Initial phase modelling in numerical explosion applied to process safety

The utilisation of computational fluid dynamics (CFD) in process safety has increased significantly in recent years. The modelling of accidental explosion via CFD has in many cases replaced the classical Multi Energy and Brake Strehlow methods. The benefits obtained with CFD modelling can be diminished if proper modelling of the initial phase of explosion is neglected. In the early stages of an explosion, the flame propagates in a quasi-laminar regime. Proper modelling of the initial laminar phase is a key aspect in order to predict the peak pressure and the time to peak pressure. The present work suggests a modelling approach for the initial laminar phase in explosion scenarios. Findings are compared with experimental data for two classical explosion test cases which resemble the common features in chemical process areas (confinement and congestion). A detailed analysis of the threshold for the transition from laminar to turbulent regime is also carried out. The modelling is implemented in a fully 3D Navier-Stokes compressible formulation. Combustion is treated using a laminar flamelet approach based on the Bray, Moss and Libby (BML) formulation. A novel modified porosity approach developed for the unstructured solver is also considered. Results agree satisfactorily with experiments and the modelling is found to be robust. © 2013 The Institution of Chemical Engineers.

Effect of depithing on the safety and environmental aspects of bagasse stockpiling

Large scale sugarcane bagasse storage in uncovered stockpiles has the potential to result in adverse impacts on the environment and surrounding communities through hazards associated with nuisance dust, groundwater seepage, spontaneous combustion and generation of contaminated leachates. Managing these hazards will assist in improved health and safety outcomes for factory staff and reduced potential environmental impacts on surrounding communities. Removal of the smaller fibres (pith) from bagasse prior to stockpiling reduced the dust number of bagasse by 50% and modelling suggests peak ground level PM10 dust emissions would reduce by 70%. Depithed bagasse has much lower water holding capacity (~43%) than whole bagasse. This experimental and modelling study investigated the physical properties of depithed and whole bagasse. Dust dispersion modelling was undertaken to determine the likely effects associated with storage of whole and depithed sugarcane bagasse.

Modeling Of Work-Related Musculoskeletal Disorders In Chemical Process Industry In India

In this modern complex world, stress at work is found to be increasingly a common feature in day to day life. For the same reason, job stress is one of the active areas in occupational health and safety research for over last four decades and is continuing to attract researchers in academia and industry. Job stress in process industries is of concern due to its influence on process safety, and worker‘s safety and health. Safety in process (chemical and nuclear material) industry is of paramount importance, especially in a thickly populated country like India. Stress at job is the main vector in inducing work related musculoskeletal disorders which in turn can affect the worker health and safety in process industries. In view of the above, the process industries should try to minimize the job stress in workers to ensure a safe and healthy working climate for the industry and the worker. This research is mainly aimed at assessing the influence of job stress in inducing work related musculoskeletal disorders in chemical process industries in India

Treatment of gray water using anaerobic biofilms created on synthetic and natural fibers

Gray water treatment and reuse is an immediate option to counter the upcoming water shortages in various parts of world, especially urban areas. Anaerobic treatment of gray water in houses is an alternative low cost, low energy and low sludge generating option that can meet this challenge. Typical problems of fluctuating VFA, low pH and sludge washout at low loading rates with gray water feedstock was overcome in two chambered anaerobic biofilm reactors using natural fibers as the biofilm support. The long term performance of using natural fiber based biofilms at moderate and low organic loading rates (OLR) have been examined. Biofilms raised on natural fibers (coir, ridge-gourd) were similar to that of synthetic media (PVC, polyethylene) at lower OLR when operated in pulse fed mode without effluent recirculation and achieved 80-90% COD removal at HRT of 2 d showing a small variability during start-up. Confocal microscopy of the biofilms on natural fibers indicated thinner biofilms, dense cell architecture and low extra cellular polymeric substances (EPS) compared to synthetic supports and this is believed to be key factor in high performance at low OLR and low strength gray water. Natural fibers are thus shown to be an effective biofilm support that withstand fluctuating characteristic of domestic gray water. (C) 2013 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

