Ethylene Explosion

FIG. 26-30 Siipp ression of explosions, Pressures in an ethylene explosion and a sodium bicarbonate suppressed ethylene explosion, Tests conducted by Fike Corp, in a 1-m vessel. Ethylene concentration = 1,2 times stoichiometric concentration for combustion, (dp/dt)e = 169 bar/s (2451 psi/s), = reduced explosion pressure = 0,4 bar gauge (5,8 psig), (F/om Chatrathi, Explosion Testing, Safety and Technology News, vol. 3, issue 1, Pike Cotp., 1.98.9, hy permission. )... 

Analyze the first ethylene explosion example (3/8-in fitting failure) to determine the percentage of fuel that actually exploded compared to the quantity of ethylene released in a vapor cloud. 

Carbon Tetrachloride and Ethylene. Explosion can result from heating a mixture with a small quantity of benzoyl peroxide.8... 

Fig. 9.2 shows the result of an ethylene explosion in a banana ripening room due to faulty metering equipment. It shattered all the glass windows in a mezzanine office but occurred before office hours, so there was no serious injury. 

For operational and safety considerations of this process, the oxygen concentration in the gas loop should be kept below the ethylene explosivity region, below 8 mole% anywhere in the gas loop. The oxygen concentration can be controlled through the oxygen feed flow or the conversion of the oxy-chlorination reaction by manipulating the reactor temperature. 

Bromine. Slip the glass cover of a jar momentarily aside, add 2-3 ml. of bromine water, replace the cover and shake the contents of the jar vigorously. Note that the bromine is absorbed only very slowly, in marked contrast to the rapid absorption by ethylene. This slow reaction with bromine water is also in marked contrast to the action of chlorine water, which unites with acetylene with explosive violence. (Therefore do not attempt this test with chlorine or chlorine water.)... 

Reactions with Organic Compounds. Tetrafluoroethylene and OF2 react spontaneously to form C2F and COF2. Ethylene and OF2 may react explosively, but under controlled conditions monofluoroethane and 1,2-difluoroethane can be recovered (33). Benzene is oxidized to quinone and hydroquinone by OF2. Methanol and ethanol are oxidized at room temperature (4). Organic amines are extensively degraded by OF2 at room temperature, but primary aHphatic amines in a fluorocarbon solvent at —42°C are smoothly oxidized to the corresponding nitroso compounds (34). 

Copolymerization is effected by suspension or emulsion techniques under such conditions that tetrafluoroethylene, but not ethylene, may homopolymerize. Bulk polymerization is not commercially feasible, because of heat-transfer limitations and explosion hazard of the comonomer mixture. Polymerizations typically take place below 100°C and 5 MPa (50 atm). Initiators include peroxides, redox systems (10), free-radical sources (11), and ionizing radiation (12). 

By virtue of their unique combination of reactivity and basicity, the polyamines react with, or cataly2e the reaction of, many chemicals, sometimes rapidly and usually exothermically. Some reactions may produce derivatives that ate explosives (eg, ethylenedinitrarnine). The amines can cataly2e a mnaway reaction with other compounds (eg, maleic anhydride, ethylene oxide, acrolein, and acrylates), sometimes resulting in an explosion. 

Ethylene oxide is a colorless gas that condenses at low temperatures into a mobile Hquid. It is miscible in all proportions with water, alcohol, ether, and most organic solvents. Its vapors are flammable and explosive. The physical properties of ethylene oxide are summarized in Tables 1—7. 

Process Safety Considerations. Unit optimization studies combined with dynamic simulations of the process may identify operating conditions that are unsafe regarding fire safety, equipment damage potential, and operating sensitivity. Several instances of fires and deflagrations in ethylene oxide production units have been reported in the past (160). These incidents have occurred in both the reaction cycle and ethylene oxide refining areas. Therefore, ethylene oxide units should always be designed to prevent the formation of explosive gas mixtures. 

Explosibility and Fire Control. As in the case of many other reactive chemicals, the fire and explosion hazards of ethylene oxide are system-dependent. Each system should be evaluated for its particular hazards including start-up, shut-down, and failure modes. Storage of more than a threshold quantity of 5000 lb (- 2300 kg) of the material makes ethylene oxide subject to the provisions of OSHA 29 CER 1910 for "Highly Hazardous Chemicals." Table 15 summarizes relevant fire and explosion data for ethylene oxide, which are at standard temperature and pressure (STP) conditions except where otherwise noted. 

Liquid mists of ethylene oxide will decompose explosively in the same manner as the vapor. Burning rate increases with decreased droplet size. 

Liquid ethylene oxide under adiabatic conditions requires about 200°C before a self-heating rate of 0.02°C/min is observed (190,191). However, in the presence of contaminants such as acids and bases, or reactants possessing a labile hydrogen atom, the self-heating temperature can be much lower (190). In large containers, mnaway reaction can occur from ambient temperature, and destmctive explosions may occur (268,269). 

Ethylene oxide has been studied for use as a rocket fuel (276) and as a component in munitions (277). It has been reported to be used as a fuel in FAE (fuel air explosive) bombs (278). 

Explosions in the Absence of Air Some gases with positive heats of formation can be decomposed explosively in the absence of air. Ethylene reacts explosively at elevatea pressure and acetylene at atmospheric pressure in large-diameter piping. Heats of formation of these materials are -t-52.3 and -t-227 kj/mol (-1-22.5 and -1-97.6 X 10 Btii/lb mol), respec tively. 

Explosion prevention can be practiced by mixing decomposable gases with inert diluents. For example, acetylene can oe made nonexplosive at a pressure of 100 atm (10.1 MPa) by including 14.5 percent water vapor and 8 percent butane (Bodurtha, 1980). One way to prevent the decomposition reaction of ethylene oxide vapor is to use methane gas to blanket the ethylene oxide hquid. 

Deflagration pressure can be reduced substantially by suppression. Figure 26-30 shows the pressures measured in an ethylene-air explosion and a sodium bicarbonate-suppressed ethylene-air explosion. Fike Corporation, Blue Springs Missouri, and Fenwal Safety Systems, Marlborough, Mass., supply explosion suppression systems. 

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