GUIDELINES FOR Safe Handling of Powders and Bulk Solids CENTER FOR CHEMICAL PROCESS SAFETY of the American Institute of Chemical Engineers Three Park Avenue, New York, New York 10016 Copyright © 2005 American Institute of Chemical Engineers Park Avenue New York, New York 10016-5991 All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise without the prior permission of the copyright owner AIChE™ and CCPS® are trademarks owned by the American Institute of Chemical Engineers These trademarks may not be used without the prior express written consent of the American Institute of Chemical Engineers The use of this product in whole or in part for commercial use is prohibited without prior express written consent of the American Institute of Chemical Engineers To obtain appropriate license and permission for such use contact Scott Berger, 212-591-7237, scotb@AIChE.org Library of Congress Cataloging-in-Publication Data: CIP data applied for ISBN 0-8169-0896-6 CCPS Publication G-95 It is sincerely hoped that the information presented in this volume will lead to an even more impressive safety record for the entire industry; however, the American Institute of Chemical Engineers, its consultants, CCPS Subcommittee members, their employers, and their employers’ officers and directors disclaim making or giving any warranties or representations, express or implied, including with respect to fitness, intended purpose, use or merchantability and/or correctness or accuracy of the content of the information presented in this document As between (1) American Institute of Chemical Engineers, its consultants, CCPS Subcommittee members, their employers, their employers’ officers and directors and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequences of its use or misuse This book is available at a special discount when ordered in bulk quantities For information, contact the Center for Chemical Process Safety at the address shown above ACKNOWLEDGMENTS The American Institute of Chemical Engineers wishes to thank the Center for Chemical Process Safety (CCPS) and those involved in its operation, including its many sponsors whose funding made this project possible; the members of its Technical Steering Committee who conceived of and supported this Guidelines project, and the members of the Bulk Solids Handling subcommittee It is the subcommittee’s belief that if the information contained in this book happens to prevent one bulk solids fire or dust explosion, the efforts of all those involved in preparing this work will be justified and rewarded The members of the CCPS Bulk Solids Handling subcommittee were: Principle authors: Stanley Grossel (retired Robert Zalosh (Worcester Polytechnic Institute) Russell Kahn (Chair, Syngenta Crop Protection) Dan Sliva (CCPS Staff Liason) John Bresland (CCPS Staff Liason) Larry Britton (retired) Warren Greenfield (International Specialty Products) Dave Hermann (DuPont) Dave Kirby (Union Carbide) Melvin Nelson (Syngenta Crop Protection) Al Ness (Rohm & Haas) Jeff Philiph (Monsanto) Gary Pilkington (Abbott Laboratories) Monica Stiglich (3M) The following individuals also made contributions to the subcommittee: Walt Frank (EQE) Carla Hardy (Eastman Kodak) Ronald Kersten (TNO) Roy Winkler (Solutia) Paul Wood (Eli Lilly) xv xvi Acknowledgments Finally, these individuals are thanked for their contributions to our principle authors: Richard E Bassett (Gustafson, LLC) Lyndon Bates (Ajax Equipment Limited) Robert P Benedetti (National Fire Protection Association) Timothy J Carney (Palamatic Handling USA, Inc.) Cristoph Cesana (Kuhner) C A Crouch (Consultant) Vahid Ebadat (Chilworth Technology) Henry L Febo (FM Global Technologies LLC) John W Fields (LCI Corporation) Julie Janicke (B.A.G Corporation) Trevor A Kletz (Process Safety Consultant) R Glenn Lunger (Fuller Bulk Handling Corporation) Bill Mahoney (The Young Industries, Inc.) Peter E Moore (Kidde International) Matthew Paine (Chilworth Technology) Andre Petric (Glatt Air Techniques, Inc.) Richard D Pickup (formerly with Chilworth Technology) John L Roberts (Steri Technologies, Inc.) Martyn Ryder (Extract Technology) Robert W Schoeff (Kansas State University) Jim Shell (Niro Incorporated) Albert J Shohet (Processall, Inc.) Amy Spencer (NFPA) Bruce Teeling (Key International, Inc.) William A Thornberg (formerly with GE Global Asset Protection Services) Alan Tyldesley (U.K Health and Safety Executive) Edward B Weisselberg (Wyssmont Company, Inc.) Jack Zoppa (Vac-U-Max) Prior to publication, all CCPS books are subjected to a thorough peer review process For such effort, CCPS also gratefully acknowledges the thoughtful comments and