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Accidental electrostatic sparks in industrial plant producing/handling powders/dusts occur whenever a non-earthed electrically conducting object has been charged tribo-electrically to a high voltage and suddenly discharges its energy to earth via an air gap of appropriate length. When assessing the electrostatic spark ignition hazard in an industrial plant, the parameters of prime concern are the capacitances C of electrically conducting plant items that may become charged tribo-electrically, the voltages U to which they may become charged, and the minimum electric spark ignition energies (MIE) of the dust clouds of concern. Whenever 1 2 C U 2 > MIE , there is a possibility of accidental electrostatic spark ignition. Current standard apparatuses for determining MIE of dust clouds have a lower spark energy limit of 2–3 mJ. In an investigation by the present authors, discussed in detail elsewhere, a new spark generator capable of producing synchronized capacitive sparks of energies down to the order of 0.01 mJ was developed and used for testing a selection of ignition-sensitive powders for MIE. Several of the MIEs found were 1–2 orders of magnitude lower than the lower energy limit of current standard test apparatus. Other experiments by the present authors, also reported elsewhere, have shown that quite low MIEs can be found for some dusts even with a less optimal synchronization mechanism, which may occur accidentally in practice. The main object of the present paper is to discuss possible practical concerns arising from the finding that clouds in air of some dusts can have very low MIEs. In such cases, one may have to pay attention to even minor C values, i.e. minor plant items. Alternatively, with larger C values, even quite low voltages may give rise to hazardous spark discharges. However, some types of fine metal powders of low MIEs will quite readily form electrically conductive layers on the solid surfaces with which they make contact. Hence, electrostatic spark ignition inside process equipment containing such dusts may be less probable than in the case of process equipment containing non-conducting dusts of correspondingly low MIEs. There may be a need for a new standard test method for determination of MIEs of dust clouds in the

The lower energy limit of current standard test apparatus for determining the minimum ignition energy (MIE) of dust clouds is in the range of 1–3 mJ. This is a quite severe limitation because many dusts ignite readily at this energy level. A new spark generator, capable of producing synchronised sparks of very low energies and with an integrated system for measurement of spark energy, has therefore been developed and employed to a number of easily ignitable dusts. Before testing the MIE of dust clouds, it was considered essential to calibrate the new spark generator against a gas of known MIE. For this purpose, a mixture of propane and air was selected. However, a comprehensive literature review revealed that the reported MIEs of this gas mixture vary significantly, depending on the spark discharge characteristics, including discharge duration. When taking these factors into account, it was concluded that the new spark generator yielded reasonable results for propane/air. Applying the new spark generator to explosive dust clouds showed that a number of dusts do in fact have MIEs that are one to two orders of magnitude lower than 1 mJ. The new spark generator may therefore offer a basis for developing a standard test apparatus in the low-energy region. When using a method of triggering the spark by the explosive dust cloud itself, which probably is a more industrially relevant process than synchronisation between the dust dispersion and sparkover, somewhat higher MIEs were found compared to those determined when using synchronised sparks. However, even with this method of spark triggering, MIEs below 1 mJ were found.

Conventional tests for investigating the minimum ignition energy (MIE) of dust clouds are restricted to energies above a few mJ, due to the challenges of producing sparks of very low energies that can be synchronised with a transient dust cloud. In this paper, a new circuit for generating capacitive sparks of significantly lower energies than 1 mJ is presented. A measurement system for capturing voltage and current waveforms has been integrated in the circuit, offering the energy delivered to the spark by integration of the power-versus-time curve. When working with such low energy discharges, which are highly transient phenomena, attention must be paid to the measurement technique and methods of noise reduction in the measurement instruments. The measured spark energies range from 0.03 to 7 mJ, and they were found to constitute between 60 and 90 per cent of the energy stored on the discharge capacitors prior to breakdown. Losses to the measurement resistors are increasingly significant at higher energies and larger electrode gaps, due to the relatively large currents, and correspondingly small spark resistances. A simple circuit simulation, in which the spark conductivity is assumed proportional to the spark energy, offers voltage and current waveforms in good agreement with the measured ones, indicating that the spark is mainly resistive. In addition, the discharge channel's ability to carry current depends strongly on the supplied energy. The proportionality factor is found to depend on the breakdown voltage.

An investigation of ignition of dust clouds by the use of electric spark discharges triggered by the explosive dust cloud itself has been conducted. This method of triggering capacitive sparks probably represents a realistic mechanism for initiating accidental dust explosions in industrial practice. Unlike the conventional method for determining the minimum ignition energy (MIE) in the laboratory, the delay between dust dispersion and spark discharge is not a degree of freedom. In stead, the transient dust cloud itself is used to initiate spark breakdown between electrodes set at a high voltage lower than breakdown in pure air. In the present study, different kinds of dusts were tested as ‘spark triggers’, and they exhibited quite different abilities to trigger breakdown. Large particles were found to initiate breakdown at lower voltages than smaller ones. In general, conductive particles were not found to initiate breakdown at lower voltages than dielectric ones when using the same dust concentration. Minimum ignition energies (MIE) of three dusts (Lycopodium clavatum, sulphur and maize starch) were determined using the authors' method of study. The MIEs were somewhat higher than those obtained using conventional methods, but relatively close to the values obtained through conventional methods.