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Proceedings of ASME Turbo Expo 2012

GT2012
June 11-15, 2012, Copenhagen, Denmark

GT2012-69536

FLAMABILITY OF HIGH FLASH POINT LIQUID FUELS

Peter J Kay, Andrew P. Crayford, Philip J. James Luxford


Bowen RWE npower
GTRC, Institute of Energy Swindon, Wiltshire, SN5 6PB, United Kingdom
Cardiff University, Cardiff, CF24 3TA, United
Kingdom

ABSTRACT Gas oil (flash point > 61 °C) ignited as a free jet at a
Current European Health and Safety Legislation was working pressure consistent with previous hypotheses.
implemented to limit the chance of a serious explosion However, when the jet impinged on a solid surface then the
occurring in the workplace by highlighting potentially resulting spray could be ignited at considerably lower delivery
explosive atmospheres and ensuring that ignition sources are pressures. Although the impingement process is complex, the
not present in these areas. Though hazardous area data will be discussed in light of contemporary models that
classification for gaseous and dust explosion hazards are well predict initial jet/spray characteristics along with post-
established, the same cannot be said for mists especially for impingement characteristics. This paper presents a first step
high flash point liquids. However, a recent literature review of towards consolidating previous studies and improving future
a range of (some fatal) incidents has shown that mist safety guidelines concerned with the risk posed by the
explosions are more common and the consequences more flammability of accidental releases of pressurised high
severe than previously anticipated. This work is, for example, flashpoint fuels.
applicable to the safe use of fuels and lubricants utilised in the
gas turbine power generation and propulsion industries. NOMENCLATURE
Previous studies of jet breakup regimes and idealised Symbol
flammability studies have indicated that low pressure releases Bst Spalding Transfer Number
(<10 bar) of low volatility fuels may still give rise to cp Specific Heat Capacity
combustion hazards. Impingement of accidental releases onto D Droplet Diameter
surfaces has been shown to exacerbate the potential hazard, or d Nozzle Diameter
broaden the range of hazardous release conditions. However, L Length of Nozzle
although a theoretical case can be made for generating La Laplace Number
flammable environments under moderate release conditions, Re Reynolds Number
very little evidence has been provided to bridge the gap Tst Flame Temperature
between ‘idealised’ studies and full-scale incidents. The aim of We Weber Number
this first programme of work is to start the process of bridging μ Viscosity
this gap, leading to well founded safety guidance. ρ Density
The test programme was conducted in a custom built σ Surface Tension
spray chamber located in the Gas Turbine Research Centre φ Equivalence Ratio
(GTRC) of Cardiff University. The fuel was released at a pre- Subscript
defined range of pressures of industrial relevance at a Air
atmospheric temperature. Igniters were positioned at three d Droplet
downstream locations and the continuous electrical discharge f Fuel
had an energy no greater than 4 mJ. Tests were conducted for l Liquid
‘free sprays’ where the spray was directed along the length of min Minimum
the chamber, and for impinging sprays where the spray was o Orifice
aligned to impinge normal to a flat un-heated surface. st Stoichiometric

