The Source for Dr y Process ing and Bulk Handl ing Technology

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Milled DSI: An Alternative to Converting/Closing Your PlantRead more on page 14

Powder Shows DeliverFor professionals handling and pro-cessing powder and bulk solids, UBM Canon’s conferences and expositions provide the most comprehensive gath-ering of manufacturing expertise in North America.Read more on page 6

Size Reduction FocusThe new Netzsch Omega Dispersionizer achieves high energy efficiency through utilization of turbulence, cavitation, and shear forces, providing real energy- and time-saving potential. Read more on page 11

Flameless VentingA modern explosion protection solution must consist of prevention of explosive atmospheres, avoidance of the ignition of explosive atmospheres, and mitiga-tion of the effects of an explosion to an acceptable level.Read more on page 28

Dual-Rotor Crusher

The Carter Day/Jacobson Half Nelson Crusher (HNC) is a new dual-rotor crusher that offers quick-change screen removal without removing ductwork. The HNC has intermeshing pins and fixed sidewall combs

that work together for maximum size reduction. The new design maintains a low-profile unit that is important when minimum headroom is required. The crusher is offered in mild steel, and 304 and 316 stainless steel, with USDA applications available. This machine can accept up to 6-in. pieces. The HNC is ideal for de-agglomerating and crush-ing materials that can be broken apart by hand. Carter Day International Inc., Minneapolis, MN 763-572-3412 www.carterday.com

Interval Impactors Move Difficult Bulk Materials

The new PKL Series interval impac-tors from Martin Vibration Systems are designed to deliver the force needed to dislodge sticky materials from process vessels, chutes, pipes, storage bins, and dust collectors. The high acceleration generates individual blows similar to a hammer, while reducing noise and energy costs, as well as the potential for bin dam-age and injury. Based on individual application requirements, the company can supply interval impactors providing from 120-1700 pounds of force to move material that resists the effects of rotary vibration. Martin Vibration Systems Solutions, Marine City, MI 800-474-4538 www.shake-it.com

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TechnicalExclusive

TThe history of catastrophic industrial explosions is

a long and truly horrible one. In 1921, a silo contain-ing 4500 tn of ammonium sulphate and ammonium nitrate exploded at BASF in Germany, killing 561 workers. The explosion was so massive it was felt 300 miles away and left a crater more than 70 ft deep. In 1971, a flower mill exploded in Germany and resulted in the death of 17 workers. In 1984, an explosion in Bhopal, India immediately killed 2259 people. In 2001, a dust explosion in Toulouse, France resulted in 31 deaths. [1]

There have been many explosions in the U.S. as well, including at Imperial Sugar in 2008, where 14 died and 60 were injured; Hoeganaes Corp. in 2011, in which five died in three separate incidents in less than five months; West Pharmaceutical, 2003, where six died and 38 were injured. All of these incidents were caused by combustible dust or gas-related ex-plosions [1]

According to the Occupational Safety and Health Administration (OSHA) and the U.S. Department of Labor (DOL), at least 350 explosions caused by com-

bustible dust killed 130 workers and injured more than 800 since 1980. There are a number of statis-tics available from insurers and others that show the property damage caused by an explosion could range anywhere from an average of $400,000 to $1.6 million in loss per explosion incident [2]. Destroyed buildings and the huge loss of production, as well as the cost of reinvesting in new production equipment, can run into the billions of dollars. The average downtime after an explosion can be estimated to be at least several months, that is, long enough for cus-tomers to find another supplier [3]

The explosion at Imperial Sugar in Georgia in 2008 is the watershed “catastrophic” event, which resulted in a re-issuance of the National Fire Protection Association (NFPA) standards and implementation of a National Emphasis Program -- strict enforcement -- by OSHA. More than 30,000 companies have been made aware of combustible dust hazards and of the need for strict compliance with the NFPA standards.[4]

Some random measures have been undertaken over the years to curtail risks in production. Smoking is no longer allowed in any production facility and welding has to be done with special precaution taken, special permission/permitting, and strict di-rection. Even cell phones are banned in some pro-duction facilities.

But to achieve a truly safe production facility, a modern explosion protection solution must consist of:

* Prevention of explosive atmospheres* Avoidance of the ignition of explosive atmo-

spheres* Mitigation of the effects of an explosion to an ac-

ceptable level

Prerequisites for Explosion Any dust that has a KST value greater than 0 is defined as being a combustible dust under OSHA Guidance [5] therefore, measures to avoid or reduce the damage caused by an explosion are mandatory. This dust is not dangerous as long as the other ele-ments of the so-called Explosion Pentagon are absent - see next page.

Flameless Venting – The “New” Technology for Safe

Indoor Explosion Venting

Fig. 1 REMBE f ameless vent installed in a manufacturing facility

By Dr. Gerd Ph. Mayer, President, Rembe Inc.

