Controlling Electrostatic Hazards

Associated with

Combustible Dusts and Flammable Liquids

VAHID EBADAT, PH.D.

Chilworth Global
250 Plainsboro Road, Building # 7
Plainsboro, NJ 08536
Email: vebadat@chilworth.com

AIChE ChemE on Demand Webinar

February 23rd, 2011

1
 Controlling Electrostatic Hazards
Associated with

Combustible Dusts and Flammable Liquids

Outline
 INTRODUCTION TO ELECTROSTATICS – An Overview

 Electrostatic Charge generation

 Examples

 ELECTROSTATIC HAZARDS CONTROL – An Overview

 Metal (Conductive) Items of Plant

 People
 Non-Conductive (Insulating) Materials
 Powder Handling
 Liquid Handling

 CASE STUDY – Time Permitting

 DISCUSSION

2
 Fire Triangle

 FUEL – Liquid (vapor or mist), gas, or solid

capable of being oxidized. Combustion
always occurs in the vapor phase; liquids
are volatized and solids are decomposed
into vapor prior to combustion

 OXIDANT – A substance which supports

combustion – Usually oxygen in air
IGNITION SOURCE
 IGNITION SOURCE – An energy source
capable of initiating a combustion reaction

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 Explosion Prevention and Protection Techniques

Basis of Safety

 Elimination of ignition sources

 Avoidance of flammable atmospheres

NO FIRE
 Provision against consequences of ignition
IGNITION SOURCE
REMOVE

IGNITION SOURCE

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 Typical Ignition Sources

• Electrostatic discharges
• Electrical equipment
• Thermal decomposition
• Hot surfaces and equipment
• Hot work
• Open flames
• Mechanical friction and sparks
• Impact sparks
• Personal smoking materials

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 Recommended Practice on Static Electricity – NFPA 77

The purpose of NFPA 77 is to provide assistance in controlling the hazards

associated with the generation, accumulation, and discharge of static
electricity by providing:

 A basic understanding of the nature of static electricity

 Guidelines for identifying and assessing the hazards of static electricity

 Techniques for controlling the hazards of static electricity

 Guidelines for controlling static electricity in selected industrial

applications

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 Systematic Approach to Electrostatic Hazard Assessment

Charge Generation Schematic of a Typical Chemical Processing Plant

Tank farm
Charge Accumulation

Isolated Conductors

Insulating Objects Reactor

People Centrifuge

Liquids

Powders Vacuum Mill

Dryer
Incendivity of Discharges

Sensitivity of the Atmosphere to Ignition

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 Contact (Frictional) Charging

When two materials make and then break contact, the contacting surfaces
acquire a net charge, with one becoming negative and the other positive

Movement

+ + + + + + + + + + +
+ + + + + + + + + + +
-----------
-----------
Charges fixed on Material
Interface with No Net Charge
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 Contact Charging - Examples

 LIQUID HANDLING

 Liquid transfer through hoses and pipes

 Agitation of two phase mixtures
 Settling of two phase mixtures Tank farm
 Filtration

 POWDER HANDLING Reactor

Centrifuge

 Sieving
 Pouring
 Mixing Vacuum Mill
Dryer
 Grinding
 Pneumatic Transfer
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 Control of Electrostatic Hazards

Characteristics of Materials and Plant

The first step in assessing electrostatic problems and hazards is to establish

the electrostatic properties of the materials processed, handled, and/or used
in the plant (Ref. NFPA 77)

 Resistance-to-Ground of conductive (metal) objects and items of plant

 Electrical Resistance of operators’ footwear and floors
 Electrostatic Chargeability of liquids and powders (alternatively, measure
surface voltage or electric field during processing)
 Surface Resistivity of solid objects such as plastic containers and liners
 Volume Resistivity of powders
 Minimum Ignition Energy of flammable atmospheres

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 Relevant Laboratory Test

 Minimum Ignition Energy (MIE), (ASTM E 2019)

MIE of a flammable material is the smallest electrostatic spark energy needed
to ignite an optimum concentration of the material using a capacitive spark

Minimum Ignition Energy

Ignition
Apparatus Current Limiting
Chamber
Resistor
Switch

D.C.
Voltage Capacitor Decoupling
Source Resistor

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Electrostatic Voltmeter
 Factors Affecting Minimum Ignition Energy