Identificação de indicadores globais para o monitoramento da segurança de processos de plataformas de produção de petróleo e gás natural: estudo de caso da indústria brasileira

Este trabalho verificou o tema de segurança de processos no segmento de plataformas de produção de petróleo e gás no mar de forma a propor um modelo de indicadores globais a fim de facilitar a identificação de fragilidades no gerenciamento de riscos de processos da indústria de produção de petróleo e gás natural no mar. O resultado esperado é o fornecimento de dados para a otimização de recursos regulatórios na busca da melhoria da segurança operacional. Para tal, buscando conhecer a postura das empresas no cumprimento da necessidade regulamentar da implementação de um Sistema de Gestão de Segurança de Processos (SGSP), foram identificadas as principais práticas preventivas para a o gerenciamento de riscos. Por conseguinte, mensurou-se o esforço na implementação deste SGSP como correlação direta para a prevenção de acidentes (foco preventivo). Já a análise dos resultados deste gerenciamento de riscos (foco reativo) foi obtido através incidentes operacionais classificados de acordo com sua respectiva importância/impacto, dentro de linhas de corte pré-estabelecidas. Assim, o indicador Global preventivo (IGPRV) e o Indicador Global reativo (IGRTV) foram elaborados agregando diferentes indicadores específicos de cada segmento para simplificar a análise e incluir a articulação de conceitos de segurança de processos à atuação regulatória. Os indicadores globais propostos quantificam conceitos subjetivos e complexos para o estabelecimento de metas e permitem aferir o desempenho das ações e projetos da regulação da indústria. Também permitem a identificação e a disseminação das melhores práticas de gerenciamento de riscos, comparando-as em diferente níveis de gerenciamento. Na análise dos resultados, pôde-se perceber que a utilização dos indicadores globais propostos pode responder com sucesso às necessidades regulatórias identificadas

Study on peak overpressure and flame propagation speed of gas deflagration in the tube with obstacles

The on-way peak overpressure and flame propagation speed of gas deflagration in the tube with obstacles are important data for process safety. Based on carbon monoxide deflagration experiments, the paper presents a multi-zone integration model for calculation of on-way peak overpressure, in which the tube with obstacles is considered as a series of venting explosion enclosures which link each others. The analysis of experimental data indicates that the on-way peak overpressure of gas deflagration can be correlated as an empirical formula with equivalence ratio of carbon monoxide oxidation, expansion ratio, flame path length, etc., and that the on-way peak overpressure exhibits a linear relationship with turbulence factor and flame propagation speed. An empirical formula of flame propagation speed is given.