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Water,stp Water at Standard Temperature and Pressure explosive mist atmosphere is important and can have a
Acronyms quantifiable impact.
ASR Atmospheric Spray Rig There is a significant amount of literature published
LFL Lower Flammability Limit examining the MIE of mists, atomization of liquid jets and
MIE Minimum Ignition Energy jet/spray impingement phenomena. For example the MIE for
SMD Sauter Mean Diameter various fuels has been studied in great detail under controlled
SWP Safe Working Pressure conditions (Bane et al, 2011; Shepard et al, 1990). Much
UFL Upper Flammability Limit literature has been published on the atomisation of sprays and
their related phenomena (Lefebvre, 1989). Also there are well
INTRODUCTION established models related to the impingement of drops and
The European ATEX directives (99/92/EC and 94/9/EC) which sprays on surfaces (Bai, et al, 2002; Mundo, et al, 1998).
are implemented in the UK under the Dangerous Substances This paper aims to begin to address the issues raised
and Explosive Atmospheres Regulations (DSEAR) 2002 and by the lack of guidance in the regulations – particularly for
the Equipment and Protective Systems Intended for Use in high flashpoint, involatile fuels - by developing knowledge of
Potentially Explosive Atmospheres Regulations 1996 (EPS spray/mist ignition for practical applications through an
Regulations) require employers to classify into zones areas experimental programme based on initial conditions pertinent
where explosion hazards may occur and utilise suitably to industry. The results generated are the complex combination
designed equipment within these zones accordingly limit the of the mechanisms governing spray formation, spray
chance of an accidental ignition. Though hazardous area impingement and spray ignition. However, the results observed
classification for gases and dust explosion hazards are well will be analysed and discussed in light of models published.
established (Eckhoff, 2006), the same cannot be said for mists Potentially flammable mists can be formed in a number of
especially for high flash point liquids, as first highlighted by ways – firstly mists can be created due to atomisation of liquid
Bowen and Shirvill (Bowen et al., 1994). jets. The simplest example is the break-up of a liquid jet from a
Very little progress has been made since this first plain orifice. A jet is formed as the pressurised fluid is forced
notification (Bowen, 2011), though a recent literature review though the exit orifice, the jet is ejected with a velocity
(Santon, 2009) of a range of incidents has shown that mist proportional to the upstream pressure. Small instabilities in the
explosions are more common and the consequences more jet form and grow until, at some distance downstream, the jet
severe than previously anticipated. The study identified 37 breaks up forming a spray and if confined – a mist.
incidents including 20 explosions, of which nine were Alternatively the jet, or spray, may impinge on a solid surface
collectively responsible for a total of 29 fatalities. and due to the fluid dynamics splash on the surface undergoing
For flammable gas hazards, the classification of hazardous further atomisation creating a finer mist (Maragkos et al,
areas into zones is based on an assessment of the frequency of 2002).
the occurrence and duration of the explosive atmosphere, as
follows: EXPERIMENTAL FACILITIES
• Zone 0: An area in which an explosive gas The experiments were conducted in the Atmospheric Spray Rig
atmosphere is present continuously or for long (ASR) located at the Gas Turbine Research Centre (GTRC)
periods. part of Cardiff University located in Port Talbot. The ASR is
• Zone 1: An area in which an explosive gas 2.2 x 1.2 x 0.7 m and has the release orifice located at the
atmosphere is likely to occur in normal operation. upstream end and a natural draft extraction at the other. Three
• Zone 2: An area in which an explosive gas NGK spark plugs, which are earthed via the rig, are located
atmosphere is not likely to occur in normal operation 0.5, 1.0 and 1.5 m downstream from the orifice respectively; as
and, if it occurs, will only exist for a short time. shown in Figure 1. Each igniter had a spark gap no greater
A similar system is applied to dust explosion hazards. than 3.8 mm and was connected to a Satronic ZT 870 ignition
Guidance on the classification of areas is provided in BS EN spark generator. The ignition spark generators are capable of
60079-10 (BSI, 2009) for application to gases, vapours and producing a continuous spark (50 Hz) with a voltage of 16 kV
liquids that are handled above their flashpoint, that could and spark energies of 4 mJ.
potentially give rise to an explosive atmosphere. However, this
standard does not cover mists.
Adhering to the guidelines and mitigating a mist
explosion risk thorough the use of appropriately rated
enclosures and safety systems can be costly. Therefore
understanding the parameters that affect the likelihood of an

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(a)

Figure 1: Schematic representation of fuel delivery system.