suggestions of John Alderman (RRS) Sheila Beattie (Syngenta Crop Protection) John V Birtwistle Larry Bowler Reinhard E Bruderer (PRED) Wayne Cannell (Gowan Milling) William Chandler (OSHA) Don Connolley (Akzo) xvii Tony Downes (FMC) Bob Gravell (DuPont) Tom Hoppe (CIBA Specialty Chemicals) Pete Lodal (Eastman) Brian Dean Moore Samuel J November (Rohm & Haas) Tony Powell (3M) Sam Rodgers (Honeywell) Joe Senecal (Kidde-Fenwall) Bob Stankovich (Lilly) Kenan Stevick (Dow) Tony Thompson (Monsanto) Alan Tyldesley (Health & Safety Executive, U.K) Erdem A Ural CONTENTS Acknowledgments xi Introduction and Overview 1.1 Purpose of Book 1.2 Particulate Hazards 1.2.1 Combustibility Hazards 1.2.2 Instability Hazards 1.2.3 Reactivity Hazards 1.2.4 Toxicity Hazards 1.3 Accident Data and Case Histories 1.3.1 Dust Explosion Data and Case Histories 1.3.2 Other Particulate Incident Databases 1.3.3 Sample Case Histories for Particulate Instability, and Reactivity Incidents 1.3.4 Sample Case Histories for Asphyxia Incidents 1.4 Particulate Handling and Storage Equipment Hazard Overview 1.5 Historical and Regulatory Perspective References 2 6 11 11 15 16 21 25 Particulate Characteristics and Properties 2.1 How Particulate Characteristics and Properties Affect Hazards 2.2 Particulate Physical Characteristics 2.2.1 Size Measurement Methods 2.2.2 Particle Size Distribution 2.2.3 Fiber Characteristics 2.2.4 Flake Characteristics and Specific Surface Area 29 30 30 38 42 45 v vi Contents 2.2.5 Abrasiveness 2.2.6 Hardness and Friability 2.2.7 Agglomeration 2.2.8 Particle Size Changes due to Friability and Agglomeration 2.2.9 Bulk Density Measurements and Characterizations 2.2.10 Dust Cloud Concentration Measurements 2.2.11 Bulk Powder Moisture Measurements 2.2.12 Fluidity and Dispersibility 2.2.13 Electrical Resistivity 2.3 Overview of Particulate Chemical Characteristics 2.3.1 Flammability and Explosibility 2.3.2 Thermal Degradation and Instability 2.3.3 Chemical Reactivity: Incompatible Chemical Groups 2.3.4 Corrosivity 2.4 Overview of Particulate Toxicity 2.4.1 Particulate Properties Pertinent to Respiratory Hazards 2.4.2 Allergenic and Irritant Materials 2.4.3 Systemic and Single Exposure Toxicity 2.4.4 Carcinogenic Classifications References 46 49 49 52 57 58 64 67 69 71 71 73 74 77 79 79 80 81 83 84 Particulate Hazard Scenarios and Examples 3.1 Thermal and Shock Instability Scenarios 3.1.1 Exothermic Decomposition Explosions 3.1.2 Shock/Friction Sensitive Instability Scenarios 3.1.3 Self-Heating Hazard Scenarios 3.2 Decision Trees for Assessing Thermal Instability Hazard Scenarios 3.3 Chemical Incompatibility Hazard Scenarios 3.3.1 Contamination Hazard Scenarios 3.3.2 Water Entry Scenarios 3.3.3 Container/Packaging Incompatibility Scenarios 3.3.4 Air Access to Pyrophoric Particulates 3.4 Chemical Compatibility Charts for Assessing Hazards 3.5 Particulate Fire Scenarios 3.5.1 Smoldering Fires in Storage Piles and Dust Collectors 3.5.2 Dust Layer Fires 3.5.3 Warehouse Storage Fires 3.5.4 Particulate Flash Fires 89 89 95 98 102 107 107 110 112 112 114 117 117 118 119 122 Contents 3.6 Decision Trees for Assessing Particulate Fire Scenarios 3.7 Dust Explosion Scenarios 3.7.1 Primary Dust Explosions in Process Equipment 3.7.2 Hybrid Explosion Scenarios 3.7.3 Explosion Propagation to Connected Equipment 3.7.4 Secondary Dust Explosions in Buildings 3.8 Dust Explosion Decision Trees and Protection Flow Charts 3.9 Toxic Material Exposure Scenarios 3.9.1 Chronic Exposure Scenarios during Processing and Material Handling 3.9.2 Acute Exposure Accident Scenarios 3.9.3 Fire and Explosion Exposure Scenarios 9.3.4 Incident Cleanup Exposure Scenarios References vii 124 126 126 130 131 132 134 138 138 139 142 144 144 Assessing Particulate Hazards 4.1 Preliminary Assessments via Material Safety Data Sheets, Handbooks, Guidelines, Codes and Standards 4.1.1 Preliminary Assessment of Instability Hazards 4.1.2 Preliminary Assessments of Reactivity Hazards 4.1.3 Preliminary Assessments of Combustibility and Explosibility Hazards 4.1.4 Preliminary Assessments of Toxicity 4.1.5 Special Considerations and Cautions in Using MSDS and Generic Databases 4.1.6 Publicly Available Computer Databases 4.1.7 Company and Consortium Databases 4.2 When Are More Detailed Particulate Hazard Data Needed? 