Dust Explosions

Peter Wypych
wypych@uow.edu.au

Ingredients for Dust Explosion :

1. Dust must be Explosible & Airborne
2. PSD can support Flame Propagation
3. Dust Cloud in contact with Ignition
4. Dust Cloud Atmosphere capable of
supporting Combustion
5. Dust Conc > LEL (20 to 100 g m-3)
6. Dust Conc < UEL (2 to 6 kg m-3)
Rule of Thumb

Ingredients for Dust Explosion

Particle Size

Dust
Cloud

Oxidant

Conc

DUST
EXPLOSION

Shape

Ignition Source
Fire Triangle modified for Flammable
Dust Clouds

Explosion Control Methods

(1) Explosion Prevention
Avoid Explosible Dust Clouds
Remove all possible Ignition Sources
Create Inert Atmosphere
Examples

(2) Explosion Protection

Venting
Suppression
Isolation
Containment
Combination of above
Examples

Venting Atmosphere
Venting Duct Atmosphere
Explosion Suppression
Explosion Isolation
Explosion Containment

Gas vs Dust Explosions

Some Similarities Many Differences :
1. Combustion occurs at Surface of Material
2. Particle Inertial Forces Significant
3. Fuel Concentration Gradients Different
4. Unburnt Particles Turbulence, Severity,
Shape and Inertia of Fireball
5. Secondary Dust Explosions
6. Solids/Powder Fires Control Techniques
7. Detonation (settled dust, 30barg, 2000m/s)

Gas vs Dust
Explosions

German Mill
Explosion

Secondary Explosion
Mr. P.E. Moore, Director of Technology
Kidde plc (supplier of fire/safety products)
PBS Technology Forum, Chicago, May 2003

"Only safe plant is one that is not operating"

News Story
Pressure
Wave

Silo Fires

Main Explosion Parameters

Max Unvented Explosion Pressure, Pmax
(closed vessel)
Pmax 10 bar g USUALLY >> Pdes
(e.g. bins, filters, etc)
Max Rate of Pressure Rise, (dP/dt)max
Dependent on Dust Properties and Vessel
Volume (V)
More Convenient Parameter that Combines
Effects of V and (dP/dt)max Dust Explosibility
Characteristics, Kst
(2)
where V = 20 litre or 1 m3 Standard Vessel [2]

Main Explosion Parameters

Kst also Used to Classify Dusts

Main Explosion Parameters

FIGURE 2 Typical Pressure Traces of Dust Explosions

in a Closed Vessel

Explosion Test Data

PSD, s, bl
Moisture and Temp (dust and air)
Kst and Pmax (preferably using a 1 m3 vessel)
(dP/dt)max and Dust Concentration
Lower Explosibility Limit, LEL
Upper Explosibility Limit, UEL
Min Ignition Temp Dust Layer and Dust Cloud
Min Ignition Energy Dust Cloud

Principles of Explosion Venting

Rear vs Top Venting

Safe Venting

Indoor
Venting
Brilex1

Brilex2

Fundamental Design Parameters:

Max Total Dirty Volume of Equipment, V

(dP/dt)max
Kst
Pdes of Enclosure (weakest component)
Opening Pressure of Vent Panel, Pstat

4 Main Methods to Estimate Av:

Kst Nomograph Method

St Group Nomograph Method
Radandt [5] Nomographs (Pmax 10 bar g)
Scholl [6] Equation

 Kst Nomographs Approximated by:

a = 0.000571 exp(2 Pstat)

b = 0.978 exp(-0.105 Pstat)
c = -0.687 exp(0.226 Pstat)

Note: ensure correct units used (in paper)

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 Kst Nomographs subject to following

Limitations (cannot extrapolate):
Pstat = 0.1 to 0.5 bar g
Minimum Pred = Pstat + 0.1 bar g
Maximum Pred = 2 bar g
10 Kst 600 bar m s-1
Pmax < 10 bar g (St 1 & St 2 Dusts)
Pmax < 12 bar g (St 3 Dusts)
1 V 1000 m3
L/D < 5 [3,4] or L/D < 2 [8] Implications
Venting Atmosphere (unrestricted)

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 St Nomographs Approximated by:

Note: ensure correct units used (in paper)

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 Radandt Nomographs Approximated by:

Scholl [6] Equation:

Use with Care!!

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 Worked Example No. 1

Storage Bin = 16 m3 (L/D < 2)
Dust Collector = 2 m3
Dust: Kst = 150 bar m s-1; Pmax = 9 bar g
Venting Panel Pstat = 10 kPa g
Press Strength of Bin = 45 kPa g
Press Strength of Filter = 70 kPa g

Determine Av using all 4 Methods:

V = 16 + 2 = 18 m3; Pdes = 45 kPa g (bin)
Select [4] Pred = (2/3) Pdes = 30 kPa g
Kst = 150 bar m s-1 Group St 1

Results

Hence Av = 0.77 to 1.6 m2

Unless Reasons to do Otherwise
Should Select Kst value 1.5 m2

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Effect of Vent Ducts

Worked Example No. 2
Sugar Beet (Pmax = 9 bar g; Kst = 150 bar m/s)
Group St 1
Existing Stand-Alone Dust Collector,
V = 2.4 m3, L/D < 2, Pdes = 70 kPa g
Venting Panel Pstat = 10 kPa g
Filter Located 6 m from External Wall
Existing Vent Duct: D = 800 mm; L = 6.5 m

Effect of Vent Ducts

Can we Increase Vent Duct to L = 12 m??
Firstly Need to check Existing Design
Determine Av using Kst and St Group
Nomographs Vent Duct Diameter, D
Select Pred = 20 kPa g
Kst Method:
Fig 2: Av = 0.55 m2; Eqn (2): Av = 0.49 m2
St Group Method:
Fig 2: Av = 0.53 m2; Eqn (2): Av = 0.52 m2

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Effect of Vent Ducts

Selecting Av = 0.5 m2 D 800 mm
Existing Design OK??
(Nomograph Av for Venting Atm)
Effect of Vent Duct on Expl Pressure?
Calculate L/D (L/D = 8.1)
Use appropriate Design Chart Pred
For Pstat = 1.1 bar abs & Kst = 150 bar m/s:
Relevant Design Chart Fig 11

Pred =
1.2 bara

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Pred =
2.3 bara
Pred =
1.2 bara
L/D = 8.1

Effect of Vent Ducts

Hence Vent Duct increases Expl Press
to Pred = 2.3 bar abs = 130 kPa g
>> Pdes = 70 kPa g
Hence Rupture of Filter Expected
Working in Reverse Order:
Pred = 60 kPa g = 1.6 bar abs Fig 11
Max L/D = 3.8

Options??
Increase Vent Duct Diameter
Relocate Dust Collector (D = 800 mm, L = 3 m)

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Pred =
1.6 bara
Pred =
1.2 bara
L/D = 3.8

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