The fuel was presurised in an accumulator with Nitrogen
affording a delivery pressure of up to 30 bar to be delivered at
the nozzle. A pneumatic valve just upstream of the final orifice
controls the timing and duration the release. The igniters and
final valve are controlled remotely. High definition videos of
the release events were simply recorded using a Cannon D60
SLR camera. The release orifice used throughout the
experimental program had a diameter of 1 mm and an aspect
ratio of unity.
The igniters were initiated prior to the fuel being released, (b)
and the fuel was sprayed until ignition was observed or a Figure 2: Video still of ignition of free spray at 2.5 SWP. (a)
maximum of 10 seconds, whichever came first. For the Pre-ignition and (b) Post-ignition
impingement tests the setup remained nominally identical with It is interesting to note that the spray was ignited by
the only modification being made to the location and igniter 3 which corresponds the location farthest downstream.
orientation of the nozzle. For the impingement studies the For comparison Figure 3 shows a video still of the free spray at
nozzle was located 60 mm from the impingement surface at a the SWP, which did not ignite during the 10 second delivery
perpendicular distance of 100 mm from the first igniter, the schedule.
fuel was sprayed vertically downwards normal to the flat
impingement surface.
The fuel used throughout all the tests was Gas-oil with a
quoted flash point of > 61 °C, which was released at
atmospheric temperature.

RESULTS
Due to the confidential nature of the research programme
the delivery pressures utilised for this study cannot be detailed
at this time consequently the results presented are non-
dimensionalised against a Safe Working Pressure (SWP). The
SWP is defined as the pressure at which there were no
recorded ignition events during the free spray experiments. Figure 3: Video still of ignition of free spray at 1.0 SWP
For the free spray experiments the release pressure was set Figure 4 presents two video stills showing pre and
at an initially high value and repeat experiments conducted at post-ignition of the impinging spray at 1.0 SWP. It is
decreasing delivery pressures until no ignition was observed interesting to note that the spray was ignited at Igniter 1
during the three repeated experiments. Figure 2 presents two corresponding to the closest downstream location (60mm)
video stills showing pre and post-ignition of the free spray at which is in contrast to the 1500 mm distance observed for
2.5 SWP. ignition of the free spray.

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smaller droplets have a larger surface area to volume ratio
compared with larger drops for the same mass. This promotes
drop evaporation which in turn increases combustion
efficiency, which in turn can increase heat release rate and
over pressure significantly affecting the severity of the
incident. Figure 5 shows the number-under-size and mass
under size plots for the free sprays for the range of SWP’s
investigated. The mass-under-size plots were predicted from a
previously developed model by Kay et al, the data and
validation are discussed elsewhere (Kay et al, 2010). However
the correlation for predicting the mean spray diameter is
reproduced in Equation (1).
0.97
(a) 𝐷𝑆𝑀𝐷 −0.85 0.44
𝐿 0.114 𝜇𝑙,𝑜 (1)
= 74𝑊𝑒𝑙,𝑜 𝑅𝑒𝑙,𝑜 � � � �
𝑑𝑜 𝑑𝑜 𝜇𝑤𝑎𝑡𝑒𝑟,𝑠𝑡𝑝
−0.37 −0.11
𝜎𝑙,𝑜 𝜌𝑙,𝑜
.� � � �
𝜎𝑤𝑎𝑡𝑒𝑟,𝑠𝑡𝑝 𝜌𝑤𝑎𝑡𝑒𝑟,𝑠𝑡𝑝

Figure 5 highlights the difference between


considering sprays by number or by mass. For example,
approximately 10 % of the mass is contained in droplets with a
diameter less than 400 microns for the 2.5 SWP case –
whereas 90 % of the droplets by number are contained within
this size range. This is simply because mass is proportional to
the diameter cubed, therefore if the diameter of a droplet is
(b) doubled then it will have 8 times the volume – effectively
Figure 4: Video still of ignition of impinging spray at 1.0 meaning that a significant proportion of the mass is contained
SWP. (a) Pre-ignition and (b) Post-ignition within a relatively few number of large droplets. In the context
of flammable risk hazards larger droplets not only reduce the
Table 1 presents a summary of the experimental results. evaporation rate but are less likely to be present in the spark
Table 1: Summary of test results gap at the time of a spark as, depending on the downstream
Test Number Pressure [SWP] Setup Ignition? location of the ignition source, the droplets are more likely to
1 2.5 Free Spray Yes have rained out.
2 2.0 Free Spray Yes
3 1.5 Free Spray Yes
4 1.0 Free Spray No
5 1.0 Impingement Yes
6 0.5 Impingement Yes

