241.BF500 Safety Precautions When Using Coal and Lignite General Precautions For Inflammable Dust Safety Instruction

Safety Precautions When Using
Solid Fuels
Approved date: 03-Dec-15

Created by: N.Gupta
Approved by: FleM
Doc. No.: 12861-09-3.0

Safety Precautions when using solid fuels
12861-09-3.0
List of contents:
Page:
1 General Notes .............................................................................................. 4

2 General Information ...................................................................................... 5
2.1 Scope ........................................................................................................... 5
3 General Rules ............................................................................................... 5
4 Solid Fuel Dust Explosions .............................................................................. 6
4.1 Reducing the Risk of Explosions ....................................................................... 6
4.2 Precautions Against Fire.................................................................................. 7
Solid fuel piles ............................................................................................... 7
Solid fuel meal bins ........................................................................................ 8
5 Solid Fuel Meal Firing ..................................................................................... 9
5.1 Machines ...................................................................................................... 9
5.2 Interlocking................................................................................................... 9
6 Plant conditions ........................................................................................... 10
Solid Fuel Safety: ........................................................................................ 10
6.1 Zone Classification ....................................................................................... 11
6.2 Dust Escape ................................................................................................ 12
6.3 Pressure Relief ............................................................................................ 12
7 Inspection, Maintenance and Repair ................................................................ 12
8 Deactivating Machines During Repair ............................................................... 15
9 Monitoring Equipment ................................................................................... 15
10 Machines and Equipment ............................................................................... 15
11 Solid Fuel Stores .......................................................................................... 16
12 Rubber Belt Conveyors .................................................................................. 16
13 Raw Solid Fuel Bins ...................................................................................... 17
14 Solid Fuel Mill Plants And Solid Fuel Drying Plants .............................................. 17
15 Separator ................................................................................................... 18
16 Cyclone ...................................................................................................... 18
17 Solid Fuel Mill Filter ...................................................................................... 19
17.1 Fire fighting ................................................................................................ 20
17.2 Special precautionary measures for electrostatic precipitators ........................... 23
Before start-up: ........................................................................................... 23
Operation: .................................................................................................. 23
Maintenance ................................................................................................ 23
18 Solid Fuel Meal Bins...................................................................................... 23
18.1 Fire Monitoring ............................................................................................ 24
19 Fans .......................................................................................................... 25
20 Air Sluices .................................................................................................. 25
21 Screw Conveyors ......................................................................................... 25
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 2/27
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22 Pipe Connections, Flexible Hoses, Expansions Joins ............................................ 25

22.1 Bunker Filters .............................................................................................. 26
22.2 Central Filters .............................................................................................. 26
23 Inertization Equipment .................................................................................. 26
24 Hot Gas Generators ...................................................................................... 26
25 Written Incident Investigation Report Should Include the Following: ..................... 27
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WARNING!
This manual addresses safety risks which, in FLSmidth’ s experience, could be encountered
during the operation, maintenance or repair of equipment used in connection with
handling, conveying, stacking, grinding and burning solid fuels and related dust collection
and gas handling equipment and other related activities. It is not feasible to address or
account for all other risks or circumstances that could arise during the performance of your
work. Therefore, be aware that you may encounter risks or circumstances that are
not mentioned in this manual. In such events, we strongly recommend that you
perform a risk and safety analysis before beginning or (if already in progress)
continuing with the affected activity.
This manual is not intended to replace prevailing industrial safety practices or safety laws
that may apply to your work. It is your responsibility to be aware of and follow all such
practices and laws as well as the owner’s and your employer’s site safety programs and
requirements. The safe performance of your work is your and your employer’s
responsibility. FLSmidth will not monitor, inspect or be responsible for either your or your
employer’s (i) means, methods or techniques in performing work or (ii) safety procedures
or compliance with applicable safety practices, laws, programs or requirements.
1 General Notes
This manual pertains to the “solid fuel mill plant”. Each solid fuel mill plant differs
from site to site and industry to industry. Therefore, it is the plant owner’s
responsibility to designate the individual areas or departments that make up the solid
fuel mill plant on which you may be working.
In addition to reading this manual, be sure to read and follow the pertinent
instruction manuals for the equipment on which you will be working and the
plant specific operating manual and process instructions.
Regardless of the precautions that are recommended in this manual, the owner and
contractors should ensure that at least the following measures are taken:
• The plant’s interlock and control systems and fire extinguishment/suppression
systems are properly functioning;
• Operators and others who may be involved in start-up, operation, maintenance
and repair of the equipment and other related activities understand and are
trained and familiar with regard to such equipment and systems;
• personnel at plants in the United States are current at all times on their
applicable MSHA/OSHA training
• site and project safety meetings are held routinely;
• conditions at and around the solid fuel mill plant are routinely checked for
safety hazards and risks and these are prevented and mitigated and
appropriate warnings are promptly issued;
• all personnel are continuously alert and aware of conditions as they exist and
develop at and around the solid fuel mill plant;
• all personnel are equipped with whatever safety equipment, sensing devices
and other tools they will need to perform their work safely;
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• safety training is repeated as needed or required; and,

