Dust Explosions:

Basics and Prevention

SACHE Faculty Training Seminar
Rich Matusewicz
Arkema Inc.
September 15, 2008

September 15, 2008

Page 1 of 24
Presentation Outline

Personal Introduction
Inerting

Dust Explosion Pentagon
Ignition Sources

Fuel
Explosion Venting

Oxygen
Suppression

Ignition
Safeguards in
Combination

Dispersion

Closing

Confinement

Suggested References

Mitigation

Questions
September 15, 2008
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Flammability Triangle

Oxygen Fuel

Ignition

September 15, 2008

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Dust Explosion Pentagon

Fuel

Oxygen Ignition

Dispersion Confinement

September 15, 2008

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Dust Explosion Requirements - Fuel

Any Organic Dust Having a Particle
Size Below 400 Microns (0.016
Inches) Should Be Evaluated.

Fuel
Examples Include:

 Cornstarch
 Flour
 Polymer Fines

Metallic Dusts are also Hazardous.

Some Dusts With a High Halogen

Content (e.g., Halon) Have Fire
Retardant Properties.

September 15, 2008

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Dust Explosion Requirements Fuel (contd.)

Polyethylene Dust Data

10
9
Explosion Pressure (bar)

8
7
6
5
4
3
2
1
0
0 50 100 150 200 250 300 350 400
Particle Size (microns)

September 15, 2008

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Dust Explosion Requirements Fuel (contd.)

The Severity of a Potential Explosion Is

Predicted Based on Standardized
Laboratory Tests.
Fuel

Explosion Severity KSt (bar

m/sec)

Examples:
Dust KSt Rating
 Coal Dust 129 Moderate
 Flour 202 Severe
 Polymer 383 Very Severe
Fines
 Magnesium 508 Very Severe
Powder
September 15, 2008
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Dust Explosion Requirements Fuel (contd.)

The Explosivity of a Dust

Depends on:

Fuel  Moisture Content

 Particle Shape
 Morphology
 Et Cetera . . .

It Is Very Important to Adhere

to the Standard Method
Procedures to Determine KSt.

It Is Also Important to Obtain a

Representative Sample for
Analysis.
September 15, 2008
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Dust Explosion Requirements - Oxygen

MOST Dust Explosions Require Oxygen
from an Outside Source

Most Common Source Air

Oxygen
Oxygen Could Be Included in Fuel

Molecule.

MOC Minimum Oxygen Concentration

Examples: MOC
Dust O2 in N2 (vol%)
 Coal Dust 12 - 14
 Flour 11
 Polymer 10 - 11
Fines
 Magnesium 3
September 15, 2008 Powder
Page 9 of 24
Dust Explosion Requirements - Ignition

Minimum Amount of Energy

Required to Initiate an Explosion -
MIE

Ignition
Examples:
Dust MIE (mJ)
 Cornstarch 300
 Wheat Flour 540
 Copolymer 11
Fines
 Aluminum > 1,800
Shavings

September 15, 2008

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Dust Explosion Requirements Ignition Sources

Thermal:
 Flames (Cigarette, Welding)
 Glowing Embers (Decomposition,
Ignition i.e. Smoldering Nest)
 Hot Surface (Overheated Motor,
Heater Malfunction)

Mechanical
 Spark (Metal to Metal Contact)
 Excessive Friction

Electrical
 Contact Spark
 Static Discharge
September 15, 2008
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Dust Explosion Requirements - Dispersion

No Dispersion
No Explosion
 Surface Burning on Layer of Dust

Degree of Dispersion =
Dispersion f(particle size, air flow, dust flow)

Watch for Secondary Explosions in
Areas with Poor Housekeeping

Potential Problem Areas:

 Baghouses
 Silos/Hoppers (While Filling)
 Charge Chutes
 Mixers/Blenders
 Dryers
September 15, 2008
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Dust Explosion Requirements Dispersion Limits

12
Explosion Pressure (bar)

10

4
Minimum Explosive Concentration (MEC)
2

0
0 50 100 150 200 250 300 350

Dust Concentration (g/m3)

September 15, 2008

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Dust Explosion Requirements - Confinement

Explosion or Flash???

No Confinement

Confinement No High Overpressure -
Flash Only

Fireball/Flash Fire is Still
Dangerous
Confined Systems: Non-Confined Systems:
 Baghouses  Bulk Powder
 Silos/Hoppers Unloading
 Charge Chutes  Bag Charging
 Mixers/Blenders  Open Mixers
 Dryers
September 15, 2008
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Dust Explosion Mitigation Options

Prevention:
 Inertion
 Eliminate Ignition
Sources

Protection:
 Explosion Venting
 Suppression
 Containment
 Isolation
September 15, 2008
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Dust Explosion Prevention: Inerting

Operate Below Minimum Oxygen

Oxygen Concentration - MOC
 Use Nitrogen, Carbon Dioxide,
Combustion Gases

Effective, But Can Be Expensive

Need for Quality Oxygen Sensors
 Dust Proof
 Well Maintained

September 15, 2008

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Dust Explosion Prevention: Ignition

Eliminate Ignition Sources:
 Follow Electrical Classification
Requirements
 Ground Equipment to Safely Discharge
Ignition Static Charges
 Eliminate Hot Spots
 No Open Flame Policy
 Use Magnets to Trap Stray Metal Pieces
 Etc.
Good Ideas!!! Prudent Practices!!!
BUT . . .
Can You Really Guarantee NO Ignition Sources???

September 15, 2008

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Dust Explosion Protection (Added to Prevention)

Explosion Venting:

Confinement

 Vent Opens Automatically at Onset

of Pressure Wave
 Will Still Have Fireball/Flash
 Vent Discharges to a Safe Location
 Requires Careful Design
September 15, 2008
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Dust Explosion Protection: Suppression

High Tech Explosion Suppression Systems can be

Designed and Integrated as Part of the Equipment
Configuration
 Extinguishers Discharge Inside of Confined Vessel
Halogenated Hydrocarbons
Ammonium Hydrophosphate (Monobasic)
Others

Fast Activation at Onset of Minute Increases in Pressure

Suppression Occurs Before Design Pressure of the
Vessel is Exceeded

September 15, 2008

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Dust Explosion Protection Suite Example
Water Deluge Puts Out Residual Fire

Explosion Vents Protect Dryer/Baghouse

Suppression System Extinguishers
Are Activated by Pressure Rise
Dryer
Bag
House

Suppression PT
PT
System

Rotary Valves Isolate Dryer/

Baghouse from Packaging

To Packaging
To Packaging

September 15, 2008

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Closing

Dust Explosions Represent a

Considerable Hazard

Once the Mechanisms are
Understood, More Easily Mitigated

Mitigation Consists of Prevention and
Protection Safeguards

Knowledge is the Key

September 15, 2008

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References

Butterworth Heinemann
Second Edition 1997
Reed Educational and
Professional Publishing Ltd.

September 15, 2008

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References (contd)

November, 2004
John Wiley & Sons, Inc.

September 15, 2008

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 Questions???

September 15, 2008

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