Journal of Loss Prevention in The Process Industries最新文献

{"title":"Calibration and sensitivity analysis of under-expanded hydrogen jet CFD simulation based on surrogate modeling","authors":"Xiaoyang Luan ,&nbsp;Bin Zhang ,&nbsp;Michael Short ,&nbsp;Tao Chen","doi":"10.1016/j.jlp.2024.105535","DOIUrl":"10.1016/j.jlp.2024.105535","url":null,"abstract":"<div><div>Accidental leaks from high-pressure hydrogen storage containers can lead to under-expanded jet flows, posing risks of fires or explosions. Practitioners traditionally harness Computational Fluid Dynamics (CFD) software to assess the hazards of such hydrogen releases. The Reynolds-Averaged Navier-Stokes (RANS) equations, often chosen by their efficiency and reliability and significantly influences CFD results. However, the closure coefficients within RANS harbor uncertainties. These coefficients, often defaulting to values ascertained from foundational flow experiments, may not generalize across diverse flow contexts, especially for intricate flow challenges like under-expanded hydrogen jets with high velocities and pressures. This study employs surrogate modelling to recalibrate these closure coefficients for CFD simulations of under-expanded hydrogen jets. Sensitivity analysis with Sobol indices quantifies their impact. The recalibration resulted in significantly improved accuracy, compared to their default values, of the CFD against literature reported experimental data. The results can enhance safety assessments and measures for hydrogen applications.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105535"},"PeriodicalIF":3.6,"publicationDate":"2024-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166856","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The characteristics and mechanism of core-shell structure fly ash/KH2PO4 composite inhibitor in suppressing coal dust explosions","authors":"Zhenbao Li ,&nbsp;Weichen Zhao ,&nbsp;Chao Li ,&nbsp;Zichen Fan ,&nbsp;Mingneng Chen ,&nbsp;Liang Xian","doi":"10.1016/j.jlp.2024.105533","DOIUrl":"10.1016/j.jlp.2024.105533","url":null,"abstract":"<div><div>Coal dust is highly susceptible to explosions when exposed to an ignition source, leading to significant casualties and property damage. To develop a more effective coal dust suppressant, a composite inhibitor consisting of fly ash (FA) and KH₂PO₄ was prepared using a planetary ball mill. The suppression characteristics of the FA/KH₂PO₄ composite were investigated using a 20 L spherical explosion test system and FTIR analysis. Kinetic modeling of the FA/KH₂PO₄ inhibition of explosions was performed in conjunction with Chemkin software. The results indicated that a 1:1 ratio of FA to KH₂PO₄ provided optimal suppression. At a dosage of 55 wt%, complete suppression was achieved. The FA/KH₂PO₄ composite inhibited the oxidation of coal by reducing the reaction rate of radicals originating from the preheating zone. KH₂PO₄ suppresses explosions by capturing active radicals and inhibiting the formation of key functional groups, while FA contributes to suppression through the creation of physical barriers and radical adsorption. This combination exhibits a synergistic effect in suppressing coal dust explosions.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105533"},"PeriodicalIF":3.6,"publicationDate":"2024-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166468","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The explosion characteristics investigations of novel biofuel-propyl acetate","authors":"Hongtao Wang ,&nbsp;Tingting Bao ,&nbsp;Jiaqing Ding ,&nbsp;Cangsu Xu ,&nbsp;Xiaolu Li ,&nbsp;Francis Oppong","doi":"10.1016/j.jlp.2024.105534","DOIUrl":"10.1016/j.jlp.2024.105534","url":null,"abstract":"<div><div>Propyl acetate can used as fuel in many industries and transportation and it is important to understand its explosivity. This work examined the explosion of propyl acetate for different equivalence ratios at pressures of 1–4 bar and temperatures of 390–450 K. According to the study, the adiabatic flame temperature of propyl acetate in lean and extremely rich mixtures was unaffected by the initial pressure, but in slightly rich mixtures and at the equivalence ratio of 1.0, it was slightly affected. As the initial temperature and equivalence ratio increased, the adiabatic flame increased. The initial temperature insignificantly influenced the maximum rate of pressure rise, the highest rate of heat produced, and the severity index but substantially affected the highest explosion pressure. In contrast, the explosion's highest pressure, maximum rate of pressure rise, highest rate of heat released, and severity index all increased as the initial pressure and equivalence ratio increased. However, the experimentally measured severity index results (&lt;200 bar-m/s) showed that protection against the explosion of propyl acetate/air mixtures would be practical and effective. The information from this study is appropriate for developing a basic theoretical framework of propyl acetate explosivity.