EXPLOSION PROTECTION IN DEDUSTING PLANTS

BETH Filtration GmbH 2008 . Seite 2

BETHPULS Bag Filter prototype explosions pressure test

Explosion pressure shock resistant design in combination with explosion pressure venting

 BETH Filtration GmbH 2008 . Seite 3

BETHPULS Bag Filter prototype explosions pressure test

Explosion pressure shock resistant design in combination with explosion pressure venting Photo page 2

Place of testing: Bergbau Versuchsstrecke / Dortmund Derne Kind of dust Dust explosion class Vessel volume Vent area Reduced explosion pressure Number of tests Max. explosion overpressure : Lignite ( 500 g / m3 ) : St 1 : 22 m3 : 2 m2 : 1.18 bar ( 0.18 bar overpressure ) : 36 : 0.44 bar

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Explosion Protection in Dedusting Plants

Dedusting plants are in operation for the
collection and separation of dust. Consideration different kind of dust in dedusting plants concerning the applications and industrys For example: Wood, wood products Food, grain, cereal Coal, coal products Secondary fuel Plastic, rubber Chemical products, Metal etc.

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Explosion Protection in Dedusting Plants

Vattenfall Europe Mining AG dedusting of the actual largest lignite mill of world

Source of dust Type of dust Capacity of the mill Bulk density dust Dust capacity Raw gas volume Operating temperature Dew point Raw gas dust content Operating pressure

: Vertical roller mil : Lignite : 88 t/h : 0.35 0.5 t/m3 : max. 293.3 m3/h : max. 150,000 Am3/h : 55 80C (short peaks 100C) : 30.9C : max. 587 g/m3 : - 45 mbar (rawgas inlet filter)

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Explosion Protection in Dedusting Plants

Vattenfall Europe Mining AG dedusting of the actual largest lignite mill of world BETHPULS Bag Filter 6.90x10.7.20 (double line)

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Explosion Protection in Dedusting Plants

Vattenfall Europe Mining AG dedusting of the actual largest lignite mill of world BETHPULS Bag Filter 6.90x10.7.20 (double line)

Filter type : BETHPULS 6.90x10.7.20 Operation method : On-line Number of filter bags : 900 Dimensions filter bags : 160 x 5,200 mm Filter cloth : PEAC 600 Si Filtering surface area : 2,400 m2 Air to cloth ratio : max. 1.044 m3/m2 x min Admissible operating pressure: - 140 mbar Main dimensions filter : 7.28 m x 10.2 m x 12.4 m

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Explosion Protection in Dedusting Plants

Vattenfall Europe Mining AG dedusting of the actual largest lignite mill of world BETHPULS Bag Filter 6.90x10.7.20 (double line) Dust characteristics Kind of dust Dust explosion class KSt- value Explosion overpressure pmax Lignite St 1 150 bar x m x s-1 9.0 bar

Protective measures
Prevention of effective ignition sources Explosion pressure shock resistant Explosion venting Venting device Number / size Disengagement

up to1.4 bar according VDI 3673 BETH Explosion doors 16 / 0.53m2per each Diverter/rotary valves

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Explosion Protection in Dedusting Plants

Defination of dust according VDI 3677 part 1 = Particle < 500 m This definition of dust are also valid in the explosion protection VDI 2263 Dust Fires and Dust Explosions Hazards Assessment Protective Measures Exception: Flock = Short staples which are generated by cutting endless fibers, grinding etc. Length: 0,5 2,5 mm Weight:0,5 bis 22 dtex = gram / 10 km fiber lenght Source: BMFT Band 64 Humanisierung des Arbeitslebens

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Explosion Protection in Dedusting Plants

For the Recognition of Hazards according DIN EN 1127-1 Explosive atmospheres Explosion prevention and protection Part 1: Basic concepts and methodology German version EN 1127-1 : 1997 in dedusting plants and the required Analysis of Hazards is it very important to know Safety Characteristics of Dust ( Burning and Explosion Behaviour )

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Explosion Protection in Dedusting Plants

Burning and Explosion Characteristics of Dust according BIA report 12/97 and / or BIA data bank GESTIS-STAUB-EX or tests according VDI 2263 Part 1 Test Methods for die Determination of the Safety Characteristic of Dust through authorize test / proof institute

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Explosion Protection in Dedusting Plants

A dust explosion is possible when the hazard triangle is closed

Ignition source

Oxygen

Explosive dust Dust content in air higher the explosive limits ( lower dust concentration ) Oxygen concentration in the dust/air mixture higher limiting concentration Effective ignition source