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For example, sugar or flour stored in bags in a warehouse or other confined area are harmless products as long the fine dust particles are not airborne and dis-persed, creating a concentration in the air which is defined to be combustible.

In addition, a source of igni-tion has to be present, which can be a mechanically-created spark, a spark created by discharging static electricity, a hot surface, or an open fire.

If you have all of the elements — combustible dust, a confined area, oxygen, an ignition source, and perfect dispersion of dust particles — an explosion would occur. But, the truly catastrophic results of these explosions are actually caused by the maximum explosion pressure build-up in the confined area. This build-up could

burst the enclosure which would not be able to withstand the pres-sure. Both fragments of metal and

flames released into work areas would cause deadly injuries and extensive property damage.

And then there is the second-ary explosion. Typically, the ex-ploding enclosure/enclosed area is connected to another room or other enclosure (a dust collector might be connected to a mixer or blender, for example). The shock wave of the first explosion “blows” into perfectly dispersed airborne dust in the connecting enclosure or enclosed area, caus-ing catastrophic damage reminis-cent of recent combustible dust explosions. Given the explosion risk potential in manufacturing

facilities, what should a modern explosion protection solution in-clude?

Prevention of Explosive AtmospheresExplosion prevention, also known in the past as primary explosion protection, includes all measures to be undertaken to avoid a com-bustible atmosphere:

Substitution: includes, for example, suspension of highly combustible aluminum powder in oil to avoid reaction with oxygen via a fine layer of oil around each particle

Fig. 2 - Explosion Pentagon

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conveying processes cannot be conditioned.

Blanketing with Inert Gas:

This procedure quite often is used in batch operations such as in pharmaceutical production and can be quite costly.

Some measures of explosion prevention are not practical and find their limitations especially in the food processing industry. So, for example, neither water nor oil can be used to produce flour or coffee!

Avoidance of the Ignition of Explosive AtmospheresThis second step to explosion protection includes taking all possible measures to avoid any source of ignition such as me-chanically generated sparks, flames, hot surfaces, avoiding static electricity (grounding of all equipment is mandatory), using only intrinsically safe electric/electronic parts. [9]

Now, in accordance with pre-vention of explosive atmospheres theory, if you could eliminate ignition sources with 100% cer-tainty, eliminate oxygen with 100% certainty, or control dust concentrations, there would be no need for additional combus-tible dust explosion protection because you would have elimi-nated a required element for a combustible dust explosion.

In real processes, control of dust concentration and concen-tration of oxygen is quite difficult and expensive. Redundant sys-tems increase the cost of invest-ment.

Avoiding ignition sources is mandatory and the first step for explosion prevention, but con-trolling ignition sources is not enough since an unforeseeable ignition can result from some-thing as simple as a screw or hammer dropping and causing a spark. Prevention and avoidance of ignition of explosive atmo-spheres alone will not eliminate the risk of an explosion.

In many production processes, fine particles are created, either by grinding, conveying, or any other step in processing. In al-most all industries, it is recog-nized that these fine particulates create an environmental problem or health hazard for workers op-erating in an enclosed area.

Dust collecting systems are installed to eliminate these is-sues, [10] but they create a whole new set of risks. Despite the

Cleaning and Diluting: This is the housekeeping issue. Avoid dust accumulations in production that otherwise cause a combus-tible atmosphere when airborne. Cleaning dusty areas with pres-surized air is no longer allowed; vacuum systems must be used. [6] Even vacuum system equip-

ment must be explosion-proof, [7] since the accumulation of dust inside these systems creates an explosion risk if there is a source of ignition.

Conditioning of a combus-

tible into a non-combustible

product: This procedure, some-

times as simple as spraying wa-ter on powders, is quite often used in coal mines and wood processing industries. [8] NFPA 120,664 Conditioning finds its limitations if moisture changes the worth or handling of prod-uct so, for example, pneumatic

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first reported combustible dust explosion in an Italian flour mill in 1785, [11] the knowledge that some fine particulates could mix with air in a confined space and cause a combustible mixture un-der the right set of circumstances has been ignored or neglected.

Today, thousands of dust col-lectors fulfill the requirement of providing clean air for a manu-facturing environment but many, perhaps most, of these dust col-lectors do not have proper explo-sion protection. Many of them do not even have a simple explosion panel. Yet they are installed in-doors and cause an even higher risk for workers and property than would be the case without the dust collectors at all.

Mitigation of the Effects of an Explosion As far back as the 1920s, combus-tible dust standards were issued by the NFPA. The first standards appeared as recommendations, whereas the newer standards seem to ÒimplyÓ a mandatory ap-proach to protect against the risk of combustible dust explosions, especially in light of OSHAÕs National Emphasis Program that is essentially enforcing the NFPA standards for combustible dust through its general duty clause.

