Pub Date : 2025-12-05DOI: 10.1016/j.jlp.2025.105877
Shuhao Zhang , Xiangchun Li , Xiaowei Li , Jianhua Zeng , Yuzhen Long , Baisheng Nie , Mingxiu Xing
Unsafe behaviors in coal mining are a leading cause of accidents, posing significant risks to worker safety and operational efficiency. Understanding the underlying neural mechanisms associated with these behaviors can provide valuable insights for early intervention and prevention. Electroencephalography (EEG) offers a non-invasive method to monitor brain activity and cognitive states in real-time. This study investigates EEG signal patterns linked to unsafe behaviors in coal mine workers within a controlled simulation environment. We focus on power spectral features in key frequency bands—alpha (α), beta (β), and gamma (γ)—including both absolute and relative power, as well as the α/β ratio, to explore their relationship with cognitive load and attentional processes during different task stages. The findings reveal distinct EEG dynamics that reflect shifts in cognitive resource allocation and neural activation when workers engage in potentially hazardous actions. These insights provide a foundation for developing neural-based early warning systems aimed at enhancing safety monitoring and reducing accident risks in mining operations.
{"title":"From brain to behavior: EEG signatures of unsafe actions in occupational simulations","authors":"Shuhao Zhang , Xiangchun Li , Xiaowei Li , Jianhua Zeng , Yuzhen Long , Baisheng Nie , Mingxiu Xing","doi":"10.1016/j.jlp.2025.105877","DOIUrl":"10.1016/j.jlp.2025.105877","url":null,"abstract":"<div><div>Unsafe behaviors in coal mining are a leading cause of accidents, posing significant risks to worker safety and operational efficiency. Understanding the underlying neural mechanisms associated with these behaviors can provide valuable insights for early intervention and prevention. Electroencephalography (EEG) offers a non-invasive method to monitor brain activity and cognitive states in real-time. This study investigates EEG signal patterns linked to unsafe behaviors in coal mine workers within a controlled simulation environment. We focus on power spectral features in key frequency bands—alpha (α), beta (β), and gamma (γ)—including both absolute and relative power, as well as the α/β ratio, to explore their relationship with cognitive load and attentional processes during different task stages. The findings reveal distinct EEG dynamics that reflect shifts in cognitive resource allocation and neural activation when workers engage in potentially hazardous actions. These insights provide a foundation for developing neural-based early warning systems aimed at enhancing safety monitoring and reducing accident risks in mining operations.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105877"},"PeriodicalIF":4.2,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145747525","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-05DOI: 10.1016/j.jlp.2025.105875
Wojciech Moroń
Experimental investigations of explosive properties have confirmed that toner powder presents a significant explosion hazard. Existing explosion protection systems are mainly based on complex detection mechanisms and mitigation of the consequences of an explosion event. This study presents an explosion suppression approach employing inert dust, demonstrated using a small-scale recycling facility for spent laser printer cartridges as a case study. The scope of work encompassed a detailed operational analysis of the facility, identification of explosion hazard areas and zones, followed by laboratory-scale experiments and full-scale on-site tests. The aim of this study is to assess the possibility of using inert material to neutralize the explosive properties of toner powder. In this case, calcium carbonate dust was chosen as an inert material. Furthermore, the mechanism of explosion suppression by inert dust was examined using TGA/DSC analyses. The results demonstrated that explosions in the recycling installation can be eliminated by continuous dosing of inert material. The explosion inhibition effect achieved exceeded 90 %, confirming the effectiveness of inert dust as a suppression medium. Analysis of the suppression mechanism revealed that the calcination of calcium carbonate generates products that enhance the suppression effect and significantly limit explosion propagation.