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105534"},"PeriodicalIF":3.6,"publicationDate":"2024-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166497","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experiments and simulations of large scale hydrogen-nitrogen-air gas explosions for nuclear and hydrogen safety applications","authors":"M. Lucas ,&nbsp;N. Salaün ,&nbsp;G. Atanga ,&nbsp;B. Wilkins ,&nbsp;S. Martin-Barbaz","doi":"10.1016/j.jlp.2024.105531","DOIUrl":"10.1016/j.jlp.2024.105531","url":null,"abstract":"<div><div>Hydrogen safety is a general concern because of the high reactivity of hydrogen compared to hydrocarbon-based fuels. The strength of knowledge in risk assessments related to the physical phenomena and the ability of models to predict the consequence of accidental releases is a key aspect for the safe implementation of new technologies. Nuclear safety considers the possibility of accidental leakages of hydrogen gas and subsequent explosion events in risk analysis. In many configurations, the considered gaseous streams involve a large fraction of nitrogen gas mixed with hydrogen. This work presents the results of an extensive large scale explosion experimental campaign for hydrogen-nitrogen-air mixtures. The experiments were performed in a 50 m³ vessel at Gexcon's test site in Bergen, Norway. Covering a nitrogen fraction range from 0 vol% to 80 vol%, equivalence ratio range from 0.8 to 1.3 and exploring four distinct congestion levels, this research provides comprehensive insights into the complex interplay of variables influencing explosion behaviours in such mixtures. The experiments are simulated in the FLACS-CFD software to inform about the current level of conservatism of the predictions for engineering application purposes. The study shows the reduced overpressure with nitrogen added to hydrogen mixtures and supports the use of FLACS-CFD-based risk analysis for hydrogen-nitrogen scenarios.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105531"},"PeriodicalIF":3.6,"publicationDate":"2024-12-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Consequence analysis of accidental gas leak from storage tank group using LES method","authors":"Guangwei Zhang ,&nbsp;Ziying An ,&nbsp;Xiaoping Liu ,&nbsp;Xiaoping Li","doi":"10.1016/j.jlp.2024.105529","DOIUrl":"10.1016/j.jlp.2024.105529","url":null,"abstract":"<div><div>Hazardous clouds and toxic zones resulting from gas leaks from storage tanks in chemical plants present immediate threats to environmental health and industrial process safety. However, the fluctuation characteristics and fluctuation-induced consequence variations received limited attention. This study employed the large-eddy simulation (LES) to address the time-averaged and dynamic characteristics of consequences associated with gas leaks from a tank group, focusing on the impacts of leak locations and wind directions. Four metrics were introduced to quantify consequences: volumes of flammable and toxic gas clouds (V_F, V_T), toxic zone area (A_T) and toxic dose for population (TD). The results indicated that the Reynolds-averaged Navier–Stokes model (RANS) markedly overestimated the mean values of these metrics compared to LES, with the prediction of AT even increased by 147.5%. The leeward leak from the rear-row tank presented the highest mean and peak values. Both the peak and mean values were generally higher when the wind direction (<span><math><mrow><mi>θ</mi></mrow></math></span>) was 0°, except for TD. Moreover, AT and TD were significantly impacted by pulsating flow, with fluctuation-induced components generally reaching 30%–40%. When <span><math><mrow><mi>θ</mi><mo>≤</mo><mrow><mn>0</mn><mo>°</mo></mrow></mrow></math></span>, A_T was primarily influenced by pulsating flow rather than mean flow. The results provide guidance for the design of chemical industrial parks, ensuring the industrial processes safety and refining emergency response strategies.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105529"},"PeriodicalIF":3.6,"publicationDate":"2024-12-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166465","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental investigation of dust explosions with a focus on black mass in battery recycling","authors":"Chen Huang ,&nbsp;Andrei N. Lipatnikov ,&nbsp;Cecilia Lövström ,&nbsp;Nijaz Smajovic ,&nbsp;Leena Andersson ,&nbsp;Abdelrahman Ismail","doi":"10.1016/j.jlp.2024.105526","DOIUrl":"10.1016/j.jlp.2024.105526","url":null,"abstract":"<div><div>The number of batteries in various applications at end-of-life and production waste from battery gigafactories increase significantly. At the same time, new EU regulations are introduced to promote battery recycling, which is a new and rapidly