• adequate signage (for example, warnings, escape routes) is plainly visible,
properly positioned and maintained at all times.
2 General Information
2.1 Scope
• Design basis Identification of danger and preparation of procedures to

counter possibilities of danger.
• Preparation of explosion protection document.
• Preparation of fire and warning instructions.
3 General Rules
Handling of solid fuel and operating the solid fuel mill plant involves a variety of risks.
For example:
• Unground solid fuel may ignite spontaneously or be spontaneously ignited when
fed to raw solid fuel storage, raw solid fuel silos or to the solid fuel mill;
• Solid fuel dust may explode when the following conditions are present
simultaneously:
o oxygen (O 2 ) is above the lower explosion limit, e.g. atmospheric air,
o Solid fuel dust is in suspension in concentrations between the upper and

lower explosion limit, and
o There is an ignition source with sufficient energy.

The risk of fire or explosion may be reduced if precautionary measures are observed.
It is important that all personnel involved in handling solid fuel and solid fuel meal or
in the operation, repair or maintenance of the solid fuel mill plant are aware of
conditions that could cause spontaneous ignition and/or explosion. (See Section 4).
Daily fire and explosion mitigation precautions should be followed at the solid fuel mill
plant. These include:
• Daily inspection of buildings, machines and plant to minimize dust
accumulations.
• Good housekeeping: Cleaning and removal of extraneous combustible materials
with appropriate dust vacuum equipment or similar.
• Continuous monitoring of operating conditions.
• Efficient, fire-suppression and fire-fighting systems and equipment are properly
functioning and maintained and an adequate supply of appropriate fire-
suppression/extinguishing materials is on hand.
• Proper pressure and other relief measures are in place and functioning properly.
When a new shipment of solid fuel is delivered, obtain information about the
flammability, combustibility and other properties of the solid fuel during handling,
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stockpiling, storage, conveyance and its use. Such information can be obtained from
the solid fuel supplier or other users of the same type of materials. However, solid
fuel- even from the same mine or other source- may have different properties or
otherwise may not behave the same way.
4 Solid Fuel Dust Explosions

A mixture of solid fuel dust and air can be ignited and unexpectedly develop a violent
pressure increase. The explosiveness of the solid fuel dust/gas mixture depends on
several factors, among which are ignition temperature, lower and upper explosion
limits, the chemical composition of the solid fuel type, atmospheric conditions,
venting, containment, grain size, humidity and pressure relief.
An explosion can occur under a variety of circumstances, including- for example-
when the following conditions exist at the same time:
i. The dust content in the solid fuel/air mixture is within a fixed explosive
range indicated by upper and lower explosion limits.
ii. A sufficiently high temperature called the ignition temperature exists,

originating from glowing solid fuel dust, a spark, static electricity or
other source that creates heat or friction.
iii. The gas or air has an O 2 concentration sufficient to promote and sustain
combustion.
Turbulence inside a bin or other container can accelerate conditions that can cause an
explosion.
For information regarding lower and upper explosion limits, ignition temperature,
smoldering temperature and oxygen concentration, see the Operating
Instruction/process instruction or manual for the solid fuel mill department.
The explosion hazard may be higher in dry and fine-grained solid fuel dust as well as
in gaseous types of solid fuel that has poor ash content.
The explosiveness of solid fuel dust/gas mixtures will vary in intensity depending on
the nature of the mixture.
An energy charge of 10 joule is theoretically sufficient to start an explosion depending
on the fuel type. Ignition energy of more than 10 joule may be created in the mill by
any condition or event that can create a spark or other source of energy. This
includes, for example, iron pieces or rocks introduced together with raw solid fuel;
the impacts of grinding media, rollers or grinding tables; a hot bearing in a conveyor;
or friction between steel parts in a fan.
4.1 Reducing the Risk of Explosions

To reduce the risk of solid fuel dust explosions, prevent the conditions under i.
through iii. above from occurring at the same time. This can be done by eliminating
one or more of the conditions. If an explosion occurs, the cause must be determined
and eliminated to prevent a reoccurrence.
Protection of plant and personnel can further be promoted through:
• planning of process control;
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• selecting the proper gas composition (e.g., oxygen content) for the process gas
to the solid fuel mill plant;
• cleaning around the machines of the solid fuels mill plant and duct connection
(consistent with the degree of danger posed by the solid fuel type);
• ensuring that all pressure-relief valves and vents are clear and in good
operating order;
• Using explosion-proof equipment meeting ATEX standards.
4.2 Precautions against Fire