{"title":"The explosion suppression effects of added limestone dust on minimizing the risk of dust explosions in the printer cartridge recycling installation","authors":"Wojciech Moroń","doi":"10.1016/j.jlp.2025.105875","DOIUrl":"10.1016/j.jlp.2025.105875","url":null,"abstract":"<div><div>Experimental investigations of explosive properties have confirmed that toner powder presents a significant explosion hazard. Existing explosion protection systems are mainly based on complex detection mechanisms and mitigation of the consequences of an explosion event. This study presents an explosion suppression approach employing inert dust, demonstrated using a small-scale recycling facility for spent laser printer cartridges as a case study. The scope of work encompassed a detailed operational analysis of the facility, identification of explosion hazard areas and zones, followed by laboratory-scale experiments and full-scale on-site tests. The aim of this study is to assess the possibility of using inert material to neutralize the explosive properties of toner powder. In this case, calcium carbonate dust was chosen as an inert material. Furthermore, the mechanism of explosion suppression by inert dust was examined using TGA/DSC analyses. The results demonstrated that explosions in the recycling installation can be eliminated by continuous dosing of inert material. The explosion inhibition effect achieved exceeded 90 %, confirming the effectiveness of inert dust as a suppression medium. Analysis of the suppression mechanism revealed that the calcination of calcium carbonate generates products that enhance the suppression effect and significantly limit explosion propagation.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105875"},"PeriodicalIF":4.2,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145747527","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-04DOI: 10.1016/j.jlp.2025.105878
Zheng Duan , Bei Pei , Yuxuan Deng , Xinyi Li , Liang Wang , Chang Lu
Methane explosions in confined pipelines pose a persistent hazard in gas transmission and urban distribution systems, and explosion venting is a primary mitigation measure. However, the synergistic interaction between end and side vents and its influence on flame dynamics and overpressure relief remain insufficiently understood. This study experimentally investigates the coupled effects of end-vent area and side-vent position on the propagation of explosions in a 15 cm × 15 cm × 200 cm transparent acrylic duct filled with 9.5 % methane–air premixed gas. End vents with areas of 100, 64, and 36 cm2 are combined with side vents located 0.7, 1.0, and 1.3 m from the ignition end. High-speed imaging and pressure transducers are employed to capture flame evolution and explosion overpressure histories, and each condition is repeated three times to ensure reproducibility. Without side vents, the flame exhibits a staged evolution from spherical to finger-shaped, planar, and tulip flames. Decreasing end-vent area advances tulip-flame formation, reduces flame propagation velocity, and prolongs the overall propagation time due to stronger wave reflection and sustained internal overpressure. With coupled end–side venting, flame dynamics display a characteristic three-stage behavior: pressure-driven acceleration upstream of the side vent, pronounced deceleration as the flame traverses the vent owing to lateral mass discharge and momentum extraction, and mild re-acceleration near the end vent. The side vent markedly reduces peak explosion overpressure and the duration of high-pressure loading, and it effectively suppresses secondary overpressure peaks by discharging unburned mixture and reshaping the internal flow field. The mitigating effect of the side vent strengthens as the end-vent area decreases, because the end vent controls the pressure differential driving side-vent discharge. A dimensionless synergy coefficient Ψ, defined from the peak overpressures with single and dual vents, increases from 0.073 to 0.48 (a 558% enhancement) when the end-vent area is reduced from 100 to 36 cm², demonstrating strong nonlinear coupling between the vents. These findings elucidate the fluid–dynamic mechanism of synergistic venting and provide a quantitative basis for optimizing multi-point explosion venting configurations in industrial pipeline protection.
