Multidisciplinary Advanced Engineering Consultants and Software Developers
Pioneers in Engineering Automation and Digitisation
Case Studies
By selecting these case studies, we aim to teach from the lessons learned
Dust Explosion Accident Investigation
Overview: Explosive Event in a Plastic Factory
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This accident investigation revolved around a violent explosion that occurred in a plastic factory.
The accident caused one fatality and two serious injuries. The explosion was so strong that it completely decimated the building housing the plant and shattered windows several kilometers away. The accident lead to the hearing of a court case.
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Potential Scenarios: High Probability
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The public prosecutor at the time alleged that a gas cylinder in the plant was responsible for the massive explosion. However, explosion modelling guided and overseen by Dr. Madhat Abdel-jawad from Advanced Analysis, showed that even all of the gas in the cylinder in question would not be sufficient to generate sufficient overpressure to cause the amount of damage caused by the accident.
Dust lift rate due to gas explosion in a fume hood calculated using exploCFD
Numerical Modelling
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Instead, the modelling showed that a small gas explosion in a fume hood was sufficient to rupture the relatively weak 30” piping downstream of the suction hood and agitate and ignite an appreciable amount of epoxy dust, generating a dust explosion powerful enough to destroy the building.
Dispersion, Fire and Explosion Consequence Analysis
Probabilistic Consequence Analysis
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The flammable gas clouds resulting from the dispersion analysis were simulated for delayed ignition and explosion overpressures, for critical locations and structures for the site. Also modelled, were fires and other explosions arising from the Boilers on site.
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Consequence Analysis: Dispersion, Fire, Explosion
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The study included toxic and flammable dispersion modelling, as well as, fire and explosion modelling. Computational Fluid Dynamics (CFD) analysis was carried out on releases of Ammonia, Methane and Hydrogen, and other gases, including CO. On this particular site, the most severe consequences were found to arise from toxic releases. Of importance, was the potential effect on the surrounding area, which includes other industrial sites, as well as, an encroaching residential area. A 10-5 gas cloud superimposed onto a google maps image was generated.
Consequence Analysis Capability
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The flammable gas clouds resulting from the dispersion analysis were simulated for delayed ignition and explosion overpressures, for critical locations and structures for the site. Also modelled, were fires and other explosions arising from the Boilers on site.
Flammable Gas Cloud on exploCFD
The study was used as a basis for the siting of a new laboratory, admin and workshop buildings. The study was also used to evaluate the escape routes and muster areas for each scenario.
Advanced Analysis has a highly advanced capability for carrying out consequence and risk analysis for toxic and flammable releases, as well as, fires and explosions.
Gas Explosion on Site using exploCFD