NFPA 68, 69 and 654 are gen-eral standards for a wide variety of industries:

Standard Content

NFPA 68Explosion Protection by Deflagration Venting

NFPA 69Explosion Preventing Measures

NFPA 654

Handling of Combustible Particulate Solids Ð ÒProcess RegulationÓ

Table 1. NFPA Standards 68,

69, 654

NFPA 68 describes the need for explosion venting and the calcu-lation of the vent area required. NFPA 69 provides a description of how to prevent an explosion. NFPA 654 can be described as the process standard, giving guidance on how to isolate an enclosure to prevent flame propagation and secondary explosions.

Mitigation of Explosion Effects: Indoor Venting As the Third Layer of Modern Explosion Protection

The most commonly used method for deflagration preven-tion in the U.S. is chemical sup-pression and, for many years, was the only method used to

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protect indoor enclosures from the risk of combustible dust ex-plosions where venting to the outside wasn’t an option. With chemical suppression, bottles of an extinguishing agent under pressure of 80 Barg are installed in an enclosure or duct. These

bottles are triggered by devices such as spark detectors or pres-sure sensors. In the event a spark or increase in pressure is detected, the suppression bottles quickly release their agent and extinguish the flame, thereby stopping propagation.

One real drawback to chemical suppression is the “false trigger-ing” of the system due to sudden but small changes of pressure in real world manufacturing pro-cesses. After “false triggering,” the process being protected by suppression is contaminated and

has to be cleaned. The suppres-sion bottles must be refilled or replaced and the system must be recertified by authorized person-nel. Thus, a facility will suffer from downtime and real expen-ditures due to “false triggering”. [12]

In addition, in small enclo-sures, chemical suppression reaction time might not be fast enough to reduce the pressure build-up inside an enclosure be-low the enclosure’s design pres-sure. Bursting of the enclosure or deformation could be the re-sult.

Lastly, suppression systems require quarterly maintenance per NFPA 69, by authorized per-sonnel (which is quite often the vendor’s personnel) and create high maintenance costs for the lifetime of production.

For products/dusts with very high Kst values, suppression sys-tems are still the only choice for explosion prevention for enclo-sures located indoors that can-not be vented to the outside. For the vast majority of applications, however, indoor flameless vent-ing systems are the best solution.

Flameless VentingToday, there are options for safely venting indoor enclosures. Explosion vents or panels are the least expensive method of vent-ing an enclosure so long as that enclosure can be safely ducted to the outside. After an event, the vent must be replaced.

NFPA 68 describes the calcula-tion of the vent area necessary to safely vent the deflagration, based on KST value and Pmax, the maximum explosion pressure

This second step to

explosion protection

includes taking all pos-

sible measures to avoid

any source of ignition

such as mechanically

generated sparks,

flames, hot surfaces.

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and the Pred, or reduced design pressure, of the enclosure.

Many dust collectors are in-stalled indoors; they are located close to the source of dust, and frequently away from outside walls. Any duct between the dust collector and the wall that will “lead” explosion pressure to the outside will cause back pressure. This has a huge impact on the strength of the dust collector. [13]

There are many dust collectors installed with a very low Pred, either because they have been so designed, without taking into consideration the potential of an explosion, or they have weak-ened after many years of use. The average Pred of rectangular dust collectors today is less than 0.3 Barg.

There are many experts, OSHA inspectors, and publication edi-torials that have, over the years, recommended that a dust col-lector be installed outdoors to avoid the catastrophic results of a combustible dust explosion. In fact, this is simply wrong and not practical. This “solution”

would cost industry a fortune to relocate dust collectors and in-stall more powerful blowers and fans and result in a tremendous increase in energy costs.

Let us remember that simply placing a dust collector or other enclosure outdoors does not necessarily reduce the risk of property damage or people being injured or killed. If an event oc-curs, the length of the flame can be 100 ft or longer and, there-fore, care must always be taken to be sure that an explosion vent/panel does not face the di-rection of a neighboring building, a driveway, or other area where people or vehicles could be lo-cated. And, for some production, dust collectors must be installed inside. This is true, for example,

of sugar-based products. Changes in temperature and humidity would block filter elements. In such cases, and in many others, indoor flameless venting is the best option.

An explosion can be vented safely indoors (as well as out-doors) with a flameless venting system.[14]

Flameless Venting TechnologyFlameless venting technology was invented in the 1990s in Europe by REMBE GmbH. The flameless vent consists of a cage, wrapped with a specially-devel-oped mesh material. The bottom of the cage is hermetically sealed with a round burst panel.

