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1 Explosion hazard and electrostatic charging

When does an explosion hazard arize?

COPY from Swiss Safety Institute


1 Explosion hazard and electrostatic charging

An explosion hazard arizes when:

•when flammable gases, liquids or powders


are stored, processed, produced in a plant

•and gases, vapors, mists or dusts are present


as amixture with air (explosive mixtue).

•An explosive mixture is present when flamm-


able gases, vapors, mists or dusts are present
in such quantities in air that spontaneous flame
propagation (explosion) occurs after ignition.
1 Explosion hazard and electrostatic charging

When does an explosion occur?


1 Explosion hazard and electrostatic charging

An explosion requires the simultaneous presence


at the same location of

Fuel or flammable material


(gas, vapor, mist or dust)

Effective Efficiently mix with


ignition source oxygen (usually air)
Powder Explosion

• Combustable material
• Fine dispersion (< 500 microns) , conc.
> lel
• Oxygen (from air...)
• Effective ignition source
1 Explosion hazard and electrostatic charging

What are effective ignition sources?

• Hot surfaces
• fires
• flames
• smoldering material
• mechanical and electric
generated sparks
• discharges of static electricity

Ignition sources differ according to (among other things) their energy content.
The explosive mixtures also exhibit different ignition sensivities.
Not every ignition source has sufficient energy to ignite all types of explosive
mixtures.
In other words, not every ignition source is incendive in a given situation, it is
usually necessary to investigate the ignition sources in detail to assess the
ignition hazard in conjunction with the explosive mixtures.
1 Explosion hazard and electrostatic charging

When does an electric charge become an ignition hazard?

An electrostatic charge by itself


does not necessarily represent
an ignition hazard.
Such a hazard exists only when
the charge is so high that discharges
occur owing to the elecric filed.
1 Explosion hazard and electrostatic charging

How does a discharge of static electricity occur?

If the carge continues to accumulate


because of charges formed in the
separation processes cannot flow to
ground quickly enough,

a discharge will occur

when the breakdown field strength


is reached.
1 Explosion hazard and electrostatic charging

Charge separation
separation processes usually between
product and plant units to charging of the
surfaces in contact.

Charge accumulation
Charges can accumulate for example on
products, plant units, packaging, containers
and persons.

Charge dissipation
If a connection of sufficient conductivity is
established between ground and the sites of
the accumulated charge, the charge can
safely flow to ground.
1 Explosion hazard and electrostatic charging

Basic scheme of electrostatics

Schematic representation of the steps:

• charge separation

• charge accumulation

• charge dissipation
1 Explosion hazard and electrostatic charging

Basic scheme of electrostatics

Schematic representation of the steps:

• charge separation

• charge accumulation

• charge dissipation

• Ignition
2 Origin of electrostatic charges (charge separation)

What is a separation process?

Every process in which surfaces in contact with


each other (even if only briefly) are separated
is known as a separation process.
2 Origin of electrostatic charges (charge separation)

Typical separation processes:

Pouring bulk material Flow of a liquid through a


out of a bag or pipeline
container

a person walking on
a floor unrolling of a film

atomizing or the impact of dust particles


spraying of a liquid on the wall of a separator
2 Origin of electrostatic charges (charge separation)

When is a substance insulating (nonconductive)?

The insulating properties


of solids, bulk material and
liquids are determined by
measurement of the electric
resistance.

• Typical insulating solids are


plastics (PE, PVC, PTFE).
Note particularly that dry
organic powders can be
insulating.
•Typical insulating liquids
include Hydrocarbons such as
benzene, heptane, toluene,
xylene.

An electric charge must always be anticipated in separation processes


if one of the contact surfaces is electrically insulating.
2 Origin of electrostatic charges (charge separation)

Do other charging mechanisms exist in addition to


separation processes?

Induction:

It is a phenomenon which
is characterized by the
ability of charges on a
conductive surface to be
moved by the effect of
charges on a neighboring
surface (electric field) so
that charging results.