密闭管道中的甲烷爆炸对输气和城市配气系统造成了持续的危害，而爆炸通风是主要的缓解措施。然而，端侧通风口之间的协同作用及其对火焰动力学和超压释放的影响仍未得到充分的了解。实验研究了在15 cm × 15 cm × 200 cm填充9.5%甲烷-空气预混气体的透明丙烯酸管道中，端部通风口面积和侧部通风口位置对爆炸传播的耦合影响。末端通风口面积分别为100,64和36cm2，与位于0.7,1.0和1.3 m的点火端侧通风口相结合。采用高速成像和压力传感器捕捉火焰演变和爆炸超压历史，每种情况重复三次以确保再现性。没有侧面通风口，火焰表现出阶段性的演变，从球形到手指形，平面，和郁金香火焰。减小末端通风口面积可以促进郁金香火焰的形成，降低火焰的传播速度，并且由于更强的波反射和持续的内部超压而延长了整体传播时间。使用耦合的端侧通风，火焰动力学表现出一个特征的三级行为：压力驱动的加速在侧通风口上游，明显的减速火焰穿过通风口由于侧向质量排放和动量提取，和温和的再加速在末端通风口附近。侧通气孔显著降低爆炸超压峰值和高压加载持续时间，并通过排出未燃混合气和重塑内部流场有效抑制二次超压峰值。侧通气孔的缓解作用随着端通气孔面积的减小而增强，这是因为端通气孔控制着驱动侧通气孔排放的压差。当末端通风口面积从100 cm²减少到36 cm²时，由单通风口和双通风口峰值超压定义的无量纲协同系数Ψ从0.073增加到0.48（增加558%），表明通风口之间存在强烈的非线性耦合。研究结果阐明了协同通风的流体动力学机理，为工业管道保护多点爆炸通风配置优化提供了定量依据。
{"title":"Synergistic suppression of methane explosion propagation in pipelines with coupled end–side vents","authors":"Zheng Duan , Bei Pei , Yuxuan Deng , Xinyi Li , Liang Wang , Chang Lu","doi":"10.1016/j.jlp.2025.105878","DOIUrl":"10.1016/j.jlp.2025.105878","url":null,"abstract":"<div><div>Methane explosions in confined pipelines pose a persistent hazard in gas transmission and urban distribution systems, and explosion venting is a primary mitigation measure. However, the synergistic interaction between end and side vents and its influence on flame dynamics and overpressure relief remain insufficiently understood. This study experimentally investigates the coupled effects of end-vent area and side-vent position on the propagation of explosions in a 15 cm × 15 cm × 200 cm transparent acrylic duct filled with 9.5 % methane–air premixed gas. End vents with areas of 100, 64, and 36 cm<sup>2</sup> are combined with side vents located 0.7, 1.0, and 1.3 m from the ignition end. High-speed imaging and pressure transducers are employed to capture flame evolution and explosion overpressure histories, and each condition is repeated three times to ensure reproducibility. Without side vents, the flame exhibits a staged evolution from spherical to finger-shaped, planar, and tulip flames. Decreasing end-vent area advances tulip-flame formation, reduces flame propagation velocity, and prolongs the overall propagation time due to stronger wave reflection and sustained internal overpressure. With coupled end–side venting, flame dynamics display a characteristic three-stage behavior: pressure-driven acceleration upstream of the side vent, pronounced deceleration as the flame traverses the vent owing to lateral mass discharge and momentum extraction, and mild re-acceleration near the end vent. The side vent markedly reduces peak explosion overpressure and the duration of high-pressure loading, and it effectively suppresses secondary overpressure peaks by discharging unburned mixture and reshaping the internal flow field. The mitigating effect of the side vent strengthens as the end-vent area decreases, because the end vent controls the pressure differential driving side-vent discharge. A dimensionless synergy coefficient Ψ, defined from the peak overpressures with single and dual vents, increases from 0.073 to 0.48 (a 558% enhancement) when the end-vent area is reduced from 100 to 36 cm², demonstrating strong nonlinear coupling between the vents. These findings elucidate the fluid–dynamic mechanism of synergistic venting and provide a quantitative basis for optimizing multi-point explosion venting configurations in industrial pipeline protection.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105878"},"PeriodicalIF":4.2,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-04DOI: 10.1016/j.jlp.2025.105874
Chin-Lung Chiang , Wei-Chun Chen , Cheng-Li Chuang , Yi-Ying Ho , Jia-You Gao , Paul Amyotte , Yu-Chi Cheng
Firecracker powders present inherent dust explosion hazards during manufacturing, handling, and storage. This study evaluated the explosion sensitivity and severity of two commercial firecracker formulations (conventional and eco-friendly) based on key combustibility parameters. The conventional powder exhibited a minimum ignition energy (MIE) of 9 mJ, a minimum ignition temperature (MITC) of 280 °C, a minimum explosible concentration (MEC) of 95 g/m3, and a deflagration index (Kst) of 555 bar m/s. In comparison, the eco-friendly formulation showed MIE > 1000 mJ, MITC = 300 °C, MEC = 250 g/m3, and Kst = 75 bar m/s. The Kst results classified the conventional powder as St-3 and the eco-friendly type as St-1, indicating a substantial difference in explosion severity. Overall, the results suggest that newer formulations designed with environmental considerations may also provide enhanced intrinsic safety. This work provides practical insights into pyrotechnic hazard classification and supports the development of safer and more sustainable firecracker products.
