 MPa, 2614 K and 3.5 m/s, respectively. The optimal concentration of cornstarch explosion is 750 g/m³, and its peak overpressure, maximum flame temperature and average flame propagation speed are 0.76 MPa, 2098 K and 1.77 m/s, respectively. For a three-components system, adding methane can significantly increase the explosive intensity and combustion performance of cornstarch. The explosive intensity parameters (peak overpressure, maximum flame temperature, average flame propagation speed) of a certain concentration of cornstarch first increase and then decrease with the increase of methane concentration. The maximum explosion intensity parameters of a three-components system with a certain concentration of lean-methane/air are higher than that of single-phase, but always lower than that of the stoichiometric methane/air. Moreover, the mutual coordination of dust and combustible gas in energy release and the mutual competition mechanism in oxygen consumption are described.

Ignition temperature and mechanism of carbonaceous dust clouds: The roles of volatile matter, CH4 addition, O2 mole fraction and diluent gas

Minimum ignition temperature of dust clouds (MITC) was studied experimentally and theoretically in different atmospheres. Three carbonaceous dusts were tested in both air and O₂/CO₂ atmospheres with CH₄ mole fraction from 0% to 2%. Results showed that the ignition risk of the three dusts significantly increases (decrease of MITC by ~100 ℃) with increasing X_O2 from 21% to 50%, but significantly decreases replacing N₂ in air with CO₂. The inhibition effect of CO₂ on MITCs could be diminished by increasing X_O2 or adding CH₄. The addition of small amount of CH₄ has different effects on the MITCs of different dust samples, following the opposite order of volatile matter content: anthracite>bituminous coal>starch. Two modified steady-state ignition models, considering the density of mixture gas and dust cloud, X_O2 and its diffusivity, were developed to interpret the experimental observations. The analysis revealed that the global heterogeneous ignition model suits well for the hybrid mixtures of anthracite or bituminous coal dusts. In contrast, the proposed global homogeneous ignition model was found to be only valid for the pure starch dust, and the extra CH₄ addition could strongly affect the ignition process of starch, particularly in O₂/CO₂ atmospheres with higher X_O2.

Issues of Corrosion and Degradation under Dusty Deposits of Energy Biomass

The aim of the study is to identify and determine the role of microbial degradation taking place in dusty deposits in potential threats (i.e., destruction of protective coatings and development of corrosion) to the means of transport in conditions of transshipment of energy biomass. This paper presents the results of research on the impact of powdery fractions of wood biomass and biomass obtained from oil plants in the degradation of paint coatings and corrosion processes. During the research, exposure to simulated port climate, OM, SEM, and EDS studies were used. It has been found that the presence of the fraction containing protein compounds and amino acids (e.g., dust of rapeseed meal) stimulates the growth of microorganisms whose metabolism products favour the destruction of protective coatings and the development of corrosion. Under the same conditions, the destruction of protective zinc coatings has been observed. It was found that already 14 days of exposure to oily biomass deposits results in damage to paint coatings caused by microbiological processes. The 8-week exposure causes serious degradation of protective coatings and the base material itself. The biomass of wood origin, containing compounds of the tannin type, did not show as much aggressive activity as the biomass with protein compounds.

Analysis and Characterization of Risk Methodologies Applied to Industrial Parks

It is important to evaluate the risks in industrial parks and their processes due to the consequences of major accidents and especially the domino effect. Scientific works present a wide possibility of models to deal with these situations. In this work, based on the information extracted from the scientific literature, six groups of risk methodologies are defined, analyzed, and characterized with methods that cover the standards, preventive, probabilistic, traditional, modern, and dynamic evaluation that are applied or could be used in industrial parks. It also tries to achieve the objective of determining which are more appropriate if the possible situations and causes that can produce an accident are taken into account, identifying and evaluating them with characteristics of simultaneity and immediacy, determining the probability of an accident occurring with sufficient advance in time to avoid it under the use of a working operational procedure. There is no definitive methodology, and it is necessary that they complement each other, but considering the proposed objective, the integrated application of traditional methodologies together with the management of safety barriers, the dynamic evaluation of risks, and the inclusion of machine learning systems could fulfill the proposed objective.