DISCUSSION
The first observation is that ignition occurred for releases
where the temperature of the fuel is below the flashpoint,
highlighting the fact that flashpoint cannot be used as a
measure for risk assessment relating to mist explosions.
The interesting observation from Table 1, is that
impingement of the spray results in an ignitable mixture at
delivery pressures half that of pressures previously considered
safe. There are still practical applications where fuel is
transported at this pressure, and consequently still a risk. The
thermo-fluid dynamics associated with this observation will be
analysed and discussed highlighting reasons for the differences Figure 5: Mass-under-size and number-under-size plots for
in ignitability. various SWP.
The size distribution in a spray has a significant The minimum ignition energy (MIE) required to
influence on its combustion characteristics. For example, ignite a droplet has been studied and quantified previously

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(Ballal and Lefebvre, 1978) and is proportional to its diameter
(cubed). The model to predict the MIE for quiescent mists,
which was derived and subsequently validated experimentally
is given in Equation (2). This model relies on a number of
parameters including droplet diameter, equivalence ratio, gas
and liquid properties and evaporation constants.
1 𝜋𝑐𝑝,𝑎 ∆𝑇𝑠𝑡 𝐷3 𝜌𝑓 3/2 (2)
𝐸𝑚𝑖𝑛 = � � . � �
6 𝜌𝑎
1/2 𝜑𝑙𝑛(1 + 𝐵𝑠𝑡 )
The formula presented in Equation (2) is based on the
theory of the quenching distance between droplets in a
homogeneous quiescent mist. The MIE is then proposed as the
energy required to raise the temperature a sphere of air, with a
diameter equal to the quenching distance, from ambient to the
stoichiometric adiabatic flame temperature.
In this study the MIE model of Ballal and Lefebvre
has been combined with the droplet size model of Kay et al for Figure 7: Mass-under-size and number-under-size with MIE
2.5 SWP and 1.0 SWP and is presented in Figure 6 and Figure for 1.0 SWP.
7 respectively. These refer to the experimental data observed in It is now possible to get an idea of how the
Figure 2 and Figure 3 respectively. The MIE for the upper distribution of droplet sizes within the spray will affect its
flammability limit (UFL), stoichiometic and lower flammability. For example, Figure 6 shows that with an
flammability limit (LFL) conditions have been superimposed. ignition energy capped at 4 mJ, the largest droplet diameters
The scale for the secondary y-axis presenting the MIE has been for a flammable mist (based on Ballal and Lefebvre’s model) is
capped at 4 mJ, which is the anticipated spark energy utilised 63 microns - for stoichiometric mixtures. This can be related to
in this study (as stated in the spark generator datasheet). the number and mass under-size plots, as <0.1 % by-mass and
62 % by-number of the spray are below this theoretical
maximum diameter.
It was not possible to measure the true equivalence
ratio at the igniter prior to combustion and so results will be
discussed in a comparative sense. Figure 6 and Figure 7 show
that as the SWP is decreased from 2.5 to 1.0 then the
proportion of mass and number of droplets that could
theoretically be ignited decreases. This information is
presented in
Table 2 presents the maximum droplet diameter that
can be ignited by a 4 mJ spark and consequently the
percentage mass and number of droplets with a diameter below
this limit can be considered flammable.
Table 2: Summary of Ignition Spray Data
Condition UFL Stoich LFL
Diameter limit for a 4 mJ spark [µm] 48 63 177
Figure 6: Mass-under-size and number-under-size with MIE Mass-under-size for 2.5 SWP [%] <0.1 <0.1 1.6
for 2.5 SWP. Number-under-size for 2.5 SWP [%] 58 62 84
Mass-under-size for 1.0 SWP [%] <0.1 <0.1 <0.5
Number-under-size for 1.0 SWP [%] 38 48 74
The flammable percentage of the spray required for the spray
to combust is not easy to define, and further investigation
would be required to assess the affect of droplet size and
concentration on the MIE. Again the guidance in current
legislation is poor, for example in BS EN 60079-10-1 (BSI,
2009) it states that the flammable aerosol component of a spray
release may involve as little as 1% of the total mass released.
It is noted that, at the conditions tested, the pressure
at which the free spray did not ignite is fixed at 1.0 SWP. This