4.3 Laboratory Test Methods for Detailed Assessments of Particulate Hazards 4.3.1 Particulate Sampling and Conditioning for Testing 4.3.2 Laboratory Testing for Instability Hazards 4.3.3 Laboratory Test Methods for Chemical Incompatibility Hazards 4.3.4 Self-Heating, Spontaneous Combustion, and Pyrophoric Solids Test Methods 4.3.5 Dust Layer Combustibility Test Methods 4.3.6 Electrostatic Charging and Discharge Testing for Particulates 149 149 153 155 157 160 160 161 162 162 162 165 187 190 204 216 viii Contents 4.3.7 Dust Cloud Explosibility Test Methods 4.3.8 Fire Exposure Tests 4.3.9 Particulate Toxicity Testing 4.3.10 UN Testing Scheme for Classification of Materials as Explosives 4.4 Scaling Considerations in Applying Laboratory Test Data 4.5 Larger-Scale Testing and Theoretical Modeling References 221 251 254 257 257 259 264 Equipment Hazards and Preventive/Protective Measures 5.1 Introduction 5.2 Safety Aspects of Batch versus Continuous Operation 5.3 Particulate Solids Processing Equipment Hazards and Preventive and Protective Measures 5.3.1 Bag Openers (Slitters) 5.3.2 Blenders/Mixers 5.3.3 Drying Equipment 5.3.4 Dust Collectors 5.3.5 Extruders 5.3.6 Feeders and Rotary Valves 5.3.7 Hoses, Loading Spouts, and Flexible Boots and Socks 5.3.8 Mechanical Conveyors and Bucket Elevators 5.3.9 Pneumatic Conveyors 5.3.10 Portable Containers 5.3.11 Portable Container Emptying (Unloading) Equipment 5.3.12 Portable Container Filling Systems 5.3.13 Samplers and Sampling Systems 5.3.14 Screens and Classifiers 5.3.15 Silos and Hoppers 5.3.16 Size Enlargement Equipment 5.3.17 Size Reduction Equipment 5.3.18 Solids Charging Systems 5.3.19 Tableting Systems 5.3.20 Valves for Solids 5.3.21 Weighing Systems 5.4 Loading and Unloading of Railcars and Hopper Trucks 5.4.1 Types of Railcars and Hopper Trucks 5.4.2 Railcar and Hopper Truck Loading 5.4.3 Railcar and Hopper Truck Unloading 273 274 274 274 276 279 291 299 300 304 306 312 316 321 326 327 327 329 337 338 341 346 346 347 348 348 348 350 Contents 5.5 Instrumentation 5.5.1 Flow Instruments 5.5.2 Level Instruments 5.5.3 Pressure Instruments 5.5.4 Temperature Instruments References ix 353 354 354 354 355 355 Designing and Installing Systems to Prevent and Control Combustion, Explosions, Uncontrolled Reactions, and Release of Toxic Particulate Solids 6.1 Introduction 6.2 Causes of Fire and Deflagration 6.2.1 The Fire Triangle 6.2.2 Types of Ignition Sources 6.3 Ignition Sources: Description, Control, and Removal 6.3.1 Electrostatic Hazards and Their Control 6.3.2 Spontaneous Combustion: Evaluation and Control 6.3.3 Pyrophoric and Water-Reactive Solids 6.3.4 Flames and Hot Gases 6.3.5 Hot Work 6.3.6 Hot Surfaces 6.3.7 Hot Particles 6.3.8 Friction and Impact 6.3.9 Chemical Reactions 6.3.10 Physical Sources 6.3.11 Electrical Equipment 6.3.12 Lightning 6.3.13 Projectiles 6.4 Electrical Equipment Hazards and Area Classifications 6.4.1 Electrical Equipment Hazards 6.4.2 Electrical Area Classification 6.5 Deflagration Prevention Methods 6.5.1 Prevention or Minimization of Dust Cloud Formation 6.5.2 Oxidant Concentration Reduction (Inerting) 6.5.3 Combustible Concentration Reduction (Air Dilution) 6.6 Deflagration Protection Methods 6.6.1 Deflagration Venting 6.6.2 Deflagration Suppression 6.6.3 Deflagration Pressure Containment 361 361 362 363 363 363 373 377 381 382 382 383 385 387 391 391 391 392 392 392 394 398 398 399 408 410 410 416 426 801 Index Terms N National Ambient Air Quality Standards (NAAQS) National Emission Standards for Hazardous Air Pollutants (NESHAP) National Fire Protection Association (NFPA) combustibility/exposibility hazards preliminary assessment dust cloud explosibility tests fire exposure tests instability ratings, preliminary assessment operation and maintenance reactivity hazards preliminary assessment National Institute for Occupational Safety and Health (NIOSH) fiber characteristics health standards respirators National Oceanic and Atmospheric Administration (NOAA/EPA Reactivity Worksheet) Negative-pressure pneumatic conveyors, equipment descriptions NFPA See National Fire Protection Association (NFPA) NIOSH See National Institute for Occupational Safety and Health (NIOSH) NOAA/EPA Reactivity Worksheet Nonroutine release, impact measurement Nuclear scales, equipment descriptions O Occupational health and environmental concerns operations considerations (nonroutine) emergency response cleanup employee safety emergency venting permits and reporting requirements protective systems activation cause disabled releases, impact measurement operations considerations (routine) asphyxiation hazards clean rooms air filters air handling systems air pressure classification of Links 518 519 519 22 155 226 251 149 487 153 156 227 254 150 157 228 154 44 528 539 540 74 76 77 76 77 555 560 557 559 558 555 556 561 558 559 544 547 552 548 553 673 74 556 746 517-564 554 559 556 558 557 554 556 560 560 561 556 523-554 542 545 550 551 550 551 546 557 558 561 561 543 546 551 551 552 This page has been