Process Safety Engineering: Fires & Explosions: Univ. of Riau/ Chem. Eng. Dept

Process Safety Engineering:
Fires & Explosions
Univ. of Riau/ Chem. Eng. Dept.

Fires & Explosions
Accident
Statistics
Evaluation of the largest chemical plant accidents:
▪ Most of the large accidents are due to fires and

explosions.
Introduction
The distinction between fires and explosions is the rate of energy release
FIRE: release energy slowly, rapid exothermic, oxidation, with flame
EXPLOSION: higher energy release rate (mixture) pressure or shock wave

Fires can also result from explosions, and explosions can result from
fires
EFFECTS • injuries / casualties Thermal radiation,

• property losses asphyxiation, toxic
• process products, blast, fragments
interruption
REQUIRED KNOWLEDGE FOR PREVENTION
• material properties
• nature of fire and explosion process
• procedures to reduce hazards (Ch.
7)
Fire Triangle
▪ Combustion or fire: Combustion or fire is a chemical
reaction.
Fire Triangle
Application of the Fire Triangle
Texas Fertilizer Plant Blast
“So this is what has happened, that the fire has
got out of control and basically heated up the
vessel. What seems to me to be wrong about
this whole incident is that instead of evacuating
the plant, when the fire establishment could not
control it, there seemed to be brought up more
and more fire people and they were putting
them at risk. I don’t know, it sounds as if there
have been a lot of deaths among fire people”
Waco, Texas early April 18, 2013
The fertilizer plant indicated the worst case scenario would be a 10-minute release
of ammonia gas that would not harm anyone.
West Fertilizer told the Environmental Protection Agency that it presented no risk of fire
or explosion, despite having 54,000 pounds of anhydrous ammonia
The chief safety expert at the Russia’s Nitrogen Industry Institute, Igor Solovyev,
reminded that there haven’t been any serious accidents at fertilizer plants in half a
century and that serious violations of safety arrangements must have led to the Texas
explosion.
Texas Fertilizer Plant Blast
West Chemical and Fertilizer was fined
$2,300 in March 2006 for failing to update a
risk management plan and for having poor
employee-training records and no formal
written maintenance program, according to
the EPA. The company later certified it had
corrected the deficiencies, the EPA said
Combustion Behavior – Most Hydrocarbons
Combustion Behavior – Carbon Disulfide
Combustion Behavior – Methane
Combustion Behavior – Dusts
Definitions - 1
➢ LFL: Lower Flammability Limit
Below LFL, mixture will not burn, it is too lean.
➢ UFL: Upper Flammability Limit

Above UFL, mixture will not burn, it is too rich.
▪ Defined only for gas mixtures in air.

▪ Both UFL and LFL defined as volume % fuel in air.
Flammability limits: Vapor-air mixtures will ignite and burn only

over a well-specified range of compositions.
Definitions - 2
▪ Flash Point: Temperature above which a liquid produces enough

vapor to form an ignitable mixture with air.
- Defined only for liquids at atmospheric Pressure.

- The flash point generally increases with increasing pressure.
▪ Auto-Ignition Temperature (AIT): Temperature above which

adequate energy is available in the environment to provide an
ignition source.
Definitions - 3
▪ Limiting Oxygen Concentration (LOC):

Oxygen concentration below which combustion is not
possible, with any fuel mixture.
➢ Expressed as volume % oxygen.
➢ Also called: Minimum Oxygen Concentration

(MOC) , Max. Safe Oxygen Conc. (MSOC) ,Others
! Read the definitions at both page 227 and

228
Typical Values - 1
Typical Values - 2
Flammability Relationships
Minimum Ignition Energies
What: Energy required to ignite a flammable
mixture. Typical Values: (wide variation expected)
Vapor 0.25 mJ
s: about 10
Dusts: mJ
➢ Static spark that you can
feel:
about 20
mJ
Experimental Determination - Flashpoint
Flash point temperatures for pure materials
Experimental Determination: P versus t
Experimental Determination - LFL, UFL
Flammability Limits of Mixtures
Assumptions:
1) Product heat capacities constant

2) No. of moles of gas constant
3) Combustion kinetics of pure species unchanged
4) Adiabatic temperature rise the same for all
species
Flammability Limit Dependence on Temperature
As temperature increases:
UFL increases, LFL decreases

--> Flammability range
increases
Flammability Limit Dependence on Pressure
As pressure increases:
UFL increases (broadening the flammability

range) LFL mostly unaffected
P is pressure in mega-Pascals,
absolute
No theoretical basis for this yet!