growing business. Large amounts of combustible dust are generated in battery recycling. Managing combustible dust hazards at the battery recycling plants is one of the key factors to minimize the incidents and down time and, therefore, to improve the work environment, and to increase the profitability of the business. Accordingly, the present work aims at exploring the risk of explosion of black mass dusts associated with battery recycling. Specifically, four black mass samples from different battery recycling plants are experimentally investigated. Microscope images, particle size distribution, water content and organic carbonates are analyzed. Dust explosion experiments are performed in a 20-L vessel. Parameters including dust concentration, ignition energy, ignition delay, dust injection pressure are varied. Results show that a 10 kJ ignition energy cannot generate high explosion overpressure, whereas an ignition energy of 20 kJ yields an explosion overpressure above 6 bar for black mass sample C at a concentration of 300 g/m³. The obtained experimental results are compared with published data on various explosion-related characteristics of other dusts relevant to battery recycling, in particular, aluminum and graphite dusts.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105526"},"PeriodicalIF":3.6,"publicationDate":"2024-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166463","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"How to realize the knowledge reuse and sharing from accident reports? A knowledge-driven modeling method combining ontology and deep learning","authors":"Nannan Xue,&nbsp;Wei Zhang,&nbsp;Huayu Zhong,&nbsp;Wenbin Liao,&nbsp;Tingsheng Zhao","doi":"10.1016/j.jlp.2024.105525","DOIUrl":"10.1016/j.jlp.2024.105525","url":null,"abstract":"<div><div>The exploration and understanding of past accidents are of great significance in enhancing the process safety. However, manually reading and analyzing a large number of accident reports is a time-consuming and inefficient task. In this study, a novel modeling method is developed to build the knowledge graph of process safety accidents, aiming to overcome the problem of knowledge reuse and sharing. Firstly, the dataset consists of 409 process safety accident reports selected from the official website of the Ministry of Emergency Management of China. Secondly, the ontology design schema is defined based on the seven-step method, including 34 ontology classes and 11 relations. Then, a new joint extraction model for the process domain is proposed based on the CasRel framework, which achieves 95.85% in precision, 61.54% in recall, and 74.95% in F₁-score. Finally, the knowledge graph containing 9192 nodes and 11,257 edges is constructed in the Neo4j graph database, followed by the discussion of various related applications such as query, statistics, and analysis. The results indicate that the proposed method is a useful tool for obtaining valuable knowledge from accident reports, contributing to analysis and prevention of accidents.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105525"},"PeriodicalIF":3.6,"publicationDate":"2024-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166467","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Simplifying standards, opening restrictions part II: The significance of the ignition source on the safety characteristics of dusts in the 20 L-sphere","authors":"Bretislav Janovsky ,&nbsp;Stefan H. Spitzer ,&nbsp;Jan Karl ,&nbsp;Prokop Janovsky","doi":"10.1016/j.jlp.2024.105524","DOIUrl":"10.1016/j.jlp.2024.105524","url":null,"abstract":"<div><div>The ignition behavior of chemical ignitors has been increasingly discussed in conjunction with their influence on the safety characteristics of the dust and hybrid mixture determined in the 20 L-sphere. Specifically, the turbulence generated by the ignitors and/or preconditioning of the system by a large and hot fireball. The effect of the explosion pressure generated by the chemical ignitors is included in the standards by means of the so-called pressure ratio (<em>PR</em>) (ASTM E1226 – 19, 2019; ASTM E1515-14, 2022) or the corrected explosion overpressure <em>p</em>_<em>m</em> (ASTM E1226 – 19, 2019; EN 14034-1, 2011). The overpressure caused by the ignitors should also be subtracted when the dusts are tested on their explosibility (ISO 80079 -20-2,; EN 14034-3, 2011; EN 14034-4, 2011).