reformatted by Knovel to provide easier navigation 549 554 802 Index Terms construction of fire protection/loss prevention types of employee precautions health standards housekeeping/cleanup hazards isolation rooms maintenance operations, environmental issues monitoring employee exposure and risk assessment equipment and areas permits personal protective equipment (PPE) hand and foot protection head, eye, and face protection maintenance, inspection, and repair of protective clothing respiration system design ventilation product stewardship protection requirements regulatory requirements Oil/vapor adsorption, self-heating hazards Operation and maintenance See also Maintenance corrosion/erosion equipment integrity documentation inspection and testing upgrading and repairs housekeeping practices incident investigations maintenance generally predictive preventive recommendations for management of change process hazard analysis regulatory requirements Optical flame detectors Ovens, hazards Oxidants Links 552 553 546 528 526 542 544 540 553 554 547 529 527 524 523 523 529-540 525 524 526 531 529 534 530 536 541 526 540 521 517 517 101 485-516 532 530 535 531 537 533 501 506 497 501 497 501 491 512 507 512 507 509 508 510 487 491 485 546 20 545 541 548 549 550 528 542 534 536 538 539 540 518 102 519 520 521 502 507 498 503 504 505 499 500 501 498 499 500 495 513 508 496 514 509 497 522 508 510 509 511 488 492 486 457 21 This page has been reformatted by Knovel to provide easier navigation 512 489 493 487 510 511 490 494 491 803 Index Terms concentration reduction prevention/control systems P Packed bed scrubbers, equipment descriptions Particle size changes, friability and agglomeration Particle size distribution dust cloud explosibility test physical characteristics Particle size measurement methods, physical characteristics Particulate characteristics/properties chemical corrosivity flammability and explosibility reactivity thermal degradation and instability hazards and physical abrasiveness agglomeration bulk density measurements bulk powder moisture measurements dust cloud concentration measurements electrical resistivity fiber characteristics flake characteristics fluidity and dispersibility hardness and friability particle size changes particle size distribution size measurement methods toxicity allergenics and irritants carcinogenic classifications respiratory hazards systemic and single exposure toxicity Particulate fire scenarios decision trees for assessment of Links 399 404 387 400 405 388 401 406 389 402 407 403 408 634 52 57 635 53 54 55 56 39 40 41 42 31 36 32 37 33 34 72 77 78 72 75 74 30 73 78 79 73 76 74 79 75 47 50 58 66 59 64 70 43 46 68 48 51 225 38 30 35 29-88 71 76 77 71 74 73 29 30-70 46 49 57 64 58 63 69 42 45 67 49 52 57 38 225 30 35 79 84 80 83 79 81 117 122 124 77 67 60 65 61 44 45 53 54 55 56 39 40 41 42 31 36 80 32 37 81 33 34 82 83 81 84 80 82 118 123 125 83 119 124 126 120 125 121 126 This page has been reformatted by Knovel to provide easier navigation 62 804 Index Terms dust layer fires flash fires smoldering fires warehouse storage Particulate hazards See Equipment hazards; Hazards; Hazard scenarios Particulate-removing respirators (PAPRs) Particulate sampling, laboratory test methods Pelican diverter sampler, equipment description Pellet mills, equipment description Permits emergency venting occupational health and environmental concerns Personal protective equipment (PPE) hand and foot protection head, eye, and face protection, and face protection maintenance, inspection, and repair of protective clothing respiration Phase Doppler laser diffraction, size measurement methods Physical adsorption, prevention/control systems ignition sources Physical characteristics abrasiveness agglomeration bulk density measurements bulk powder moisture measurements dust cloud concentration measurements electrical resistivity fiber characteristics flake characteristics fluidity and dispersibility hardness and friability particle size changes particle size distribution size measurement methods Pinch valves, equipment descriptions Pin disk mills, equipment descriptions Pin mixers, equipment descriptions Pitting corrosion Plain chain conveyor, equipment descriptions Plant design considerations See Design considerations Links 118 122 117 119 119 123 118 120 536 162 704 717 556 523 529-540 531 529 534 530 536 541 124 121 122 537 163 538 164 165 532 530 535 531 537 533 534 47 50 58 66 59 64 70 43 46 68 48 51 536 538 539 540 67 60 65 61 62 44 45 36 391 30-70 46 49 57 64 58 63 69 42 45 67 49 52 57 38 225 30 35 737 723 587 502 661 69 53 54 55 56 39 40 41 42 31 36 738 32 37 33 34 503 662 