In Class Problem
What is the UFL of a gas mixture composed of 1% methane, 2%
ethane and 3% propane by volume at 50°C and 2 atmospheres:
Data:
Component MW Heat of
Combustion
(kcal/mol)
Methane 16.04 212.79
Ethane 30.07 372.81
Propane 44.09 526.74
Solution Procedure:
1. Correct for temperature

2. Correct for pressure (only for
UFL)
3. Find for mixture.
Correction for Temperature : UFL from Table 6-1
Eq. 6-5  UFLT  UFL25 1  0.75(T  25) /
∆H c  Methane UFL50  151  0.75(25) /
212.79  16.32 Ethane UFL50  12.51 
0.75(25) / 372.81  13.13 Propane UFL50 
9.51  0.75(25) / 526.74  9.84

Correction for Pressure (UFL
only)
Eq. 6-6  UFLP  UFL  20.6(log10 P 
1)
 101kPa   MPa  
P  2atm  
atm  1000kPa
 0.202MPa
 UFL1atm  20.6(log10 (0.202MPa) 
UFL2atm
1)
UFL2atm
UFLMethaneUFL 1atm  6.290
22.61
 19.40
UFLEthane

UFLPropane 16.13
Mixture
calculation
Mixture Vol% Mol frac Comb

Methane 1 0.1667
Ethane 2 0.3333
Propane 3 0.5000
Combustibles 6
Equation 6-3 for

mixtures 1
UFLmix  n
yi
Ʃ
i1 UFLi
1
UFLMixture   18.0 vol%
0.1667 0.3333 0.5
 
22.61 19.40 16.13
Since total combustibles in air 1+2+3=6 < 18 then the system is

in the combustible range (below UFL)
Estimating Flammability Limits
▪ For many hydrocarbon vapors the LFL and the UFL are a function of
the stoichiometric concentration (Cst) of fuel.
where Cst is volume % fuel in fuel plus air.

Estimating LOC
Flammability Diagram
The Air Line is drawn as a

straight line between the
upper apex, representing
100% Fuel, and the point
on the lower line at 79%
nitrogen / 21% oxygen,
Representing 100% air.
The LFL and the UFL points
In Appendix B of the
textbook, the LFL and UFL
for ethylene are given as
2.7% and 36%,
respectively.
These ar
plotted
values on the Air Line
e
at the corresponding
Fuel percentages.
Stoichiometric concentration
The general combustion reaction is
to
used the coefficient z,
corresponding
determine the moles of
to
required for complete
oxygen
combustion of one
mole of ethylene.
The Stoichiometric
Line
The Stoichiometric Line
drawn as shown. is
It represents all
stoichiometric C2H4 + O2
mixtures, with varying amounts
of inert nitrogen
Limiting or Minimum Oxygen
Concentration
On Table 6-2 of the text, the LOC or

MOC for ethylene is given as 10 vol.
It oxygen.
% is plotted on the
Line as shown.Stoichiometric
Another way to estimate the LOC

is by using the following
approximation:
The general shape of the flammability
boundary
This
diagram reflects
that the
ethylene
relatively fact
broad has
flammability limits;
broade tha
r n
typical
hydrocarbons.alkan
e
Drawing an Approx. Diagram
1. Draw LFL and UFL on air line (% Fuel in air).