爆竹粉末在制造、处理和储存过程中存在固有的粉尘爆炸危险。本研究基于关键的可燃性参数，对两种商业鞭炮配方（传统和环保）的爆炸敏感性和严重程度进行了评价。常规粉末的最小点火能量（MIE）为9 mJ，最小点火温度（MITC）为280℃，最小爆炸浓度（MEC）为95 g/m3，爆燃指数（Kst）为555 bar m/s。相比之下，环保型配方的MIE = 1000 mJ, MITC = 300℃，MEC = 250 g/m3, Kst = 75 bar m/s。Kst结果将常规粉末分类为St-3，环保型粉末分类为St-1，表明爆炸严重程度有很大差异。总的来说，研究结果表明，考虑到环境因素而设计的新配方也可能提供更高的内在安全性。这项工作为烟火危害分类提供了实际的见解，并支持开发更安全、更可持续的爆竹产品。
{"title":"Assessing intrinsic hazard characterization of conventional and eco-friendly firecracker powders based on dust combustion and explosion parameters","authors":"Chin-Lung Chiang , Wei-Chun Chen , Cheng-Li Chuang , Yi-Ying Ho , Jia-You Gao , Paul Amyotte , Yu-Chi Cheng","doi":"10.1016/j.jlp.2025.105874","DOIUrl":"10.1016/j.jlp.2025.105874","url":null,"abstract":"<div><div>Firecracker powders present inherent dust explosion hazards during manufacturing, handling, and storage. This study evaluated the explosion sensitivity and severity of two commercial firecracker formulations (conventional and eco-friendly) based on key combustibility parameters. The conventional powder exhibited a minimum ignition energy (<em>MIE</em>) of 9 mJ, a minimum ignition temperature (<em>MITC)</em> of 280 °C, a minimum explosible concentration (<em>MEC</em>) of 95 g/m<sup>3</sup>, and a deflagration index (<em>K</em><sub>st</sub>) of 555 bar m/s. In comparison, the eco-friendly formulation showed <em>MIE</em> > 1000 mJ, <em>MITC</em> = 300 °C, <em>MEC</em> = 250 g/m<sup>3</sup>, and <em>K</em><sub>st</sub> = 75 bar m/s. The <em>K</em><sub>st</sub> results classified the conventional powder as St-3 and the eco-friendly type as St-1, indicating a substantial difference in explosion severity. Overall, the results suggest that newer formulations designed with environmental considerations may also provide enhanced intrinsic safety. This work provides practical insights into pyrotechnic hazard classification and supports the development of safer and more sustainable firecracker products.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105874"},"PeriodicalIF":4.2,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145747526","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-02DOI: 10.1016/j.jlp.2025.105873
Haiyan Chen , Wenxue Sun , Hao Liu , Qi Zhang , Jinshe Chen , Xiaozhen Li , Jinzhou Li , Yeye He
To investigate the effectiveness of nitrogen-phosphorus-silicon composite in suppressing Al powder explosions, a nitrogen-phosphorus-silicon synergistic explosion suppressant, MCA@ADP-MMT, was prepared using montmorillonite (MMT), melamine cyanurate (MCA), and aluminum diethylphosphinate (ADP) as the raw materials and its suppression effect and mechanism were investigated experimentally and numerically. Results show a strong correlation between suppression efficacy and suppressant concentration. At 300 %wt, MCA@ADP-MMT effectively quenches Al powder explosions, reducing maximum overpressure (Pmax) by 96.3 %, maximum pressure rise rate (dP/dtmax) by 99.8 %, and the average flame propagation speed reduced from 2.26 m/s (α = 0.25) to 0.88 m/s (α = 1). The scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) analyses reveal the physical suppression mechanism. The solid flame-retardant products, such as phosphates and silicates, produced from thermal decomposition of the composite coat the Al powder surface, which blocks heat and oxygen transfer and exerts a physical suppression effect. CHEMKIN simulations reveal the chemical mechanism. The nitrogen-, phosphorus-, and carbon-containing small molecules from explosion suppressant decomposition function through multiple mechanisms. They reduce the oxygen availability in the combustion zone by dilution, lower the combustion temperature by absorbing heat, scavenge reactive O radicals in the flame and inhibit the generation of AlO radicals, thereby terminating the chain reaction. In summary, MCA@ADP-MMT effectively mitigates Al powder explosions at elevated concentrations. This suppression performance is attributed to the synergistic effects of physical isolation-where the refractory coating impedes oxygen and heat transfer and gas phase chemical inhibition that involves dilution of oxygen, radical scavenge, and temperature reduction.