This page has been reformatted by Knovel to provide easier navigation 805 Index Terms Plant operation and maintenance See Operation and maintenance Plate dryer, equipment descriptions Plate tower scrubbers, equipment descriptions Plate-wire precipitator, equipment descriptions Pneumatic conveying dryers, equipment descriptions Pneumatic conveying systems dust explosion scenarios hazards Pneumatic conveyors equipment descriptions equipment hazards Pneumatic load-cell scales, equipment descriptions Point (limit sensing) devices, equipment descriptions Poly-Kneader ® blender, equipment descriptions Portable container(s) equipment descriptions fiber drums flexible intermediate bulk container (FIBC) multiwall paper bags rigid intermediate bulk container (RIBCs) equipment hazards Portable container emptying (unloading) equipment equipment descriptions bag dump stations drum and box dumpers flexible intermediate bulk container (FIBC) unloading system vacuum pneumatic conveyor unloading system hazards bag dump stations drum and box dumpers flexible intermediate bulk container (FIBC) unloading system vacuum pneumatic conveyor unloading system Portable container filling systems equipment descriptions drum filling systems flexible intermediate bulk container (FIBC) filling systems small bag equipment hazards Links 608 634 621 600 609 622 601 130 19 669 674 312 746 755 585 670 675 313 671 676 314 672 677 315 756 588 757 758 678 683 679 680 678 682 316-321 321 679 680 681 682 680 681 679 683 317 318 319 320 690 684 689 691 685 686 687 693 691 321 326 323 321 694 692 322 695 693 323 324 325 322 323 324 323 325 326 695 700 700 696 701 701 697 698 699 699 695 326 700 696 327 697 698 699 683-695 689 683 688 This page has been reformatted by Knovel to provide easier navigation 673 678 316 806 Index Terms Positive discharge bucket elevator, equipment descriptions Positive-pressure pneumatic conveyors equipment descriptions Powder formulation equipment, barrier isolation systems, prevention/control systems Predictive maintenance See also Maintenance Preliminary assessment See Assessment Pressure containment, deflagration protection Pressure instruments equipment descriptions equipment hazards Pressure purging, oxidant concentration reduction, deflagration prevention Prevention/control systems carbon dioxide construction strategies containment strategies barrier isolation systems controlled general ventilation local exhaust ventilation and airflow booths deflagration prevention combustible concentration reduction (air dilution) dust cloud prevention/minimization oxidant concentration reduction deflagration protection isolation systems flame front diverters flame front extinguishing systems (suppressant barriers) HSE propagation prevention device material chokes valves, automatic fast-acting pressure containment secondary explosion prevention spark detection and extinguishing systems suppression control and monitoring systems detectors fundamentals of injection systems materials Links 669 671 672 673 473 509 474 510 475 426 427 760 354 355 399 361-484 460 446 462-475 466 471 463 464 398 403 408 408 398 399 404 410-443 427-441 434 435 440 438 427 432 426 442 441 416-426 423 420 419 421 424 400 460 401 461 402 447 448 449 467 472 464 465 399 404 409 409 399 400 405 468 473 469 474 470 475 401 406 402 407 402 407 403 408 435 436 437 441 439 428 433 427 443 442 438 430 431 466 400 405 410 410 401 406 440 429 434 424 421 422 425 This page has been reformatted by Knovel to provide easier navigation 423 426 807 Index Terms venting dry chemicals electrical area classification electrical equipment hazards fire/deflagration causes foams halon replacement (clean) agents ignition sources chemical reactions electrical equipment electrostatic hazards bonding and grounding humidity control ionization and other methods linings and coatings hazards types of flames friction and impact hot gases hot particles hot surfaces hot work lightning physical adsorption projectiles pyrophoric solids spontaneous combustion water-reactive solids plant design considerations siting strategies water sprinkler/deluge systems Preventive maintenance See also Maintenance Process equipment, dust explosion scenarios blenders dryers dust collector grinder/pulverizer pneumatic conveying equipment Process hazard analysis, operation and maintenance Product stewardship, occupational health and environmental concerns Professional organizations, regulations Projectiles, prevention/control systems, ignition sources Links 410 415 458 394 392 361 457 460 363-392 387 391 363-373 369 371 371 373 364 369 381 385 382 383 382 382 391 391 392 377 373 379 475 443 449 454 