</div><div>The aim of the presented work is to show the weaknesses of the standards in the case of calculation of the corrected overpressure <em>p</em>_<em>m</em> and the pressure ratio <em>PR</em> with respect to the chemical ignitors′ explosion overpressure measured in the 20 L-sphere. Measurements of the explosion overpressure of the sole ignitors in the air are presented together with the influence of the dust concentration on the explosion pressures of the ignitors. Talc dust, Lycopodium Clavatum dust and their mixture (80 % by mass of talc and 20 % by mass of Lycopodium) were used for tests in air and nitrogen. The differences in the measured explosion pressures generated by the ignitors in the calculations of the pressure ratio <em>PR</em> and the corrected overpressure <em>p</em>_<em>m</em> were compared with calculations using the ignitors explosion overpressure calculated according to equations given by the Standards are shown. The ignition criteria given by three different standards were used as an example of ignition evaluation from the real explosion curves with different ignitors overpressures. The importance of the measurements of the real overpressures caused by the ignitors is also shown.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105524"},"PeriodicalIF":3.6,"publicationDate":"2024-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166348","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dust explosion risk in polymer powder processing: Review and testing","authors":"Luca Marmo ,&nbsp;Maria Portarapillo ,&nbsp;Almerinda Di Benedetto ,&nbsp;Roberto Sanchirico ,&nbsp;Enrico Danzi","doi":"10.1016/j.jlp.2024.105528","DOIUrl":"10.1016/j.jlp.2024.105528","url":null,"abstract":"<div><div>The plastics industry, a global giant employing over 1.5 million people in Europe, faces a formidable challenge. Almost all plastic is combustible, and generating fine particles during processing (such as mechanical operations or recycling) can cause a potential explosion hazard. There is a wealth of literature on polymer powders in their 'pure' form, exploring the basic principles of dust explosions or measuring the effectiveness of inert dust in suppressing or preventing explosions. However, despite their frequent presence in the industry, there is a significant gap in research on polymer powder mixture, and actual industrial samples conditions. Which needs to be investigated urgently. The paper overviews relevant polymer dust explosions and accident dynamics and includes experimental testing and results. Statistical data on polymer dust explosions worldwide were examined to obtain a detailed picture of the materials involved and the severity of the explosion in terms of immediate damage and interruption of operations, furtherly, discussing lessons learned concerning dust explosion risks. Finally the experimental results presented here showed that more than 90% of the samples were combustible according to ISO 80079 and should therefore be considered “explosive.” Polyolefins have more severe explosive properties (regarding maximum explosion pressure and K_St) than more complex molecules (resins or polyesters). The highest value was shown by a mixture of PS/PPE dust collected in a recycling plant. These results revealed information on the likely synergistic effect of some polymers in a mix and the potential hazard that may affect different plastics industry sectors.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105528"},"PeriodicalIF":3.6,"publicationDate":"2024-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166470","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effective alarm management to improve safety using a data-driven approach based on Bayesian networks","authors":"Guozheng Song ,&nbsp;Xinhong Li ,&nbsp;Xiaopeng Li","doi":"10.1016/j.jlp.2024.105530","DOIUrl":"10.1016/j.jlp.2024.105530","url":null,"abstract":"<div><div>Proper fault management is important for safe operations in the process industry. Since a critical alarm can have multiple potential fault modes, the diagnosis of a fault may not serve its intended purpose. Incorrect diagnosis of a fault in a critical system may cause severe consequences. It is, therefore, important to detect and diagnose faults and characterize their priority considering the risk of potentially unsafe scenarios. Risk-based fault diagnosis and prioritization help minimize ignorance of the critical fault and, most importantly, enhance safety. This study presents a data-driven methodology applying Bayesian network (BN) to decide the management priority of faults from a risk perspective. The parameters of the process model are learned from operational data to increase model feasibility and reduce input uncertainty. The challenge of incomplete data is handled using the expectation-maximization (EM) algorithm. The methodology and model are explained using an accidental oil leak in a processing facility. The assessment results reveal that compared to the previous methods, the proposed approach can avoid the oversight and neglect of a critical fault such as an oil leak, and thus prevent large amounts of oil loss.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"94 ","pages":"Article 105530"},"PeriodicalIF":3.6,"publicationDate":"2024-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143166344","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}