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Explosion Protection in Dedusting Plants

Safety Characteristics of Dust and the Explosion Hazards

are content of the

Explosion Protection Document according article 8 Directive 1999/92/EG ( ATEX 137 ) Responsible for the safety Consideration Example : Operating management of the plant : National law : Germany Betriebssicherheitsverordnung BetrSichV 6 BGR 104 ( alt ZH 1 / 10 ) Explosionsschutz-Regeln Regeln fr das Vermeiden der Gefahren durch explosionsfhige Atmosphre mit Beispielsammlung E 6

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Explosion Protection in Dedusting Plants

Possible parts of a dedusting plant can be

Inertial separators Filtering separators Electrostatic precipitators Wet separator

if required in combination including

VDI 3676 VDI 3677 VDI 3678 VDI 3679

Ducts with all parts Fans, silencer Discharge devices ( rotary valves etc. ) Screw conveyors Silos etc All parts of the dedusting must be consider for the recognition of Explosion Hazards

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Explosion Protection in Dedusting Plants

Consideration and assessment of the different separator types

Example:

Filtering separators acc. VDI 3677 Part 1 Bag filters, Envelope filters ( pocket ), Cartridge filters, Candle filters, Laef filters

Arrangement filter elements: Operation:

Vertical or horizontal Suction or pressure Regeneration divices

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Explosion Protection in Dedusting Plants

Typical examples of dedusting plants 1.) Bag filter for mill dedusting

Rawgas Cleangas

: Ducts, cyclone, bag filter, screw conveyor, rotary valves : Bag filter, ducts, fan, silencer, stack

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Explosion Protection in Dedusting Plants

Typical examples of dedusting plants 1.) Object dedusting combination cylone bag filter

Rawgas Cleangas

: Ducts, cyclone, bag filter, rotary valves : Bag filter, ducts, fan, silencer, stack

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Explosion Protection in Dedusting Plants

All parts of the dedusting plant must be consider and a assessment in zones is required: 0, 1 and 2 for gas 20, 21 and 22 for dust

Consideration of the location and installation of the dedusting plant. A influence of zones through apparatus etc. they are no part of the dedusting plant, but they are installed in the near of the dedusting plant, is possible and to consider by the selection and installation of the required protective measures.
Analysis of Hazards Explosion Protection Document Plant operating management supplier of the plant

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Explosion Protection in Dedusting Plants

Protective Measures

Possibilities of Explosion Protection Measures:

Preventive and through Design Measures Preventive:

Prevention of Explosible Dust/Air Mixtures

Prevention of Dust Explosions through Inerting Prevention of Effective Ignition Sources

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Explosion Protection in Dedusting Plants

Protective Measures Design Measures:
Explosion pressure resistant design for the max. explosion pressure Explosion pressure resistant design in combination with explosion venting (pressure relief) Explosion pressure resistant design in combination with explosion suppression Explosion Disengagement, Explosion Interruption

Explosion resistant:
Pressure resistant Pressure shock resistant = Safety factor 1.5 = Safety factor 1.0

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Explosion Protection in Dedusting Plants

BETHPULS Bag Filter prototype explosions pressure test

Clean gas housing Venting openings for rupture disks or Explosion doors

Raw gas housing

Hopper

Screw conveyor
Stage of erection

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Explosion Protection in Dedusting Plants

BETHPULS Bag Filter prototype explosions pressure test

Flames pressure

Hazards during the venting process in surrounding areas outside p red 0.53 bar g p red 0.64 bar g

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Explosion Protection in Dedusting Plants

BETHPULS Bag Filter prototype explosions pressure test

Raw gas housing: Side panels End panels Hopper: End panels Side panels

Note: The result of incorrect sizing and design in particular concerning pressure shock resistance, flame tightness, calculation of venting area, venting devices (explosion doors, rupture disks), venting efficiency, explosion values of dust etc is the same

Result of exceeding the existing explosion pressure shock resistance damaged filter housing by p red 0.75 bar g

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Explosion Protection in Dedusting Plants

EC suitability test of BETH explosion door according directive 94/9/EC (ATEX 95)

Beginning of the venting process

End of the venting explosion door closed

During venting process explosion door open pressure und flame propagation outside

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Explosion Protection in Dedusting Plants

Certificate EC suitability test BETH explosion door according directive 94/9/EC

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Explosion Protection in Dedusting Plants

Required QS certificates to supply EC suitability tested BETH explosion door acc 94/9/EC

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Explosion Protection in Dedusting Plants

Scheme of execution examples of explosion protected filters proofed by notified body