Notgrounded metal parts and persons can also be charged


by electric induction phenomena.
2 Origin of electrostatic charges (charge separation)

Where can charges accumulate?

Examples:
Pipe section • on conductive parts eletrically
with insulating insulated from ground
seals
• on surfaces of insulating
metal drum on materials and parts
insulating support
•in insulating liquids, suspensions
metal turnings in and emulsions
plastic container
• on deposits of insulating bulk
materials
person with
insulating shoes • in clouds of charged dust
particles or droplets
metal flange on
glass pipe
2 Origin of electrostatic charges (charge separation)

Examples of a charge accumulation on the surface of


insulating materials or products

Shrink film Plastic suction


device

Nonconductive Insulating bulk


filter bag material
2 Origin of electrostatic charges (charge separation)

When are charges dissipated?

...when the charged object is electrostatically conductive and


grounded.
2 Origin of electrostatic charges (charge separation)

What measured quantities are used for the


assessment of electrostatic conductivity ?

The electrical resistance is decisive:

Resistivity: Surface resistance


= material specific = charge dissipation
resisitance of a solid, from a surface of a
liquid, bulked powder solid
(material constant)

conductivity= 1/ resist.

ground leakage
Volume resistance: resisitance:
= total resistance = total resistance
between 2 points between a point
of an object and ground
(Non-) conductive Liquids
Ohm*m
CS2 1016
Hexan 1015
Diesel Oil 1013
Toluene 1013

Chloroforme 108
Methanole 106
Acetic Acid 105
Nitrobenzene 104
Glycol 103
Powder Resistivity
Combustable powder ohm*m

Additive 1012-1014
PE 108-1010

Dry wood ca. 5*109

Sugar > 109


Stilbenic Brighteners 108-1010

Metals 10-5-10-8

Powders are highly isolating: >1010 Ohm*m


2 Origin of electrostatic charges (charge separation)

Are there safe limits for the different types of resistance?

Limit values of the resistance required for hazard-free charge dissipation


depend on the type of resistance (resistivity, surface restitance...).
Different national guidelines may specify limits.
The following standard values have proved their worth in practice.

Grounding of a Grounding of
person: plant units:

resistance leakage resitance


< 108 ohms to ground
< 106 ohms
4. Types of discharge and incendivity

What is the breakdown field strength ?


If the electric field becomes very powerful as a result of high charge density ,
a discharge occurs when the breakdown field strength is reached.
To assess the incendivity (ignition effectivness) of a discharge, the energy
released inthe discharge process is decisive.

Charges can be classified into different types which can be assigned various
energy values.

Relationship between charge


density and field strength:
the higher the charge density,
the higher the field strength
(= length od arrows)
4. Types of discharge and incendivity

When does a discharge occur?

...when the electric field reaches


the breakdown field strength as a
result of a high space or surface
charge density (charge accumu-
lation).

High field strength --> discharge


4. Types of discharge and incendivity

How incendive is a discharge?


Depending on the operational situation, discharges with different energy
can occur. Their incendivity is determined by the amount of energy released.

A separation process and


charging
B spark discharge
C complete charge dissipation

A‘ separation process and


charging
B‘ brush discharge
C‘ locally restricted charge
dissipation
4. Types of discharge and incendivity

What is the minimum ignition energy?

The ignition sensivity of a substance


with regard to ist ignition by discharges
is determined by the minimum ignition
energy of the explosive mixture in
question.

The MIE is the lowest energy in the form


of a capacitor discharge needed to just
ignite the mixture of a combustable
material and air under standard
conditions.
Minimum Ignition Energy of
Gases/Vapors
Gas MIE (mJ)
CS2 0,015
Hydrogen 0,009
Methane 0,47
Propane 0,30
Ethylen 0,096
Acetylene 0,02
Methanole 0,215
Acetone 1,15
Ethylamine 2,40
Ammonia 14
MIE of Combustable Solids
MIE (mJ)
Cellulose 100
Epoxi resin 3
Bisphenol A 1
Sulfur <<1
Aluminium <1
4. Types of discharge and incendivity

What types of discharges are kown?