Some Influencing Factors Effect

Increasing Particle Size

Increasing Moisture Content

Presence of Flammable Vapor (even if below LFL)

in Dust Cloud

Increase in Ambient Temperature

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 Minimum Ignition Energy (MIE) of Some Gases, Vapors, and Dust Clouds

Minimum Ignition Energy

Atmosphere Material
(mJ)
Propanol 0.650
Ethyl Acetate 0.460
Methane 0.280
Propane 0.250
Vapor / Gas Ethane 0.240
Methanol 0.140
Acetylene 0.017
Hydrogen 0.016
Carbon Disulphide 0.009
Pvc 1,500
Zinc 200
Wheat Flour 50
Polyethylene 30
Sugar 30
Dust Cloud Magnesium 20
Sulphur 15
Aluminum 10
Epoxy Resin 9
Zirconium 5 13
 Electrostatic Control Measures
 Conductive (Metal) Plant

 Resistance to ground should be checked. If R>10 ohm, direct

ground connection is required
 Ground connections should be checked regularly

Ground Connection Point on Reactor

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Painted Metal Drums – Ground Clamp Must Penetrate the Paint

15
Fiberboard Drum – Metal Chime Must be Grounded

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Grounding Metal Chute Prior to Powder Transfer

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Electrostatic Spark from Ungrounded Chute Causing Ignition

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Internal Metal Spiral to Ensure Electrical Continuity and Shielding

19
Bonding and Grounding of Metal Flange Couplings on Insulating
Pipework

20
Vacuum Transfer of Powder from Buggy

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Ground Proving Unit

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 Electrostatic Control Measures

 Personnel

 Personnel can typically attain potentials of 10 to 15kV

 Maximum discharge energy 20mJ to 30mJ

Tank farm

Reactor

Centrifuge

Vacuum Mill
Dryer

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 Electrostatic Control Measures

 Personnel

 Personnel should be grounded so that their

resistance-to-ground <1x108 ohm
 Static dissipative footwear may be used
 Resistance of the floor/surface on which the
operator is standing should also be <1x108
ohm
 Where risk of exposure to mains electricity
exists, resistance to ground should be:
5x104 ohm < R < 1x108 ohm

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Floor Resistance Measurement

25
Manual Transfer of Powder to Reactor

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 Electrostatic Control Measures
 Non-Conductive (Insulating) Materials

 Examples include plastic hoses, drums, bags, liners

 Non-conductive materials can cause:

– Build up of static charge

– Insulation of conductive items
– Charge retention on liquids and powders in non-conductive
containers

 Grounding of non-conductive materials would not facilitate the

relaxation of electrostatic charges to ground

 Consider conductive or static dissipative materials

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 Electrostatic Control Measures
 Non-Conductive (Insulating) Liners in Containers

Liners with Surface Resistivity > 1011 ohm/square should be used ONLY if they are
essential, e.g. for reasons of chemical compatibility between the container and the
product

The ignition risk and the possibility of physiological shock from propagating brush
discharges depends on:

 Thickness of liner
 Resistivity of liner
 Handling procedure
 Electrical properties of the product
 Nature of flammable mixture that may be present

Electrically grounded antistatic or conductive liners with Surface Resistivity

less than 1011 ohm/square should be used - Expert advice may be necessary
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 Electrostatic Control Measures
 Bulk Powder

Static charge can build up on insulating powders (Volume Resistivity

>109 ohm.m) or if powder is in insulating or ungrounded conductive
vessels. Depending on Minimum Ignition Energy of the powder cloud
consider:

 Grounded conductive vessels

 Inert gas blanketing
 Explosion protection
 Electrostatic charge eliminators

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 Electrostatic Control Measures

 Flexible Intermediate Bulk Containers (FIBCs)

Various FIBC designs developed to reduce electrostatic hazards

Type A - no special static protection mechanism

 Should not normally be used where a flammable atmosphere

is present

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 Electrostatic Control Measures

 Flexible Intermediate Bulk Containers (FIBCs)

Type B - constructed from insulating fabric but has voltage

breakdown less than 6kV

 May be used if MIE of flammable atmosphere is above 3mJ

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 Electrostatic Control Measures

 Flexible Intermediate Bulk Containers (FIBCs)

Type C – A design that relies on earthing (grounding) to prevent electrostatic

hazards. Type C FIBCs shall be constructed entirely from conductive material
or at least shall contain fully inter-connected conductive threads or tapes with
maximum spacing of 20mm if the threads or tapes are in stripe pattern or
50mm if they are in a grid pattern. For FIBCs constructed of multi-layer
materials, at least one surface of the FIBC shall have a resistance of less
than 108 ohm.