急倾斜金属矿体开采岩体移动规律与变形趋势预测研究

Rockmass movement due to mining steep metallic ore body is a considerable question in the surface movement and deformation issue caused by underground mining. Research on coal mining induced rockmass movement and its prediction problem have been performed for a long-term, and have achieved great progress at home and abroad. However, the rockmass movement caused by mining steep metal mine is distinctivly different from coal seam mining.. Existing surface movement laws and deformation prediction methods are not applicable to the rockmass movement caused by mining steep metal mine. So far the home and abroad research to this theory is presently at an early stage, and there isn’t mature theory or practical prediction method, which made a great impact on production. In this paper, the research object—Jinchuan nickel mine, which is typical steep metal mine, characterized by complex geological conditions, developed faults, cracked rockmass, high geostress, and prominent engineering stability problems. In addition, backfill mining method is used in the mine, the features of rockmass movement caused by this mining method are also different from other mining methods. In this paper, the laws of rock mass movement, deformation and destroy mechanism, and its prediction were analyzed based on the collection of data, detailed in-sit engineering geology survey, ground movement monitoring by GPS, theoretical analysis and numerical simulation. According to the GPS monitoring of ground surface movement, ground subsidence basin with apparent asymmetry is developing, the influence scope is larger in the upper faulted block than in the lower faulted block, and the center of ground movement is moving along the upper faulted block direction with increasing depth of mining. During the past half and seven years, the largest settlement has amounted to 1287.5mm, and corresponding horizontal displacement has amounted to 664.6mm. On the ground surface, two fissure belts show a fast-growing trend of closure. To sum up, mining steep metal mine with backfill method also exist the same serious problem of rockmass movement hazards. Fault, as a low intensity zone in rockmass, when it located within the region of mining influence, the change of potential energy mainly consumed in fault deformation associated with rockmass structure surface friction, which is the essence of displacement and stress barrier effects characterized by fault rupture zone. when steep fault located in the tensile deformation region incurred by underground excavation, no matter excavation in hangingwall or in footwall of the fault, there will be additional tensile stress on the vertical fault plane and decrease in the shear strength, and always showing characteristics of normal fault slip, which is the main reason of fault escarpment appeared on the ground surface. The No.14 shaft deformation and failure is triggered by fault activation, which showed with sidewall move, rupture, and break down features as the main form of a concentrated expression of fault effects. The size and orientation of principal stress in surrounding rock changed regularly with mining; therefore, roadway deformation and damage at different stages have different characteristics and distribution models. During the process of mining, low-intensity weak structures surface always showed the most obvious reaction, accompany with surface normal stress decrease and shear strength bring down, to some extent, occurred with relative slide and deformation. Meanwhile, the impact of mining is a relatively long process, making the structure surface effect of roadway deformation and damage more prominent than others under the influence of mining. Roadway surrounding rockmass deformation caused by the change of strain energy density field after excavation mainly belongs to elastic deformation, and the correspondented damage mainly belongs to brittle rupture, in this circumstance, surrounding rockmass will not appear large deformation. The large deformation of surrounding rockmass can only be the deformation associated with structure surface friction or the plastic deformation of itself, which mainly caused by the permanent self-weigh volume force，and long-term effect of mining led to the durability of this deformation Good pitting fill effect and supporting effect of backfill, as well as the friction of rockmass structure surface lead to obvious macro-rockmass movement with long-lag characteristics. In addition, the loss of original intensity and new structure surface arisen increased flexibility in rockmass and fill deformation in structure surface, which made the time required for rockmass potential energy translate into deformation work associated with plastic deformation and structure surface friction consumed much, and to a large extent, eliminated the time needed to do those plastic work during repeated mining, all of which are the fundamental reason of rockmass movement aftereffect more significant than before. Mining steep deposits in high tectonic stress area and in gravity stress area have different movement laws and deformation mechanism. The steep deposit, when the vertical size of the mining areas is smaller than the horizontal size of the orebody, no matter mining in gravity stress area or in high tectonic stress area, they have similar features of ground movement with mining horizontal orebody; contrarily, there will appear double settlement centers on the ground surface under the condition of mining in high tectonic stress area, while there will always be a single center under the other condition. Meanwhile the ground movement lever, scale of mining influence area and macro features of ground movement, deformation and fracture are also different from mining in gravity stress area, and the fundamental reason lies in the impact of orientation of the maximum principal stress on rock movement features in in-site rock stress field. When mining thick and steep deposit, the ground surface movement and deformation characteristic curves are significantly different from excavating the horizontal ore bed and thin steep deposit. According to the features of rockmass movement rate, the development process of mining-induced rockmass movement is divided into three stages: raising stage, steadily stage and gradually decay stage. Considering the actual exploitation situation, GPS monitoring results and macro-characteristics of surface movement, the current subsidence pattern of Jinchuan No.2 mine is in the early stage of development. Based on analysis of surface movement rate, surface subsidence rate increase rapidly when mining in double lever at the same time, and reach its peak until the exploitation model ended. When double lever mining translate into single, production decreased, surface subsidence rate suddenly start to reduce and maintain a relatively low value, and the largest subsidence center will slowly move along with the hangingwall ore body direction with increasing depth of mining, at the same time, the scope and extent of subsidence in footwall ore body will begin magnify, and a sub-settlement center will appear on ground surface, accompanied with the development and closure trend of ground fissure, the surrounding rockmass of shaft and roadway will be confronted to more frequent and severe deformation and failure, and which will have a negative impact on the overall stability of No.2 mine mining. On the premise of continuity of rockmass movement, gray system model can be used in ground rockmass movement prediction for good results. Under the condition of backfill mining step by step, the loose effect of compact status of the hard, broken rockmass led to lower energy release rate, although surrounding rockmass has high elastic energy, loose and damage occurred in the horizontal ore body, which made the mining process safety without any large geological hazards. During the period of mining the horizontal ore body to end, in view of its special “residual support role”, there will be no large scale rockmass movement hazards. Since ground surface movement mainly related to the intensity of mining speed and backfill effect, on the premise of constant mining speed, during the period of mining the horizontal ore body to end, the rate of ground surface rockmass movement and deformation won’t have sudden change.