• Spark discharge
• brush discharge
• corona
• propagating brush discharge
• cone discharge
• lightning-like discharge
4. Types of discharge and incendivity

What ia a spark discharge ?

It is a discharge between two conductive objects at different potentials.


It occurs when the electric field in the space between the two con-
ductive objects reaches the breakdown field strength.
4. Types of discharge and incendivity

When do spark discharges occur in industrial practice ?

...when ungrounded conductive objects


(plant units, metal drums, products,
persons) are charged and when a
suitable spark gap is present.

This is the case, for instance, if a


conductive grounded object is in the
vicinity and the breakdown field strength
in the intervening space is exceeded.
4. Types of discharge and incendivity

How incendive are spark discharges ?


Capacitance potential energy
Charged object (pF) (kV) (mJ)

Flange 10 10 0,5

small container (50l) 50 8 2

person 150 12 11

metal drum (200 l) 200 20 40

In a spark discharge practically the entire energy is discharged.

W = 1/2 C * U2

Spark discharges must therefore always be regarded as incendive for


explosive gas/air, vapor/air and dust/air mixtures.
4. Types of discharge and incendivity

How can sparks discharges be avoided ?

By grounding all conductive


objects,

such as plant units, drums,


products...
4. Types of discharge and incendivity

What is a brush duscharge ?

Brush discharges occur when a conductive, grounded and curved object


(electrode with radius between 5-50 mm) is exposed to a high electric field.
The discharge is propagated from the site of the greatest curvature (highest
field strength) into the intervening space as a bright discharge channel changing
into fine branches,
When do brush discharges occur in industrial practice ?

Appoach of a con- Addition of a nonconductive


ductive electrode liquid at a high rate to a
such as a tool or tank and the approach of
finger tip to a highly the charged liquid surface
charged insulator to internal conductive,
surface. grounded fittings:
Emptying solids out •lowering of sampling can
of plastic bag in the •lowering of a probe
vicinity of metal
fittings.. the projection of flagpoles,
antennae, ship masts...
Addition of insulating Into high atmoshpheric
powdered product to fields (St. Elmos fire during
drums, vessels, silo. thunderstorm)

Lowering of a conductive
grounded sampling can
or level probe
How can brush discharges be avaided ?

By eliminating high electric fields through the use of conductive materials


and grounding them, limiting the surface of nonconducting objects, or
using shielding measures.
What is a corona discharge ?

It can be regarded as a special case of the brush discharge.

If the radius of curvature of the grounded electrode introduced into a


high electric field is very small (< 1mm), the field will only be disturbed
in the immediate vicinity of the tip. This gives rise of a very weak discharge
restricted to the neighborhood of the tip.
What is a propagating brush discharge ?

It is a discharge along the surface of a thin insulating or dieelectric layer,


very highly charged on both sides with opposite polarity.
The dielectric layer may be in the form of a separate sheet, or a coating
on a metal surface.
How do propagating brush discharges occur ?
For propag. brush discharges processes with high separation rates together
with insulating materials of high dielectric strength (high breakdown strength)
are needed.
Dust conveyed pneu-
matically at a high rate Continuous impingement
through an insulating of fresh dust particles on
pipeline or pipeline with an insulator surface.
an inner coating.

When insulating liquids


are being conveyed at
a high rate through an
insulating pipeline or When rapidly circulating
cond. Pipeline with conveyer belts or drive
inner coating. belts are either insulating
When large drums, silos or coated on one side with
are being filled with conductive material.
highly charged insul. Powders.
How incendive are propagating brush discharges ?

In a propagating brush discharge, a large part of the total stored energy is


released. The stored energy can be calculated by assuming mathematical
correlation with a plate capacitor.