Inhibition evaluation of gas inhibitors in micron-sized aluminum dust explosion

The inhibition effects of gas inhibitors (nitrogen, carbon dioxide, and heptafluoropropane) on aluminum dust explosion were investigated experimentally and numerically. The results showed that as the inhibition volume fraction increased, the flame propagation characteristics parameters and explosion severity parameters were inhibited by inert gases accordingly. The inhibition performance of carbon dioxide was superior to that of nitrogen, and the minimum inhibition volume fractions of nitrogen and carbon dioxide were determined. XRD results indicated that the crystal form of major condensed product of aluminum dust explosion using two kinds of inert gas as inhibitors was different due to the distinct inhibition effect. Moreover, the XPS analysis revealed that the nitrogen oxide of aluminum adsorbed on the surface of aluminum particles blocked gasification process of aluminum particles. To explore the inhibition mechanism microscopically, a kinetic model concerning gas phase combustion was established. The above discussion indicated that the inhibition effect was the combination of multiple factors. In addition, due to the strong reactions between aluminum particles and heptafluoropropane, it cannot be regarded as gas inhibitor in aluminum dust explosion.

Study on the effect of simulated nuclear industry working conditions on the explosion severity parameters of zirconium powder and the explosion mechanism

Explosion caused by zirconium powder was revealed as one of main reasons in accidents happened in reprocessing of spent fuel in nuclear industry. It is urgent to study the explosion severity characteristic of zirconium dust cloud due to the great harm of its explosion. According to the equipment used in the actual post-treatment process in nuclear industry, the 20L cylindrical explosion equipment as a scale model was manufactured as the experimental device. The experimental results showed that P_max and (dp/dt)_max increased at first and then decreased with the increase of concentration. Small zirconium particles produced larger value of explosion severity parameters. Interestingly, initial temperature had no significant effect on P_max of zirconium powder. However, the value of (dp/dt)_max was strongly dependent on the initial temperature. Additionally, the oxidation degree of zirconium dust and temperature generated during explosion were studied by means of oxygen content and crystal form of explosion products. The study found that the particles develop toward spheroidization and its size became smaller, indicating that zirconium particles combustion is a heterogeneous shrinking core process. Under the condition of constant mass, increased number of ZrO₂ particles leads to enlarged particle total surface area, increasing the amount of radioactive material released.

Investigation into the Suppression Effects of Inert Powders on the Minimum Ignition Temperature and the Minimum Ignition Energy of Polyethylene Dust

The risks associated with dust explosions still exist in industries that either process or handle combustible dust. This explosion risk could be prevented or mitigated by applying the principle of inherent safety. One effective principle is to add an inert material to a highly combustible material in order to decrease its ignition sensitivity. This paper deals with an experimental investigation of the influence of inert dust on the minimum ignition temperature and the minimum explosion energy of combustible dust. The experiments detailed here were performed in a Godbert–Greenwald (GG) furnace and a 1.2 L Hartmann tube. The combustible dust (polyethylene—PE; 800 mesh) and four inert powders (NaHCO3, Na2C2O4, KHCO3, and K2C2O4) were used. The suppression effects of the four inert powders on the minimum ignition temperature and the minimum explosion energy of the PE dust have been evaluated and compared with each other. The results show that all of the four different inert dusts have an effective suppression effect on the minimum ignition temperature and the minimum explosion energy of PE dust. However, the comparison of the results indicates that the suppression effect of bicarbonate dusts is better than that of oxalate dust. For the same kind of bicarbonate dusts, the suppression effects of potassium salt dusts are better than those of the sodium salt. The possible mechanisms for the better suppression effects of bicarbonate dusts and potassium salt dusts have been analyzed here.