DUST EXPLOSIONS

How to Avoid Dust Explosions

25.08.2011 | Autor: David Yates *

A large amount of asset damage and several unplanned process shutdowns can be avoided
through control of dust. Most of the organic fine dusts ignite at a temperature below 500OC.
Common high-risk zones include filters, silos and cyclones.
Recently an initial post-accident investigation in China has again highlighted the danger
of dust explosion. The accident might have been caused by an explosion of ultra-light
dust. Every year many such accidents go unreported worldwide, and there is hardly
any authentic statistical report available, especially in developing countries.
Many materials produce flammable dust clouds that can explode if ignited. Sugar,
carbon, grain, certain metals and approximately 85 per cent of all organic powders
An aerial view of Imperial

behave in this way. Broadly speaking anything that can burn and which exists in a fine
powdered form is a risk.

Sugar following 2008 dust

explosion and fire. (Picture:
The U.S. Chemical Safety
Board (CSB))

Ergnzendes zum Thema

An Explosion in a Dust Collection System
An Explosion in a Dust Collection System
While investigating a fire in Hayes Lemmerz Internationals aluminium
wheel plant, U.S. Chemical & Safety Board (CSB) found that the dust,
which exploded, originated in a scrap system at the facility. A high
concentration of aluminium dust, when suspended in air, is highly
combustible.
The dust was a byproduct of the process, in which aluminium chips and
scraps were dried prior to being sent to a furnace for re-melting. Dust
from the scraps was conveyed into a dust collector outside the building.
The board determined that an explosion in the collector sent a pressure
wave through the system ductwork and back into the building. A fireball
then erupted inside the building, which lofted and ignited further
aluminium dust that had accumulated on rafters and other equipment.
-

The Smaller the Size, The Greater the Risk

The Smaller the Size, The Greater the Risk
Particle size has a profound effect on reaction rate due to the surface
area available for reaction: a reduction to 1/8th of the original particle
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size results in an 800 per cent increase in surface area. Experimental

evidence suggests that particulate matter in excess of 500 m is
unlikely to contribute to flame propagation due to thermal inertia (heat
sink) effects.
Obvious examples of safe powders are sand and cement. Flammability data is much less commonly available for
dusts compared to gases and vapours, as factors such as particle size can affect the figures so much.
SOURCES OF RISK FOR DUST EXPLOSIONS
The main risk of ignition of dust hazards is from hot surfaces. Dusts may settle on surfaces, and the build-up can
give rise to a concentration that could be ignited.
Layers of combustible materials will burn relatively slowly owing to the limited surface area exposed to the oxygen in
the air. But, if you have the same solid in the form of a fine powder and you suspend it in air as a dust cloud, the
result will be quite different.
In this case, the surface area exposed to the air is much larger, and if ignition occurs, the whole of the cloud may
burn very rapidly. This results in a rapid release of heat and gaseous products and in the case of a contained dust
cloud this in turn will cause the pressure to rise to levels that most industrial plants are not designed to withstand.
Although a cloud of flammable dust in air may explode violently, not all mixtures will do so.
Avoiding Dust Explosions The Ideal Plant Design
Ignition within enclosed area When a dust cloud ignites in an enclosed volume, it results in a very rapid rise in
pressure within the container e.g., a silo or closed room. The container may not be strong enough to withstand the
pressure from the explosion, and it will fail in a sudden and uncontrolled manner. The plant or building will survive
only if the design or other protective measures deliberately allow for the high pressure.
Where an item of the plant fails, or an explosion vent opens as a result of a dust explosion, a fireball and shockwave
will emerge. The fireball is usually much larger than the vessel from which it comes, and is likely to spread burning
particles up to a substantial distance. Dust clouds are formed by dust falling into an area or being raised by blasts of
air. Dust is heavier than air, and therefore it will eventually settle, however an explosion within a piece of plant can
stir up these dust deposits to create a secondary explosion, which is generally more destructive than the primary
explosion.
PREVENTING DUST EXPLOSIONS
In order to prevent dust explosions, companies should follow some practices. They should find out what dangerous
materials are present in their workplace or plant, and define the resultant fire and explosion risks. They must take
action to either remove those risks, or where this is not possible, control them. A target should be made to take
action to reduce the effects of an incident involving dangerous materials. Preparation of plans and procedures to
deal with accidents, incidents and emergencies involving dangerous materials is very essential. Identification and
classification of areas of the plant where combustible dusts may occur, and avoiding ignition sources in those areas
are very important.
IDEAL PLANT DESIGN TO AVOID EXPLOSIVE DUSTS
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Ideally plant design should eliminate the risk of dust clouds forming, or make provision to eliminate the risk of ignition
sources existing in the same area. If this cannot be achieved, then protection measures must be implemented for
example, explosion venting, explosion suppression or containment. Ignition can be caused by friction, static
discharge, hot surfaces and mechanical sparks.
The probability of a hazardous area occurring in a particular area of the plant is defined by zoning and certain types
of equipment are certified as being suitable for each zone of use. Some electrical equipment is certified for gas
hazards only. It is important therefore to select equipment that is certified for gas and dust hazards. For example: II2
GD for use in Zones 21 and 22.
CONCLUSION: HOW TO AVOID DUST EXPLOSIONS
Housekeeping within the plant must be kept at a very high standard. Regular visual checks should be made to
ensure that areas remote from the process are dust free to prevent the possibility of a secondary explosion. For
example, floors, overhead pipes, the roof space above a suspended ceiling and ventilation ducts.
* Joint Managing Director of K Controls, UK.
Redakteur: Dominik Stephan
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