508 411 416 459 395 393 362 458 461 412 388 389 370 371 372 373 365 366 382 386 387 460 396 394 363 413 414 397 398 390 391 367 368 384 383 392 378 374 380 476 444 450 455 509 379 375 376 377 445 451 456 446 452 457 453 126 127 128 129 130 130 491 127 128 129 130 128 129 130 492 493 494 521 22 522 23 392 This page has been reformatted by Knovel to provide easier navigation 808 Index Terms Prolonged processes, self-heating hazards Propagating brush (Lichtenberg) discharge, electrostatic ignition sources Protection requirements, occupational health and environmental concerns Protective clothing, personal protective equipment (PPE) Protective systems See also specific systems activation cause disabled Pug mills, equipment descriptions Pulse-jet baghouses Purging, oxidant concentration reduction deflagration prevention Pyrophoric particulates, air access to, chemical incompatibility hazard scenarios Pyrophoric solid (s), prevention/control systems ignition sources Pyrophoric solid test, self-heating hazards test methods R Radiation temperature sensors, equipment descriptions Railcar and hopper trucks described loading types of unloading hazards loading types of unloading Rate-of-pressure rise tests, dust cloud explosibility tests Reaction forces, deflagration protection, venting Reactivity, chemical characteristics Reactivity hazards assessment, preliminary case histories chemical incompatibility scenarios described Reactors, barrier isolation systems, prevention/ control systems Record keeping, equipment integrity Regulatory requirements See also specific government agencies, associations and statutes Links 101 368 369 517 530 560 531 561 560 561 585 628 561 629 630 631 399 404 400 401 402 112 113 114 377 204 378 379 747 748 747 748 349 750 749 350 349 350 351 352 353 242 247 416 74 243 248 244 245 75 76 77 153 11 107 112 154 12 108 113 13 109 114 14 110 403 762 746 747 746 747 348 353 348 348 350 471 501 This page has been reformatted by Knovel to provide easier navigation 751 351 352 246 15 111 809 Index Terms occupational health and environmental concerns operation and maintenance sources of Releases, nonroutine, impact measurement Repair, upgrading and, equipment integrity Resistivity See Electrical resistivity Respiration, personal protective equipment (PPE) Respiratory hazards, toxicity Reverse-flow baghouses Ribbon blenders, equipment descriptions Rigid intermediate bulk container (RIBCs) See also Bulk containers equipment descriptions equipment hazards Risk assessment, monitoring, occupational health and environmental concerns Rod mills, equipment descriptions Roll briquetting machines, equipment description Roll crushers, equipment descriptions Rotary dryers, equipment descriptions Rotary valve(s), equipment hazards See also Feeders/rotary valves Rotary valve feeders, equipment descriptions Rotating disk valves, valves for solids, equipment descriptions Rotating double-cone vacuum dryer, equipment descriptions Rotating drum and inclined-disk granulators, equipment description S Samplers and sampling systems equipment descriptions equipment hazards Scaling considerations, laboratory test methods Scanning electron microscope Scraper conveyor, equipment descriptions Screening tests dust cloud explosibility tests instability hazards Screens and classifiers equipment descriptions equipment hazards Screw conveyor dryer, equipment descriptions Screw conveyors equipment descriptions Links 517 526 485 21 556 501 518 527 486 22 519 528 487 23 520 521 24 25 536 541 79 627 579 537 538 539 540 80 628 580 629 587 705 706 682 321 683 524 721 716 720 597 302 525 303 304 647 648 649 526 717 721 740 606 607 713 714 701 327 257 34 662 702 224 165 225 166 167 702 707 327 604 703 704 328 605 329 654 655 656 258 36 663 This page has been reformatted by Knovel to provide easier navigation 715 259 657 810 Index Terms equipment hazards Screw feeders equipment descriptions equipment hazards Secondary explosions dust explosion scenarios prevention of, deflagration protection Segmented ball valves, equipment descriptions Self-accelerating decomposition temperature (SADT), exothermic decomposition explosions Self-accelerating decomposition temperature (SADT) test, instability hazards test methods Self-Contained Breathing Apparatus (SCBA) Self-heating hazard scenarios See also Spontaneous combustion excessive storage pile heated particulate storage oil/vapor adsorption prolonged processes Self-heating hazards test methods constant temperature oven tests pyrophoric solid test theoretical basis types of UN classification tests Self-ignition temperature (SIT), exothermic decomposition explosions Shaker baghouses