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Explosion Protection in Dedusting Plants

BETH diverter based of the VDI report 701 (real execution) test of disengagement by a notified body

Test field stage of erection

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Explosion Protection in Dedusting Plants

BETH diverter based of the VDI report 701 (real execution) test of disengagement by a notified body

Cover fixed in the cage

Pressure and flame

Diverter DN 1000 Disengagement process during the test

Ductwork DN 1000

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Explosion Protection in Dedusting Plants

Possible Design Measures by Example Plant Item 1.) 1.) Object dedusting combination cylone bag filter

Protective Measure Item 3 Vessel: Explosion pressure restistant design in combination with explosion venting (pressure relief) or explosion suppression. Explosion pressure resistant design for the maximum explosion pressure

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting secondary fuel bunker

Diverter for explosion disengagement in the raw gas ductwork

Clean gas channel and duct

Vent duct behind the explosion flaps

BETHPULS Bag Filter Explosion pressure shock resistant 1.4 bar with explosion venting Fan

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting secondary fuel bunker Dust characteristics Kind of dust Dust explosion class KSt- value Explosion overpressure pmax Protective measures Prevention of effective ignition sources Explosion pressure shock resistant Explosion venting Venting device Disengagement Wood etc. St 1 200 bar x m x s-1 10 bar

up to1.4 bar according VDI 3673 BETH Explosion flaps BETH diverter/rotary valve

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting plant for aluminium powder

Duct cyclone to bag filter

Clean gas duct

Raw gas duct Bag filter

Cyclone outlet Cyclone inlet

Cyclone

Cylindrical BETPULS bag filter in combination with cyclone

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting plant for aluminium powder Dust characteristics Kind of dust Dust explosion class KSt- value Explosion overpressure pmax Lower explosible limit Protective measures Prevention of effective ignition sources Explosion pressure shock resistant up to11.0 bar Disengagement raw gas side Rapid action valve clean gas side Rapid protection valve Overspraypowder St 2 259 bar x m x s-1 9.9 bar 60 g/m3

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting a fuel-mixture preparation Clean gas duct Water-spray system Explosion flaps Bag filter Diverter with raw gas duct Maintenance platforms

Bag filter
Fan, silencer, and stack

BETHPULS Single-line bag filter protected by preventive and design measures

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Explosion Protection in Dedusting Plants

Example BETHPULS Bag Filter for Dedusting a fuel-mixture preparation Dust characteristics Kind of dust Dust explosion class KSt- value Explosion overpressure pmax Protective measures Secondary fuel (house waste, wood) St 1 77 bar x m x s-1 7.0 bar

Prevention of effective ignition sources Explosion pressure shock resistant Explosion venting Venting device Disengagement

up to1.4 bar according VDI 3673 BETH Explosion flaps BETH diverter/rotary valve

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Explosion Protection in Dedusting Plants

Conclusion Correct operation according the range of use The operation of explosion protected dedusting plants is only permissible with material and safety characteristics according the documentation of the plant ( operating instructions, data sheet etc. ) Analysis of Hazards Explosion Protection Document

Maintenance acc. the service manual of the supplier Observance of the maintenance cylce time acc. service manual
By no consideration is the dedusting plant in operation not safe Dust explosion and the damaging of the plant is possible. Danger for employees with all consequences for health and life

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Explosion Protection in Dedusting Plants

Example of damaged bag filter through a dust explosion of lignite

Reason: Operating mistake, no maintenance acc. instructions Material change ( dust with higher safety characteristics )

 BETH Filtration GmbH 2008 . Seite 39

Explosion Protection in Dedusting Plants

Example of damaged bag filter through a dust explosion of lignite

Reason: Operating mistake, no maintenance acc. instructions Material change ( dust with higher safety characteristics )

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THANKS FOR YOUR ATTENTION

Peter Stender Senior Engineer BETHFiltration GmbH

BETH Filtration GmbH Borsigstrae 8 23560 Lbeck DEUTSCHLAND Fon +49 451 5307-500 Fax +49 7151 5307-600 info@beth-filter.de www.beth-filter.de

BETH Filtration (Schweiz) AG Balz-Zimmermannstrae 7 CH-8302 Kloten SCHWEIZ Fon +41 438133-380 Fax +41 438133-382 info@beth-filter.ch www.beth-filter.ch

WEIS ENVIRONMENTAL LLC Niederlassung USA 4445 Malone Road P.O. Box 181070 Memphis, TN 38118 USA Fon +1 901 531 6081 Fax +1 901 531 6085 info@weis-environmental.com www.weis-environmental.com