为研究氮磷硅复合材料对铝粉爆炸的抑制效果，以蒙脱土（MMT）、三聚氰胺氰脲酸盐（MCA）和二乙基膦酸铝（ADP）为原料制备了氮磷硅协同抑爆剂MCA@ADP-MMT，并对其抑制效果和机理进行了实验和数值研究。结果表明，抑菌剂浓度与抑菌效果密切相关。在300 %wt时，MCA@ADP-MMT有效地淬灭了Al粉爆炸，最大超压（Pmax）降低96.3%，最大压力上升率（dP/dtmax）降低99.8%，平均火焰传播速度从2.26 m/s （α = 0.25）降低到0.88 m/s （α = 1）。扫描电镜（SEM）和x射线光电子能谱（XPS）分析揭示了物理抑制机制。复合材料热分解产生的磷酸盐、硅酸盐等固体阻燃产物包覆在铝粉表面，阻断了热和氧的传递，起到物理抑制作用。CHEMKIN模拟揭示了化学机制。抑爆剂中的含氮、含磷、含碳小分子通过多种机制进行分解。它们通过稀释降低燃烧区氧的可用性，通过吸收热量降低燃烧温度，清除火焰中的活性氧自由基，抑制氧自由基的产生，从而终止链式反应。总之，MCA@ADP-MMT有效地减轻了高浓度铝粉的爆炸。这种抑制性能归因于物理隔离的协同效应，其中耐火涂层阻碍了氧气和热量的传递，以及气相化学抑制，包括氧气的稀释、自由基清除和温度降低。
{"title":"Study on Al powder explosion suppression mechanism of MCA@ADP-MMT composite","authors":"Haiyan Chen , Wenxue Sun , Hao Liu , Qi Zhang , Jinshe Chen , Xiaozhen Li , Jinzhou Li , Yeye He","doi":"10.1016/j.jlp.2025.105873","DOIUrl":"10.1016/j.jlp.2025.105873","url":null,"abstract":"<div><div>To investigate the effectiveness of nitrogen-phosphorus-silicon composite in suppressing Al powder explosions, a nitrogen-phosphorus-silicon synergistic explosion suppressant, MCA@ADP-MMT, was prepared using montmorillonite (MMT), melamine cyanurate (MCA), and aluminum diethylphosphinate (ADP) as the raw materials and its suppression effect and mechanism were investigated experimentally and numerically. Results show a strong correlation between suppression efficacy and suppressant concentration. At 300 %wt, MCA@ADP-MMT effectively quenches Al powder explosions, reducing maximum overpressure (P<sub>max</sub>) by 96.3 %, maximum pressure rise rate (dP/dt<sub>max</sub>) by 99.8 %, and the average flame propagation speed reduced from 2.26 m/s (α = 0.25) to 0.88 m/s (α = 1). The scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) analyses reveal the physical suppression mechanism. The solid flame-retardant products, such as phosphates and silicates, produced from thermal decomposition of the composite coat the Al powder surface, which blocks heat and oxygen transfer and exerts a physical suppression effect. CHEMKIN simulations reveal the chemical mechanism. The nitrogen-, phosphorus-, and carbon-containing small molecules from explosion suppressant decomposition function through multiple mechanisms. They reduce the oxygen availability in the combustion zone by dilution, lower the combustion temperature by absorbing heat, scavenge reactive O radicals in the flame and inhibit the generation of AlO radicals, thereby terminating the chain reaction. In summary, MCA@ADP-MMT effectively mitigates Al powder explosions at elevated concentrations. This suppression performance is attributed to the synergistic effects of physical isolation-where the refractory coating impedes oxygen and heat transfer and gas phase chemical inhibition that involves dilution of oxygen, radical scavenge, and temperature reduction.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105873"},"PeriodicalIF":4.2,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691441","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.jlp.2025.105872
Xuhai Pan , Andong Yu , Yongjia Chen , Yuqi Liu , Min Hua
Styrene polymerization is a highly exothermic and thermally sensitive process prone to thermal runaway under inadequate heat removal, posing severe safety hazards in industrial operations. In this work, a combined experimental–simulation approach was adopted to investigate the thermal hazard characteristics of styrene polymerization initiated by AIBN and the influence of key operational parameters. Differential scanning calorimetry (DSC), adiabatic calorimetry (ARC), and reaction calorimetry (RC1e) were employed to systematically examine the effects of initiator concentration, ethylbenzene dilution, and reaction temperature on heat release behavior, onset temperature, and runaway propensity. The results revealed that higher initiator concentrations markedly increased heat release intensity and accelerated runaway onset, while ethylbenzene addition effectively suppressed temperature rise through dilution and enhanced heat capacity. Elevated reaction temperatures intensified exothermicity, reduced thermal buffering time, and impaired heat removal efficiency. Aspen Plus simulations show that when the cooling factor increases from 2000 to 3000 kcal m−2 h−1 K−1, the peak temperature drops sharply by approximately 97 K; however, when the jacket temperature exceeds about 377–379 K, the system undergoes a rapid and uncontrollable temperature rise. The integration of calorimetric experiments with process simulations not only validated the modeling approach but also provided mechanistic insights into runaway behavior. The findings offer quantitative safety criteria and operational guidelines for mitigating thermal hazards in industrial-scale styrene polymerization.