Shock/friction instability hazard scenarios Sieve analysis, size measurement methods Silos and hoppers equipment descriptions equipment hazards Single exposure toxicity Single leg elevators, equipment hazards Siting strategies, prevention/control systems Size distribution dust cloud explosibility test physical characteristics Size enlargement equipment equipment descriptions equipment hazards Size measurement methods, physical characteristics Links 308 644 300 301 132 442 741 133 443 89 90 176 181 538 98 177 182 539 99 134 178 179 180 540 100 101 102 193 198 203 194 199 204 195 200 96 31 97 32 98 708 330 335 82 709 331 336 83 710 332 337 444 445 446 225 38 39 40 41 42 711 716 337 30 35 712 717 338 31 36 713 714 715 32 37 33 34 99 100 101 101 190-204 190 204 191 196 201 195 89 627 95 30 707 329 334 81 311 443 102 191 192 197 202 90 This page has been reformatted by Knovel to provide easier navigation 711 333 811 Index Terms Size reduction equipment equipment descriptions equipment hazards Slide gate valves deflagration protection equipment descriptions Slitters (bag openers) equipment descriptions equipment hazards Small bag filling systems equipment descriptions equipment hazards Smoke detectors Smoldering fires, particulate fire scenarios Sodium azide, shock/friction instability hazard scenarios Sodium hydrosulfite, water reactivity hazards Solids charging systems equipment descriptions equipment hazards Spark detection, extinguishing systems and deflagration protection Spark (capacitor) discharge, electrostatic ignition sources Spark ignition tests, dust cloud explosibility tests Spontaneous combustion, prevention/control systems See also Self-heating hazard scenarios Spray chamber scrubbers, equipment descriptions Spray dryers equipment descriptions equipment hazards Sprinkler systems See Water sprinkler/deluge systems Standard ball valves, equipment descriptions Static mixers, equipment descriptions Steam-tube rotary dryer, equipment descriptions Storage hazards described self-heating hazard scenarios smoldering fire scenarios warehouse fires Stress corrosion cracking Supplied-air respirators (SARs) Suppressant barriers (flame front extinguishing systems), deflagration systems Suppression deflagration protection Links 717-727 338 339 340 427 733 428 734 429 735 577 274 275 276 696 697 698 699 729 343 730 344 345 237 238 239 375 376 377 17 18 19 20 100 118 120 121 122 539 540 541 437 438 695 326 456 117 341 118 96 112 97 727 341 346 728 342 441 442 369 235 240 373 236 241 374 636 601 283 602 284 741 587 604 16 21 99 117 119 502 538 435 416-426 This page has been reformatted by Knovel to provide easier navigation 812 Index Terms control and monitoring systems detectors fundamentals of injection systems materials Sweep-through purging, oxidant concentration reduction, deflagration prevention Systemic toxicity T Tableting systems equipment descriptions equipment hazards Temperature instruments equipment descriptions equipment hazards Testing, equipment integrity See also Laboratory test methods Textbooks combustibility/exposibility hazards preliminary assessment toxicity hazards preliminary assessment Theoretical modeling, assessment Thermal contact temperature sensors, equipment descriptions Thermal degradation, chemical characteristics Thermal fire detectors Thermal instability hazard scenarios decision trees for assessment of exothermic decomposition explosions ammonium nitrate ammonium perchlorate self-heating hazards excessive storage pile heated particulate storage oil/vapor adsorption prolonged processes Thermally unstable materials, ignition sources Thermite reactions, ignition sources Thermochemical equilibrium calculations instability hazards preliminary assessment reactivity hazards preliminary assessment Through-circulation dryers, equipment descriptions Time-of-flight instruments, size measurement methods Links 423 420 419 421 424 424 421 422 425 423 426 402 81 403 82 404 83 730 346 731 732 760 355 497 761 762 498 499 155 158 259 156 159 260 157 761 73 455 89 94 101 106 102 107 89 94 91 94 98 99 100 101 101 390 389 762 74 456 90 95 102 107 103 152 154 594 37 153 90 95 92 95 99 262 263 91 98 103 92 99 104 93 100 105 104 105 106 91 92 93 93 94 100 101 391 390 This page has been reformatted by Knovel to provide easier navigation 500 261 102 595 733 596 102 813 Index Terms Totally encapsulating chemical protective (TECP) suit Toxicity hazards allergenics and irritants assessment, preliminary carcinogenic classifications described emergency venting, occupational health and environmental concerns employee precautions respiratory hazards systemic and single exposure toxicity testing