A computational study of segregation in granular material during heaping

A continuum model of the flow of granular material during silo filling using a viscoplastic constitutive relation is presented in this paper. The constitutive model is based on the Drucker-Prager plasticity yield function. The simulation results give a realistic representation of complex features of granular flows during filling processes, such as heap formation and non-zero inclination angle of the material-air interface. The model is also coupled within the same framework with novel micro-mechanical parametrisations and the process of segregation during filling of granular mixtures can also be modelled.

Dilute acid hydrolysis of cellulose and cellulosic bio-waste using a microwave reactor system

The dilute acid hydrolysis of grass and cellulose with phosphoric acid was undertaken in a microwave reactor system. The experimental data and reaction kinetic analysis indicate that this is a potential process for cellulose and hemi-cellulose hydrolysis, due to a rapid hydrolysis reaction at moderate temperatures. The optimum conditions for grass hydrolysis were found to be 2.5% phosphoric acid at a temperature of 175 degrees C. It was found that sugar degradation occurred at acid concentrations greater than 2.5% (v/v) and temperatures greater than 175 degrees C. In a further series of experiments, the kinetics of dilute acid hydrolysis of cellulose was investigated varying phosphoric acid concentration and reaction temperatures. The experimental data indicate that the use of microwave technology can successfully facilitate dilute acid hydrolysis of cellulose allowing high yields of glucose in short reaction times. The optimum conditions gave a yield of 90% glucose. A pseudo-homogeneous consecutive first order reaction was assumed and the reaction rate constants were calculated as: k(1) = 0.0813 s(-1); k(2) = 0.0075 s(-1), which compare favourably with reaction rate constants found in conventional non-microwave reaction systems. The kinetic analysis would indicate that the primary advantages of employing microwave heating were to: achieve a high rate constant at moderate temperatures: and to prevent 'hot spot' formation within the reactor, which would have cause localised degradation of glucose.

Prediction of bisolute dye adsorption isotherms on activated carbon

The removal of acid dyes, Tectilon Blue 4R, Tectilon Red 2B and Tectilon Orange 3G, from single solute, bisolute and trisolute solutions by adsorption on activated carbon (GAC F400) has been investigated in isotherm experiments. Results from these experiments were modelled using the Langmuir and Freundlich adsorption isotherm theories with the Langmuir model proving to be the more suitable. The Ideal Adsorbed Solution (IAS) model was coupled with the Langmuir isotherm to predict binary adsorption on the dyes. The application of the IAS theory accurately simulated the experimental data with an average deviation of approximately 3% between modelled and experimental data.

Redispersion Microreactor System for Phase Transfer Catalyzed Esterification

An interdigital mixer - redispersion capillary assembly was applied to prevent the liquid-liquid bubbly flow coalescence in microreactors. The redispersion capillary consisted of 1 mm long and 0.25 mm inner-diameter constrictions placed every 0.50 m along the channel length. The system was tested on the phase transfer catalyzed esterification to produce benzyl benzoate. The application of constrictions to prevent coalescence resulted in a better reproducibility compared to a capillary without the constrictions. By controlling the total flow rate and the aqueous-to-organic ratio the bubbly flow surface-volume ratio could be increased up to 230 700 m(2)m(-3). Compared to the conventional phase transfer catalyzed esterification, the continuous operation in the interdigital-redispersion capillary assembly eliminated the use of solvents and bases, removing an energy intensive step of distillation, while increasing process safety.