Even for charged areas of 0,1 m2 the energy can amount to several joules.

Where there are explosive mixtures of gas, solvent vapor or dust with air,
ignition by propagating brush discharges must be expected.
How can propagating brush discharges be avoided ?

...by the use of conductive materials,


or materials of low dielectric strength.

Insulating layers (coatings) with a


breakdown voltage of less than
4 kV can be used. No prop. Brush
discharges will occur in such layers.
Are there other possible types of discharges ?

When filling large silos and containers


with highly insulating bulk materials,
isolated discharges at the bulked
material surface, so-called cone
discharges, have been observed.

Special knowledge is required to


assess the formation and incendivity
of these discharges.
Measures against ignition hazards resulting from electrostatic charging

Goal Measures
Keep charging rate low by restricting all separation and
Avoidance conveying rates, assist non-hazardous charge dissipation by
of high charges use of conductive materials and grounding.
Neutralize charges by use of active or passive ionizers.
Avoidance
of incendive Assess incendivity of the possible discharges and the ignition
discharges sensitivity of the possible explosive mixtures.
Exclusion of incendive discharges.
Avoidance Avoid explosible concentrations of flammable material, lower
of explosion the oxygen content (inerting).
atmosphere

Restriction
of explosion Constructional explosion protection, e.g. explosion venting,
effects to a explosion suppression.
tolerable level
Examples illustrating the avoidance of high charges in practice.

With nonconductive liquids


increase conductivity by
addition of additive, or restrict
flow rate.

Insulating solid surfaces:

charge neutralization.
Transfer of chargeable liquids through pipelines and hoses

•The tube/hose must be completely filled


•Keep the liquid pure
•Velocities must be kept low

- for chargeable esters : max. 10 m/s


- for gasoline, toluene...depending on diameter
40 mm = 7 m/s
50 mm = 6 m/s
100 mm = 3 m/s

- suspensions (crystals in nonconductive liquids) : max. 1 m/s


- CS2 : 1m/s
- hoses : in general max. 1 m/s
exception: hoses of conductive material or
non-conductive with embedded fine wire mesh (connected
conductively to metal flanges etc.
Protection Measures

Transfer of flammable liquids:

use only conductive containers


and ground.

When filling combustable dusts,


all conductive parts must be
grounded.
Small plastic containers such as
bags, bulk containers and
drums are permissible in the
ansence of flammable gases
or vapors.
Protection measures
Avoidance of
explosive atmosphere
by ventilation.

Preventive Constructive explosion


explosion protection:
protection:

inerting Explosion suppression


Examples illustrating the formation of high charges in practice

Flow of non- Transfer of a


conductive nonconductive
liquid through liquid
a pipe (metal,
glass, plastic)

Stirring of a
nonconductive Spraying of a
liquid liquid (conductive
or nonconductive)
Increasing the charging of a liquid by admixture of nonconductive solids
(suspensions)

Pure liquid

Suspension:
high charge
Gas flow (separation process)

Flow of pure air:


no charge

Flow of contaminated
air:
charging of the dust
particles
Formation of charges through friction.
Examples of measures in the handling of flammable liquids in practice:
Examples of measures in the handling of flammable liquids in practice:
Inerting of a centrifuge as an example of an explosion protection measure in
the handling of suspensions and emulsions of flammable liquids.
Examples of measures in handling of combustable dusts in practice:

Grounding of all
Grounding of
conductive plant
all conductive
units
containers,
bulk bags

Explosion Grounding of
suppression persons when
as construct. handling bulk
Explos. Prot. materials very
sensitive to
ignition.
Measures in pneumatic transport of combustable dusts:
grounding of all conductive parts and use of an inner coating with max.
4 kV breakdown voltage.

Nonconductive bulk materials


containing solvent must be
handled only under inert
conditions.
Closed filling of an inerted paddle dryer as a practical example of an
explosion protection measure in the handling of bulk material moist
with solvent

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