{"title":"Thermal hazard assessment and critical safety thresholds of AIBN-initiated styrene polymerization via calorimetry and Aspen plus simulation","authors":"Xuhai Pan , Andong Yu , Yongjia Chen , Yuqi Liu , Min Hua","doi":"10.1016/j.jlp.2025.105872","DOIUrl":"10.1016/j.jlp.2025.105872","url":null,"abstract":"<div><div>Styrene polymerization is a highly exothermic and thermally sensitive process prone to thermal runaway under inadequate heat removal, posing severe safety hazards in industrial operations. In this work, a combined experimental–simulation approach was adopted to investigate the thermal hazard characteristics of styrene polymerization initiated by AIBN and the influence of key operational parameters. Differential scanning calorimetry (DSC), adiabatic calorimetry (ARC), and reaction calorimetry (RC1e) were employed to systematically examine the effects of initiator concentration, ethylbenzene dilution, and reaction temperature on heat release behavior, onset temperature, and runaway propensity. The results revealed that higher initiator concentrations markedly increased heat release intensity and accelerated runaway onset, while ethylbenzene addition effectively suppressed temperature rise through dilution and enhanced heat capacity. Elevated reaction temperatures intensified exothermicity, reduced thermal buffering time, and impaired heat removal efficiency. Aspen Plus simulations show that when the cooling factor increases from 2000 to 3000 kcal m<sup>−2</sup> h<sup>−1</sup> K<sup>−1</sup>, the peak temperature drops sharply by approximately 97 K; however, when the jacket temperature exceeds about 377–379 K, the system undergoes a rapid and uncontrollable temperature rise. The integration of calorimetric experiments with process simulations not only validated the modeling approach but also provided mechanistic insights into runaway behavior. The findings offer quantitative safety criteria and operational guidelines for mitigating thermal hazards in industrial-scale styrene polymerization.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105872"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691437","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-29DOI: 10.1016/j.jlp.2025.105871
Christian Foussard
Lockout-Tagout (LOTO) procedures are a cornerstone of hazardous energy control in high-risk industrial settings. While regulatory frameworks prescribe clear sequences of actions, these procedures are often implemented through linear checklists that provide limited support for understanding underlying risks or managing systemic vulnerabilities. This article introduces a multi-level bow-tie representation of LOTO, developed through a research-action initiative in a SEVESO classified pharmaceutical facility. The model articulates four interdependent layers of protection: the primary level (direct energy isolation), the secondary level (protection of primary barriers), the tertiary level (organizational structures that sustain continuity and reliability), and a metacognitive level (the cognitive infrastructure that supports reflection, anticipation, and shared understanding). Each level corresponds to distinct causal and temporal dynamics that are often obscured in conventional procedural formats. Drawing on literature from cognitive science, safety culture, and organizational learning, we argue that such layered representations enhance procedural intelligibility, reveal critical points of vulnerability, and foster both adaptive training and cross-functional dialogue. While requiring a degree of cultural maturity, the model was positively received by operational teams and integrated into local training practices. Beyond LOTO, this framework offers a transferable approach to the representation of safety-critical procedures, such as confined space entry or hot work operations. Improving safety performance may ultimately depend not only on better procedures, but on better representations, those that make protection architectures visible, intelligible, and meaningful across time, teams, and contexts.
{"title":"Representing what protects Us: From action to meaning in lockout-tagout procedures","authors":"Christian Foussard","doi":"10.1016/j.jlp.2025.105871","DOIUrl":"10.1016/j.jlp.2025.105871","url":null,"abstract":"<div><div>Lockout-Tagout (LOTO) procedures are a cornerstone of hazardous energy control in high-risk industrial settings. While regulatory frameworks prescribe clear sequences of actions, these procedures are often implemented through linear checklists that provide limited support for understanding underlying risks or managing systemic vulnerabilities. This article introduces a multi-level bow-tie representation of LOTO, developed through a research-action initiative in a SEVESO classified pharmaceutical facility. The model articulates four interdependent layers of protection: the primary level (direct energy isolation), the secondary level (protection of primary barriers), the tertiary level (organizational structures that sustain continuity and reliability), and a metacognitive level (the cognitive infrastructure that supports reflection, anticipation, and shared understanding). Each level corresponds to distinct causal and temporal dynamics that are often obscured in conventional procedural formats. Drawing on literature from cognitive science, safety culture, and organizational learning, we argue that such layered representations enhance procedural intelligibility, reveal critical points of vulnerability, and foster both adaptive training and cross-functional dialogue. While requiring a degree of cultural maturity, the model was positively received by operational teams and integrated into local training practices. Beyond LOTO, this framework offers a transferable approach to the representation of safety-critical procedures, such as confined space entry or hot work operations. Improving safety performance may ultimately depend not only on better procedures, but on better representations, those that make protection architectures visible, intelligible, and meaningful across time, teams, and contexts.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105871"},"PeriodicalIF":4.2,"publicationDate":"2025-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691440","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-26DOI: 10.1016/j.jlp.2025.105870
Michelle Xin Yi Ng , Kai Xiang Yu , Joon Yoon Ten , Khang Wei Tan , Weng Hoong Lam , Peng Chee Tan , Thomas Shean Yaw Choong , Parthiban Siwayanan , Binghui Chen , Kek Seong Kim , Zhen Hong Ban
Accurate consequence modelling and risk assessment is crucial to mitigate the toxicity risks of ammonia. However, available refrigerated liquefied ammonia studies have assumed key parameters including pool size, pool shape, and lack of flashing during initial release. This work proposed a dynamic pool area estimation method for more accurate evaporation rate calculation during continuous release, rather than assume initial pool characteristics. For releases into the atmosphere, Computational Fluid Dynamics (CFD) was used for improved simulation of ammonia flashing, evaporation, and gas dispersion. The impact of wind speed, release rate, and release pressure on pool formation and ammonia gas concentration were investigated. The increase in wind speeds extended pool length, without significantly affecting size, and increased evaporation rates, but decreased hazardous zone sizes as dilution effect was stronger under wind field influence. The increasing release rates through larger hole sizes increased pool sizes, followed by higher evaporation rates and larger hazardous zones. For larger release pressures, higher release velocities formed pools further from the source, impacting initial ammonia cloud location. The results offer insights into emergency response and evacuation plan development, and the model can provide quantitative data needed for advanced digital technologies such as Artificial Intelligence (AI)-based safety systems.