Fig. 3 REMBE Q-Rohr-3 f ameless vent-

ing system

Once a deflagration starts, the increasing pressure causes the rupture disc to burst. Because the mesh material provides a very large surface area, the heat is dissipated. Dust particles can-not pass through the mesh mate-rial and are also kept inside the cylinder.

The increase of pressure outside of the flameless vent is negligible when an event occurs and the rupture disc bursts. There is no pressure wave so no dust will be-come airborne and create the po-tential for a secondary explosion.

Some of the flameless venting systems have an ATEX system certificate and can be installed in-doors to safely vent an explosion; these systems are also in accor-dance with NFPA regulations and may be Factory Mutual approved.

Flameless venting systems are passive systems. They don’t need any other device (such as a spark detector or sensor) to be trig-

While other prevention

systems, like suppres-

sion systems, do need

quarterly maintenance,

flameless venting

systems do not.

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gered; the explosion pressure will activate the system. While other prevention systems, like suppres-sion systems, do need quarterly maintenance, flameless venting systems do not. The burst panel of the flameless vent is specifi-cally equipped with burst sensors. Once an explosion occurs, the sig-

nal is activated to shut down the entire process.

Just as a point of information, in accordance with NFPA 654, an enclosure Ð in many cases a dust collector Ð also must be isolated to prevent flame propagation into adjacent enclosures causing sec-ondary explosions [15].

For companies having con-verted from suppression systems to flameless venting, the cost savings are enormous. The aver-age downtime after an explosion is suppressed can be more than three days due to the need to clean the entire production line to eliminate the suppression agent.

Compare this with a system pro-tected with a flameless vent: the downtime is significantly reduced to just the time it takes to replace the panel and rinse the vent.[16]

SummaryDuring the past 10 years, indoor

venting has become more popular in North America, not only be-cause of its effectiveness in elimi-nating the risk of damage and fatality, but also for economic rea-sons. Dust collectors donÕt have to be relocated or placed outside and downtime caused by false triggering does not occur with passive indoor venting systems. Maintenance costs are dramati-cally reduced. If an event occurs, replacing the indoor venting sys-tem disc is fairly easy and pro-duction is able to resume within a short period of time.

Dr. Gerd Ph. Mayer is president, REMBE Inc. For more information, visit www.rembe.us.

[1] Oppau explosion, http://en.wikipedia.org/wiki/Oppau_ex-plosion; Preventing and Mitigating the Effects of Fire and Explosions, OSHA SHIB 73105; Combustible dust: Identifying, addressing explo-sion risks can save lives, by Tony Supine and Mike Walters, Plant Engineering, June 2012; Dust explo-sions-Cases, causes, consequences, and control, Tasneem Abbasi, S.A; Published dissertation November 2006 http://www.aseanenviron-ment.info/Abstract/41014595.pdf

[2] Understanding the Hazard, FM Global; P0108, 9/2003; http://osbie.on.ca/help/pdf/P0108_Eng.pdf; Combustible Dust: Safety and Injury Prevention, Awareness Training Program,

[3] Modern Dust Explosion Protection of Men and Machines,

The average downtime

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the need to clean the

entire production line.

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http://www.bulk-solids handling.com/safety_environment/explo-sion_protection_fire_protection/articles/262074/

[4] Combustible Dust National Emphasis Program, OSHA Directive CPL 03-00-008, 3/11/2008. http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=directives&p_id=3830

[5] Hazardous Communication Guidance for Combustible Dusts, US DOL, Occupational Safety and Health Administration, OSHA 3371-08, 2009, p.9.

[6] National Fire Protection Association standards: NFPA 654,2013.

[7] National Fire Protection Association standards: NFPA 654, 2013.

[8] National Fire Protection Association standards: NFPA 120, 2010.

[9] National Fire Protection Association standards: NFPA 654, 2013.

[10] “Industrial Ventilation: A Manual of recommended Practices”, ACGIH, 28th edition, 2013

[11] “A Brief History of Dust Explosions” Verakis, Harry C; Nagy, John J, in Industrial Dust Explosions, ASTM STP 958. Kenneth L. Cashdollar and Martin Hertzberg, eds. American Society for Testing and Materials, Philadelphia, 1987, p 342.

[12] The Future of Explosion Protection; www.bulk-solids han-dling.com/safety_environment/

explosion_protection_fire_protection/articles/360386/index2.htm

[13] Ralph Foiles, To Vent or Not to Vent, Chemical Engineering, 2004, www.processprotection.net/pdf/2.pdf

[14] Bill Stevenson, Confection Manufacturer Analyzes Dust

Explosions, Association for Facilities Engineering, September/October 2003.

[15] National Fire Protection Association standards: NFPA 654, 2013 edition; NFPA 61, 2013;NFPA 68, 2007; NFPA 69, 2008.

See also:Ergun, Emre: Explosion Protection

System Selection, Chemical Processing Powder e Handbook, 2012.

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