2. Draw stoichiometric line from combustion equation.
3. Plot intersection of LOC with stoichiometric line.
4. Draw LFL and UFL in pure oxygen, if known (% fuel in pure
oxygen).
5. Connect the dots to get approximate diagram.
Example
Explosions - Definitions
▪ Explosion: A very sudden release of energy resulting in a shock or

pressure wave.
▪ Shock, Blast or pressure wave: Pressure wave that causes damage.
▪ Deflagration: Reaction wave speed < speed of sound.
▪ Detonation: Reaction wave speed > speed of sound.
▪ Speed of sound in air: 344 m/s, 1129 ft/s at ambient T, P.
▪ Deflagrations are the usual case with explosions involving
flammable materials.
Comparison of Behavior
Reaction front moves at
less than speed of sound.
Pressure wave moves away

from reaction front at
speed of sound.
Reaction front moves

greater than speed of
sound.
Pressure wave is
slightly ahead of
reaction front moving
at same speed.
Comparison of Behavior
Confined Explosions
Unconfined Explosions
➢ Occurs in the open. Only 2 to 10% of thermodynamic
energy ends up in pressure wave. Use 2% for this
class.
Boiling Liquid Expanding Vapor Explosion
Overpressures
Explosions result in ablast
wave movingor out pressure
from the
center at the explosion
speed of sound.
There are several ways to measure this

pressure. The usual method is to measure
the pressure at right angles to the
pressure wave. This is called the Side-on
Overpressure.
If the pressure is measured in a direction

towards the blast, you get a higher value
because of the deceleration of the
moving gas as it impacts the pressure
transducer.
Peak Side-on Overpressures
Scaled overpressure versus scaled distance
The overpressure can be
estimated using an equivalent
mass of TNT, denoted mTNT , and
the distance from the ground-
zero point of the explosion,
denoted r.
The scaled overpressure ps, is given

by
TNT Equivalency for VCEs
TNT Equiv. - Explosion Efficiency
TNT Equivalency Procedure
HW
6-1
6-3d
6-6 propylene
6-7
6-8
6-15

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Process Safety Engineering:

Fires & Explosions

Univ. of Riau/ Chem. Eng. Dept.

Evaluation of the largest chemical plant accidents:

▪ Most of the large accidents are due to fires and

FIRE: release energy slowly, rapid exothermic, oxidation, with flame

EXPLOSION: higher energy release rate (mixture) pressure or shock wave

EFFECTS • injuries / casualties Thermal radiation,

Waco, Texas early April 18, 2013

➢ UFL: Upper Flammability Limit

▪ Defined only for gas mixtures in air.

Flammability limits: Vapor-air mixtures will ignite and burn only

▪ Flash Point: Temperature above which a liquid produces enough

- Defined only for liquids at atmospheric Pressure.

▪ Auto-Ignition Temperature (AIT): Temperature above which

▪ Limiting Oxygen Concentration (LOC):

➢ Expressed as volume % oxygen.

➢ Also called: Minimum Oxygen Concentration

! Read the definitions at both page 227 and

1) Product heat capacities constant

UFL increases, LFL decreases

UFL increases (broadening the flammability

No theoretical basis for this yet!

1. Correct for temperature

Eq. 6-5  UFLT  UFL25 1  0.75(T  25) /

∆H c  Methane UFL50  151  0.75(25) /

212.79  16.32 Ethane UFL50  12.51 

0.75(25) / 372.81  13.13 Propane UFL50 

9.51  0.75(25) / 526.74  9.84

Mixture Vol% Mol frac Comb

Equation 6-3 for

Since total combustibles in air 1+2+3=6 < 18 then the system is

where Cst is volume % fuel in fuel plus air.

The Air Line is drawn as a

On Table 6-2 of the text, the LOC or

Another way to estimate the LOC

1. Draw LFL and UFL on air line (% Fuel in air).

▪ Explosion: A very sudden release of energy resulting in a shock or

Pressure wave moves away

Reaction front moves

There are several ways to measure this

If the pressure is measured in a direction

The scaled overpressure ps, is given

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