{"title":"Consequence analysis on the critical role of transient pool formation in cold ammonia release and gas dispersion using CFD approach","authors":"Michelle Xin Yi Ng , Kai Xiang Yu , Joon Yoon Ten , Khang Wei Tan , Weng Hoong Lam , Peng Chee Tan , Thomas Shean Yaw Choong , Parthiban Siwayanan , Binghui Chen , Kek Seong Kim , Zhen Hong Ban","doi":"10.1016/j.jlp.2025.105870","DOIUrl":"10.1016/j.jlp.2025.105870","url":null,"abstract":"<div><div>Accurate consequence modelling and risk assessment is crucial to mitigate the toxicity risks of ammonia. However, available refrigerated liquefied ammonia studies have assumed key parameters including pool size, pool shape, and lack of flashing during initial release. This work proposed a dynamic pool area estimation method for more accurate evaporation rate calculation during continuous release, rather than assume initial pool characteristics. For releases into the atmosphere, Computational Fluid Dynamics (CFD) was used for improved simulation of ammonia flashing, evaporation, and gas dispersion. The impact of wind speed, release rate, and release pressure on pool formation and ammonia gas concentration were investigated. The increase in wind speeds extended pool length, without significantly affecting size, and increased evaporation rates, but decreased hazardous zone sizes as dilution effect was stronger under wind field influence. The increasing release rates through larger hole sizes increased pool sizes, followed by higher evaporation rates and larger hazardous zones. For larger release pressures, higher release velocities formed pools further from the source, impacting initial ammonia cloud location. The results offer insights into emergency response and evacuation plan development, and the model can provide quantitative data needed for advanced digital technologies such as Artificial Intelligence (AI)-based safety systems.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105870"},"PeriodicalIF":4.2,"publicationDate":"2025-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621872","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-25DOI: 10.1016/j.jlp.2025.105867
Sixten Dahlbom , Šarūnas Petronis , Lars Wadsö , Christian Hulteberg , Anders Lönnermark
Lagging fires pose a significant safety risk in industrial systems where organic contaminants interact with lagging (insulation) materials. This study used isothermal calorimetry to investigate factors influencing the self-heating and ignition propensity of various C18-based substances and rapeseed oil, as contaminants in the lagging. The contaminant and lagging under investigation were added to glass ampoules, and pentane was used as a solvent to distribute the contaminant on the lagging. The factors studied were lagging materials, molecular functionalities, and metal contaminants. It was found that substances with non-conjugated double bonds, particularly those containing bis-allylic hydrogen, gave rise to the greatest peak thermal powers. Noteworthy, all tested substances exhibited some level of reactivity, suggesting no substance can be considered completely safe without system-specific analysis. To evaluate different lagging materials, rapeseed oil was used. Greater peak thermal powers were observed with glass wool and stone wool treated at temperatures ≥500 °C, likely due to the degradation of the binder materials, as supported by TGA, SEM, and EDS analyses. Furthermore, it was found that metal salts (Mn, Fe, and Cu) and copper shavings significantly increased the reactivity, while stainless steel shavings had no significant effect. Mixtures of reactive substances behaved as single entities, and their peak thermal power could be estimated as a weighted average of the pure components’ peak thermal powers. The findings have practical implications for system design, material selection, and experimental protocols, aiding engineers in evaluating fire risks and developing safer insulation systems under realistic operating conditions.