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suggests that the atomisation at this delivery pressure is
insufficient to provide small enough droplets at a high enough
droplet loading and consequently the percentage of droplets
within the flammable range was too low.
As discussed earlier; impingement exacerbated the
potential hazard. This is due to the re-atomisation of splashing
droplets, which reduces the mean droplet diameter whilst
increasing the droplet loading of the spray. Much effort has
been employed in understanding the impingement of single
and multiple droplet impacts on solid surfaces and developing
models that predict the post-impingement droplet
characteristics. Due to the two-phase thermofluid complexity
of the impingement process, previous analysis has resorted to
the development of non-dimensionalised correlations. A few of
these impingement models are employed in some of the more
widely used commercial CFD software. One of the most
commonly used correlations is the one proposed by Bai et al Figure 8: Mass-under-size and number-under-size for pre and
post-impingement sprays for 1.0 SWP.
and is discussed in detail elsewhere (Bai et al, 2002), but will
Figure 9 and Figure 10 show the post-impingement number
be described in brief here. The model, based on the impacting
and mass-under-size plots for 1.0 and 0.5 SWP. The LFL,
droplet Weber and Laplace number, first predicts whether the
stoichiometric and UFL have been superimposed as discussed
droplet will stick, spread, bounce or splash on the surface. The
earlier. Unlike the free spray data, presented in Figure 6 and
regime transition criteria are presented in Table 3 with the post
Figure 7, almost the entire spray is theoretically ignitable on a
impingement droplet characteristics based on separate
mass and number basis. These plots are a clear indication of
correlations depending on which regime the droplets are in.
how a hazard can be exacerbated due to impingement of a free
Table 3: Regime transition criteria (Bai et al, 2002)
spray.
Regime Transition Criteria
Stick Wed ≤ 2630.La −0.18 ( DRY ) ; Wed ≤ 2 (WET )
Rebound 2 < Wed ≤ 20 (WET )
Spread 20 < Wed ≤ 1320.La −0.18 (WET )
Wed > 2630.La −0.18 ( DRY )
Splash
Wed > 1320.La −0.18 (WET )
Based on the Sauter Mean Diameter (SMD) of the free spray,
the post impingement droplet characteristics were predicted
using the correlation of Bai et al. Figure 8 shows the mass and
number-under-size plots for both the pre and post-
impingement sprays. Figure 8 shows that the proportion of
mass contained within droplets with a diameter less than 200
microns has changed from less than 0.1 % for the pre-
impingement spray to greater than 90 % of the post- Figure 9: Mass-under-size and number-under-size with MIE
impingement spray. Significant changes are also observed for for 1.0 SWP.
the number-under-size plots.

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• Impingent models from the literature demonstrated
how the droplet size distribution of the free spray is
significantly altered post-impingement, again in
qualitative agreement with current experimental
observations.

Whilst the contribution of this paper is generally


qualitative in nature, it provides a notable practical step
forward in developing understanding of this poorly studied
problem towards quantitative practical industrial
guidelines and standards. This is the focus of an ongoing
joint industry project.

ACKNOWLEDGMENTS
The authors would like to thank RWE for funding the
study and the efforts of Mr Steven Morris and Mr Terry
Figure 10: Mass-under-size and number-under-size with MIE
Treherne at the GTRC in helping conduct the experiments.
for 0.5 SWP.
Although outside of the scope of this study it worth
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