Redefining of potential dust explosion risk parameters for additives in the petrochemical manufacturing process

Petrochemicals are an indispensable part of our everyday life, necessitating large-scale production facilities. Additive aids play a pivotal role in the petrochemical production process, which are required for the final product to have certain desired properties. The additives used are prone to ignition and combustion, but are frequently overlooked as a source of potential hazard. This study examines the hazard profile of five common powder additives in the petrochemical manufacturing process. The inherent combustion and explosion characteristics were investigated in detail. Each sample's potential to produce a dust explosion was evaluated based upon the parameter test results, e.g., minimum ignition energy (MIE), minimum ignition temperature (MIT), and minimum explosible concentration (MEC). MIT of all five samples was between 350 and 390 °C, and MEC was less than 45 g/m3. Two of the powders had a KSt explosion rating of “extremely strong” (St-3). After a comprehensive evaluation of dust explosion sensitivity and dust explosion severity, all five additive samples were categorised as high-level potential dust explosion risks. Process safety staff and engineers working with petrochemical production should be aware of the risks posed by dust additives and be prepared to implement more stringent loss prevention measures to curtail the likelihood of dust explosions.