{"title":"Thermal reactivity and fire risk in lagging systems: Influence of contaminants, lagging materials, and metals","authors":"Sixten Dahlbom , Šarūnas Petronis , Lars Wadsö , Christian Hulteberg , Anders Lönnermark","doi":"10.1016/j.jlp.2025.105867","DOIUrl":"10.1016/j.jlp.2025.105867","url":null,"abstract":"<div><div>Lagging fires pose a significant safety risk in industrial systems where organic contaminants interact with lagging (insulation) materials. This study used isothermal calorimetry to investigate factors influencing the self-heating and ignition propensity of various C18-based substances and rapeseed oil, as contaminants in the lagging. The contaminant and lagging under investigation were added to glass ampoules, and pentane was used as a solvent to distribute the contaminant on the lagging. The factors studied were lagging materials, molecular functionalities, and metal contaminants. It was found that substances with non-conjugated double bonds, particularly those containing bis-allylic hydrogen, gave rise to the greatest peak thermal powers. Noteworthy, all tested substances exhibited some level of reactivity, suggesting no substance can be considered completely safe without system-specific analysis. To evaluate different lagging materials, rapeseed oil was used. Greater peak thermal powers were observed with glass wool and stone wool treated at temperatures ≥500 °C, likely due to the degradation of the binder materials, as supported by TGA, SEM, and EDS analyses. Furthermore, it was found that metal salts (Mn, Fe, and Cu) and copper shavings significantly increased the reactivity, while stainless steel shavings had no significant effect. Mixtures of reactive substances behaved as single entities, and their peak thermal power could be estimated as a weighted average of the pure components’ peak thermal powers. The findings have practical implications for system design, material selection, and experimental protocols, aiding engineers in evaluating fire risks and developing safer insulation systems under realistic operating conditions.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105867"},"PeriodicalIF":4.2,"publicationDate":"2025-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621909","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-25DOI: 10.1016/j.jlp.2025.105865
Zhen Liang , Yunhao Yang , Yingjian Wang , Meng Zhang , Yufeng Zhuang
Hydrogen, as a zero-emission clean energy source with wide availability and pollution-free combustion characteristics, also exhibits high flammability and explosiveness, posing potential fire and explosion hazards. With the rapid global development of the hydrogen energy industry, Hydrogen Refueling Stations (HRSs), as critical infrastructure for fuel cell vehicles, face significant safety operation challenges. To address this, we develop an a multidimensional quantitative modeling and integrated analysis framework for safety risks in HRSs. First, Hazard and Operability Study (HAZOP) analysis is used to identify hazard sources and extract key deviations and key scenarios that may lead to safety risks. Next, a Bow-Tie model is employed to identify and model top events, intermediate events, and basic events, clearly outlining accident evolution pathways. To quantitatively evaluate event likelihoods under uncertainty, a Fuzzy Bayesian Network (FBN) is developed by combining expert fuzzy evaluations with historical accident data, enabling probabilistic inference, backward reasoning, and sensitivity analysis to reveal dominant risk factors and critical causal chains. Meanwhile, Analytic Hierarchy Process (AHP) is used to evaluate the consequence severity across the human, equipment, environment, and management dimensions, forming a multidimensional severity assessment system. Finally, accident likelihood and severity are integrated within a risk matrix based on the As Low As Reasonably Practicable (ALARP) principle to classify overall risk levels. The findings provide scientific support for safety optimization, accident prevention, and emergency management of HRSs, contributing to the safe and sustainable development of the hydrogen energy industry.
{"title":"Multidimensional quantitative modeling fusion analysis of safety risks in hydrogen refueling stations: A case study of a station in Beijing","authors":"Zhen Liang , Yunhao Yang , Yingjian Wang , Meng Zhang , Yufeng Zhuang","doi":"10.1016/j.jlp.2025.105865","DOIUrl":"10.1016/j.jlp.2025.105865","url":null,"abstract":"<div><div>Hydrogen, as a zero-emission clean energy source with wide availability and pollution-free combustion characteristics, also exhibits high flammability and explosiveness, posing potential fire and explosion hazards. With the rapid global development of the hydrogen energy industry, Hydrogen Refueling Stations (HRSs), as critical infrastructure for fuel cell vehicles, face significant safety operation challenges. To address this, we develop an a multidimensional quantitative modeling and integrated analysis framework for safety risks in HRSs. First, Hazard and Operability Study (HAZOP) analysis is used to identify hazard sources and extract key deviations and key scenarios that may lead to safety risks. Next, a Bow-Tie model is employed to identify and model top events, intermediate events, and basic events, clearly outlining accident evolution pathways. To quantitatively evaluate event likelihoods under uncertainty, a Fuzzy Bayesian Network (FBN) is developed by combining expert fuzzy evaluations with historical accident data, enabling probabilistic inference, backward reasoning, and sensitivity analysis to reveal dominant risk factors and critical causal chains. Meanwhile, Analytic Hierarchy Process (AHP) is used to evaluate the consequence severity across the human, equipment, environment, and management dimensions, forming a multidimensional severity assessment system. Finally, accident likelihood and severity are integrated within a risk matrix based on the As Low As Reasonably Practicable (ALARP) principle to classify overall risk levels. The findings provide scientific support for safety optimization, accident prevention, and emergency management of HRSs, contributing to the safe and sustainable development of the hydrogen energy industry.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105865"},"PeriodicalIF":4.2,"publicationDate":"2025-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621869","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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