Avaliação da gestão da segurança do processo na central de ciclo combinado da Tapada do Outeiro e propostas de melhoria

A Gestão da Segurança do Processo consiste na implementação de procedimentos para controlar os perigos resultantes de fabrico, manuseamento e utilização de substâncias perigosas e da utilização de sistemas sob pressão em instalações industriais, pelo que se torna numa ferramenta de Gestão muito importante na indústria. Pela pesquisa realizada, a Gestão da Segurança do Processo é um tema pouco desenvolvido no nosso país, embora esteja diretamente relacionada com a Diretivas Seveso. Como colaborador da Central de Ciclo Combinado da Tapada do Outeiro, propus-me a avaliar a Gestão da Segurança do Processo na Central. A Direção da Central apoiou o tema, reservando a confidencialidade do trabalho final devido a assuntos sensíveis do negócio. Como resultado final do Projeto temos a avaliação da Gestão da Segurança do Processo na Central de Ciclo Combinado da Tapada do Outeiro, permitindo à gestão da Central identificar oportunidades para melhorar a efetividade do cumprimento deste objetivo.

Determinación de las condiciones de trabajo y salud del personal de laboratorios universitarios como estrategia de intervención de riesgos laborales

Introducción: Las condiciones de trabajo y salud de la población trabajadora han sido estudiadas en los diferentes sectores económicos, y para esto se han aplicado diversos instrumentos para la identificación de los factores de riesgo. Sin embargo, el estudio en los trabajadores de las instituciones de educación superior, aún es escaso y limitado. Este trabajo de investigación abordó las condiciones de trabajo y salud y los factores de riesgo asociados de los empleados de laboratorios y de talleres de las diferentes unidades de una Universidad privada en Bogotá D.C. Objetivo: Determinar las condiciones de trabajo y salud del personal de laboratorios y de talleres en el 2014 de las diferentes unidades de una Universidad privada en Bogotá D.C. Métodos: Se realizó un estudio de corte transversal, en una muestra de 87 trabajadores de laboratorios y de talleres. En el análisis univariado se calcularon para las variables cualitativas frecuencias y proporciones, y para las variables cuantitativas medidas de tendencia central y dispersión acorde a la distribución de los datos. Para el análisis bivariado, se realizó la comparación de las prevalencias entre los factores de riesgo locativos, físicos, químicos, biológicos, biomecánicos y psicológicos de cada unidad y las condiciones de trabajo y salud; así como su asociación con los factores sociodemográficos y laborales, por medio de la prueba de asociación Chi-Cuadrado de Pearson. El nivel de significancia establecido fue p<0.05. Resultados: Se encontró que las variables respiración de sustancias y manipulación manual de cargas se encuentran asociadas al cargo de los trabajadores de laboratorios y de talleres. También de la muestra de trabajadores la mayoría infirió no tener una exposición significativa a los riesgos locativo, físico, biológico y psicosocial; mientras que para riesgo químico y biomecánico se encontraron frecuencias de más del 60% entre los participantes. Los hallazgos de este estudio corresponden únicamente a la percepción de los trabajadores frente a sus condiciones de trabajo y salud, puesto que no se realizaron mediciones higiénicas ni exámenes médicos a los participantes. Conclusiones: En este estudio se encontró que la exposición a riesgos locativo, físico, biológico y psicosocial es baja; mientras que es alta para riesgo químico debida a la manipulación e inhalación de sustancias químicas tóxicas, y a riesgo biomecánico a causa de las posturas prolongadas y mantenidas, la manipulación manual de cargas, los movimientos repetitivos y realizar fuerzas. En relación a las condiciones de salud mental, se encontró que la población no presenta algún estado emocional o psicológico que llame la atención, lo que en consecuencia se refleja en el buen estado de salud físico.