for, laboratory test methods Toxic materials exposure scenarios acute chronic cleanup operations fire and explosion Toxic Substance and Control Act (TSCA) Trade associations, regulations Trichloroisocyanuric acid, water reactivity hazards Tube-and-auger sampler, equipment description Tube probe sampler, equipment description Tubular precipitator, equipment descriptions Tumbling type blenders/mixers, equipment descriptions Turbine blenders/mixers, equipment descriptions Turbine mills, equipment descriptions Turbotray dryers, equipment descriptions Twin-legged elevators, equipment hazards Twin-rotor blenders, equipment descriptions Two-stage precipitator, equipment descriptions U Ultrasonic spectroscopy, size measurement methods United Kingdom, dust cloud explosibility tests See also Health and Safety Executive (HSE, UK) United Nations explosives classification hazardous materials instability designations self-heating hazards classification tests United States, dust cloud explosibility tests United States Department of Transportation (DOT) United States Environmental Protection Agency (EPA) United States Food and Drug Administration (FDA) United States Occupational Safety and Health Links 530 79 84 80 157 83 555 528 79 81 254 138 143 139 138 144 142 518 22 112 703 703 624 578 581 723 593 311 585 625 531 80 81 158 84 529 80 82 81 82 159 160 83 83 255 139 144 140 139 256 140 257 141 141 142 143 144 24 25 142 579 724 312 586 587 196 227 228 74 487 76 518 520 521 37 225 257 151 195 226 21 21 486 531 21 This page has been reformatted by Knovel to provide easier navigation 77 519 485 520 814 Index Terms Administration (OSHA) Unloading equipment hazards See Portable container emptying (unloading) equipment Upgrading, repair and, equipment integrity V Vacuum pneumatic conveyor unloading system equipment descriptions equipment hazards Vacuum-shelf dryer, equipment descriptions Valves, automatic fast-acting, deflagration protection Valves for solids equipment descriptions butterfly valves diaphragm valves diverter valves gate lock valves gate valves iris diaphragm valves pinch valves rotating disk valves segmented ball valves standard ball valves equipment hazards Vented hot gases, ignition sources Ventilation controlled general, containment strategies emergency venting, occupational health and environmental concerns local exhaust, airflow booths and, containment strategies occupational health and environmental concerns permits Venturi scrubbers, equipment descriptions Vertical orbiting screw blender, equipment descriptions Vertical orbiting screw vacuum dryer, equipment descriptions Vibratory conveyors equipment descriptions equipment hazards Vibratory feeders equipment descriptions equipment hazards Volumetric feeders equipment descriptions Links 21 524 157 526 485 527 486 529 520 544 691 323 607 692 693 427 432 428 433 429 434 430 431 735 736 501 733-744 739 736 744 741 733 743 737 740 741 741 346 382 608 737 742 734 738 347 463 464 554 555 556 464 540 523 636 580 465 466 556 637 638 656 308 658 659 646 302 647 644 649 645 610 This page has been reformatted by Knovel to provide easier navigation 646 647 648 815 Index Terms equipment hazards W Warehouse storage, particulate fire scenarios Water reactivity chemical incompatibility hazard scenarios ignition sources Water sprinkler/deluge systems, prevention/ control systems Web (sheeting) dryers, equipment descriptions Web scrubbers, equipment descriptions Weighing systems equipment descriptions equipment hazards Weight belt feeder, equipment descriptions Wet precipitator, equipment descriptions Wet scrubbers, equipment hazards Worker safety, maintenance recommendations Z Zig-Zag® blender, equipment descriptions Zirconium, water reactivity hazards Zirconium potassium, shock/friction instability hazard scenarios Links 300 301 302 303 119 120 121 122 110 379 111 380 112 449 454 593 634 639 450 455 594 635 640 451 456 452 457 453 636 641 637 638 744 347 649 625 298 512 745 746 626 299 585 111 587 95 96 This page has been reformatted by Knovel to provide easier navigation 304 ... Committee who conceived of and supported this Guidelines project, and the members of the Bulk Solids Handling subcommittee It is the subcommittee’s belief that if the information contained in... to prevent one bulk solids fire or dust explosion, the efforts of all those involved in preparing this work will be justified and rewarded The members of the CCPS Bulk Solids Handling subcommittee... responsible for designing and running processes handling powders and bulk solids in the chemical, pharmaceutical and related manufacturing industries The book can also be an aid for process hazard