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Societal concerns.
Hazard & Safety
Can cause:
Injury
Death
Damage to equipment/ property
Physical Hazards
falling objects, slips & trips, dangerous machinery, …
Physical agents
noise, vibration, electricity, radiation, …
Chemical Hazard
solvents, metals, …
Work Place Hazard
Biological Hazard
micro-organisms and toxins
Psychosocial issues
ergonomics (design of work place environment)
work stress, violence, bullying
Major Concern in a Chemical Industry
Areas of Concern
1. Dangerous Materials
2. Flammable Gases, Vapours and Dust Hazards
3. Hazardous Chemical Reactions
4. Hazards of Pressure Vessels
5. Hazards due to Instrument Failures
6. Hazardous of Unit Operations
7. Entry in to Confined Spaces
8. Hazards due to Corrosion
9. Working with Pipelines
10. Plant Alteration and Modification
Dangerous Substances
1. Explosives
2. Gases
3. Flammable Liquids/Solids
4. Oxidizing Substances
5. Miscellaneous Dangerous Substances
Dangerous substance
Fuels
Liquids
Solids
Gases
Solvents
Paper, boxes, etc.
Plastics
Carpets
Furniture
Waste materials
Common Sources of Ignition
Smoking
Electrical equipment
Heaters
Contractors tools and equipment
Arson
Effective Ignition Source
Open flames: this varies from a lit cigarette to welding
activity.
Mechanically generated impact sparks: for example, a
hammer blow on a rusty steel surface compared to a
hammer blow on a flint stone. The speed and impact angle
(between surface and hammer) are important; a 90 degree
blow on a surface is relatively harmless.
Electric sparks. For example a bad electrical connection or
a faulty pressure transmitter. The electric energy content of
the spark determines the effectiveness of the ignition
source.
Effective Ignition Source
Ventilation
Control of Static Electricity
Solvent Transfer
Jet Fire
Pool fire
Flash fire
Fire ball
Image courtesy: Google Images
Definitions
.
Flammability/Explosive Limit
The upper flammability limit (combustible-
rich limit mixture) is the highest concentration
of fuel in air that burns continuously.
Such values should not be treated as
absolute physical constant such as melting
*
point or density of a pure substance, but
*
rather as guidelines when establishing criteria
for safe conditions.
For example, flammability limits vary
with temperature, pressure, and
conditions of combustion. *Upper Explosive Limit
*Lower Explosive Limit
Flammability Limit
Vapor
pressure curve
• Flash Point
Temperature
Reaction front
Reaction front
overpressure
Shock front
modest
Shock front
overpressure
Overpressure, Damage
~ kPa
Cleveland Open
Cup Method.
Closed cup
produces a better
result - reduces
drafts across cup.
An open-cup flash point determination
2 − c/Tb
b(c/Tb ) e
Tf = a +
(1 − e− c/Tb )2
Chemical group a b
c
Hydrocarbons 225.1 537.6 2217
Alcohols 230.8 390.5 1780
Amines 222.4 416.6 1900
Acids 323.2 600.1 2970
Ethers 275.9 700.0 2879
Sulfur 238.0 577.9 2297
Esters 260.5 449.2 2217
Halogens 262.1 414.0 2154
Aldehydes 264.5 293.0 1970
Temperature and Pressure dependencies
0.75
LFLT =LFL25 − (T − 25)
ΔH c
0.75
UFLT =UFL25 + (T − 25)
ΔH c
Where ∆Hc is the net heat of combustion (kcal/mole), and T is temperature in oC.
As temperature increases: UFL increases, LFL decreases
Flammability range increases
Pressure has little effect on LFL where as UFL change as follows:
UFL p =
UFL + 20.6(logP + 1)
1
LFL =
yi
∑ LFL
i
1
UFL =
yi
∑ UFL
i
LFL UFL
0
0 2 4 6 8 10
Pressure (bar-abs)
Pmax
8
TI PI
6
Igniter 0
0 50 100 150 200 250
Time (ms)
Typical pressure vs. time data
obtained from gas explosion
apparatus shown in the left.
Experimental Apparatus
The LFL for butane is 1.9 % by volume (from literature). From the stoichiometry
By substitution, we obtain
Oxygen Fuel
Nitrogen
Constructing Flammability Diagram
40% Nitrogen
40% Fuel
20% Oxygen
Oxygen Fuel
Nitrogen
Constructing Flammability Diagram
1. Draw Air Line Air line represents all
2. Enter LFL & UFL possible combinations of
3. Determine z fuel plus air. The air line
extends from point where
4. LOC = z LFL
fuel is 0% to oxygen 21%
Oxygen and nitrogen is 79% to a
point where fuel is 100%,
oxygen 0% and nitrogen
0%. The equation for this
line is
Fuel% = -(100/79) x N2%
Nitrogen + 100
Constructing Flammability Diagram
Stoichiometric line represents all
5. Add Stoichiometric Line
stoichiometric combinations of fuel &
oxygen
UFL
Oxygen Fuel
LFL
Nitrogen
Diagram
5. Add Stoichiometric Line
6. Get Pure Oxygen LFL
and UFL (if available)
LOC
7. Construct curve
UFL(O2)
Oxygen Fuel
LFL(O2)
UFL
LFL
Nitrogen
Methane Flammability Diagram
LFL
Hydrogen Flammability Diagram
Hydrogen Explosion
Class IA
Flash point below 73 F (22°C), boiling point below 100 F (37°C).
Class IC
Flash point at or above 73 F (22°C), and boiling point below 100 F
(37°C).
Class II Flash point at or above 100 F (37°C) and below 140 F (60°C)
e.g. acetic acid camphor oil
methyl lactate cyclohexane
hydrazine kerosene
Class III Flash point at or above 140 F and below 200 F (93°C)
e.g. aniline furfuryl alcohol
phenol carbolic acid
naphthalenes pine oil
Classes of Flammable and Combustible Liquids
Hazard
At normal room temperatures, flammable liquids can give
off enough vapor to form burnable mixtures with air. As a
result, they can be a serious fire hazard. Flammable liquid
fires burn very fast. They also give off a lot of heat and
often clouds of thick, black, toxic smoke.
ATmosphères EXplosibles
Employers must classify areas where dangerous
explosive atmospheres may occur into zones.
The classification given to a particular zone, and its
size and location, depends on the likelihood of an
explosive atmosphere occurring and its persistence if it
does.
Areas classified into zones (0, 1, 2 for gas-vapor-mist and
20, 21, 22 for dust) must be protected from effective
sources of ignition.
ATEX Directive
Dangerous substance
Fire triangle: Conditions where fires and /or explosions
can occur.
Explosion: BLEVE, VCE, Detonation and Deflagration
Theoretical and experimental determination of
upper/lower flammability limits, flash point
Flammability diagram
Utilization of inerting to prevent fires/explosions.
Flammable and combustible liquids.