 Resistance from any location on FIBC to ground <1x108 ohm

 Must be electrically grounded during filling and emptying
 May be used where a flammable atmosphere is present
 If left electrically isolated from ground would pose greater ignition risk than Type A
and B FIBCs 32
 Electrostatic Control Measures

 Flexible Intermediate Bulk Containers (FIBCs)

Type D - constructed from fabrics with static dissipative threads

and/or properties to control discharge incendivity

 When electrically isolated, and subjected to “high charging” conditions

should not give rise to incendive static discharges
 Do not require grounding during use
 May be used where a flammable atmosphere is present
 Would pose ignition risk if FIBC surface is contaminated
 May charge proximate ungrounded conductors by induction

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 Electrostatic Control Measures

 Understanding Electrostatic Hazards of FIBCs

 Applicable Test Method: IEC 61340-4-4

Electrostatic Classification of Flexible Intermediate Bulk

Containers (FIBC) - Test Methods and Requirements

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 Electrostatic Control Measures
 Liquids

Static electricity hazards can arise in various liquid handling operations

including filling, sampling, filtration and mixing. The following suggestions
can reduce the electrostatic ignition hazards.

 Use Electrically Grounded Conductive Plant

All items of plant including pipes, vessels, containers etc. should be
electrically conductive and/or static dissipative and grounded
 Increase Liquid Conductivity
When handling low conductivity liquids an antistatic additive may be
used in very small concentrations in order to raise the liquid conductivity
 Control of Liquid Entry to the Vessel
Liquid should enter a vessel through a dip leg with submerged ends or
bottom inlet point
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 Effect of Humidity on Charge Accumulation

 If water vapor is present in air, it absorbs onto surfaces and forms a

slightly conducting surface layer

 The extent to which the water absorbs and the increase in conductivity
depends on the nature of the surface and the humidity of the atmosphere

 Although there is not a definitive relative humidity where the conductivity

of all materials changes, holding the relative humidity at about 65% may
significantly reduce electrostatic effects without introducing an unpleasant
environment

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 Electrostatic Control Measures

 Electrostatic charge eliminators

Eliminators rely on very low energy electrical discharges or a radiation
source for the creation of ions.
If discharges are produced by the static charges to be neutralized, eliminator is PASSIVE
If discharges are produced by a high voltage source, eliminator is ACTIVE
RADIOACTIVE sources can also be used to eliminate static charges

Passive Active Radioactive

Ionized Air
High Voltage Air
Grounded
Guard
Grounded
Guard
(+ve) Molecule - +
+ + + +
+ + + + + + + +
+ + + + + + + +
+ +
+ + + + + + + +
+ +
--------- --------- Alpha Particle

Alpha Particle
Charged Material Charged Material
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 Explosion Prevention and Protection Techniques

Basis of Safety

 Elimination of ignition sources

 Avoidance of flammable atmospheres

 Avoid flammable/explosible concentrations

 Exclusion of oxygen by adding inert gas

 Provision against consequences of ignition

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 Explosion Prevention and Protection Techniques

Basis of Safety

 Elimination of ignition sources

 Avoidance of flammable/explosible atmospheres

 Provision against consequences of ignition

Preventative measures alone may not ensure adequate level of safety.

Protective measure should be taken as well

These measures are:

 Containment by explosion resistant construction, Design based on
ASME Boiler and Pressure Vessel Code, Section VIII, Division I
 Explosion suppression by injecting a suppressant, NFPA 69
 Explosion venting to a safe place, NFPA 68

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Case Study

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Operator Scooping Powder into the Sieve

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Clamp Bonding the Bin to the Plant Ground

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Operator Scooping Powder into the Sieve

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Bin Covered by Plastic Sheet to Prevent Dust Cloud from Spreading

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The Aftermath of the Flash Fire

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 Controlling Electrostatic Hazards
Associated with

Combustible Dusts and Flammable Liquids

VAHID EBADAT, PH.D.

Chilworth Global
250 Plainsboro Road, Building # 7
Plainsboro, NJ 08536
Email: vebadat@chilworth.com

AIChE ChemE on Demand Webinar

February 23rd, 2011

46