When solid fuels containing small and large pieces are stored, the large pieces must not be
allowed to accumulate at walls or around columns. Otherwise, such an accumulation may
result in a chimney-effect causing increased oxidation and thus a risk of spontaneous
ignition.
High solid fuel piles should be built up in layers which are compacted layer by layer with a
bulldozer. This will compress the solid fuel and thereby reduce air pockets.
Stockpiles of solid fuel should be located and maintained away from heating by nearby
kilns or other hot-running equipment, solar heat, or other heat-generating or heat-
dispersing conditions. -.
When stored for lengthy periods in dry, warm and sunny climates, open solid fuel stores
should be covered with a thin layer of limestone, raw meal, filter dust or a similar material
to reflect the sun’s rays and prevent solar heating of the solid fuel pile.
Keep the solid fuel away from oil-soaked cotton waste, rags, pieces of wood and similar
foreign objects which may increase the risk of spontaneous ignition.
Manage Stock Piles:
Solid fuel piles

It is very difficult to extinguish fires in solid fuel piles. If hot spots, burning or
smoldering materials, or glowing embers are detected, remove them as quickly as
possible from the solid fuel stock pile and spread until cooled. If necessary, spray
ample quantities of water over the spread-out solid fuel. However, this may cause
problems to subsequent transport and grinding of the solid fuel.
Attempts to put out fire with water without spreading out the pile will normally be
inadequate, because the water cannot penetrate into the pile. Likewise, trying to
extinguish fire in a solid fuel pile without digging into the center of the fire in an
attempt to “drown”' the fire from outside will be inadequate. This will normally
result in water penetrating only 3-4 meters into the pile, which is seldom enough to
extinguish a fire in the core of the pile.
The quantity of water supplied must be ample, because the supply of too little water
may cause a gas explosion. When water vapor comes into contact with burning solid
fuel, the water vapor may, under the influence of a low content of O2 in the air, be
transformed into “water gas”. This is an explosive type of gas consisting of carbon
monoxide (CO) and hydrogen (H2). This is especially the case when sulfurous solid
fuel is used. Sulfurous solid fuel can have high pyrite content. Pyritic sulfur oxidizes
more easily than non-pyritic sulfur, has a lower ignition temperature than non-
pyritic sulfur and, therefore, can be more combustible.
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ATTENTION!
Covering the pile with limestone, raw meal or foam may delay the development,
but will not extinguish a solid fuel fire.
To prevent solid fuel from being ignited, it must be mixed with 65 % inert dust.
Carbon dioxide (CO2) or other inert gasses have no extinguishing effect in solid
fuel piles.
Compaction of solid fuel piles during or after a solid fuel fire is risky,
because the core of the solid fuel pile may have been burnt away, with the
risk of collapse.
Using water for fire-fighting in enclosed spaces may cause steam explosions.
Water vapor can react to burning solid fuel and form explosive water gas. Keep all
personnel who are not involved in firefighting a safe distance away from the fire
and properly position and equip all firefighting personnel to minimize the risks of
burns and other dangers from potential steam gas explosions.
Solid fuel meal bins

ATTENTION!
A solid fuel meal bin should be equipped with an automated or manual
inertization system that will spray inert gas in the bin if fire is detected.
Ensure that:
• the inertization system is in good operating condition at all times;

• sufficient inert gas is always kept in reserve for at least two
volume inertization for each bin;
• inertization equipment can be activated from the central control
room;
• inertization equipment can also be activated locally.
• Contain the fire through inertization of the surroundings
It is very difficult to extinguish fires in solid fuel meal bins, and inertization alone
may not be sufficient in all instances to extinguish a fire in a solid fuel meal bin.
Thus, the following actions should be taken if a fire develops in a solid fuel meal
bin:
• If the control room is unable to activate the inertization system, activate it
locally.
• After the fire is extinguished, convey any remaining solid fuel meal to the
kiln for burning. If it is not possible to remove burning accumulations of solid
fuel meal by the normal mechanical means (e.g. vibrators and anvils on a
filter bottom hopper), then wash out the solid fuel meal with water. Solid
fuel meal with water content higher than 16 % is not assumed to be
explosive.
• Burning solid fuel meal must not be stirred up as it may cause an explosion.
When using water to extinguish a fire, the water must be atomized first.
Atomizing water can minimize stirring-up embers and solid fuel dust, and
displace the air to a certain extent.
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5 Solid Fuel Meal Firing

Ground solid fuel meal is supplied to the burner for burning in the pyro processing
system by a bin extraction system, a flow regulation system and a conveying system.
5.1 Machines
Extraction, flow regulators and conveyors for solid fuel meal constitute a closed
system.
To prevent backfiring in the burner and to assist mixing solid fuel meal with the
combustion air rapidly and accelerate combustion in the kiln:
• Feed the solid fuel meal into the kiln at a velocity higher than its combustion
velocity of 12-15 m/s;
• Maintain transport velocity of air from the rotary blower at a rate higher than
25 m/s;
• Maintain burner tip velocity exceeding 100 m/s by adjusting primary air as
needed.
Un-burnt gases or solid fuel meal can be carried forward in the kiln system and create
a fire or explosion hazard. To reduce this risk, maintain:
• Sufficient volume of combustion air (air-to-fuel ratio) in the kiln system;
• A temperature of the combustion air sufficient to ensure continuous ignition of
the solid fuel meal; and
• A consistent fineness of the solid fuel to the extent required for complete
combustion of the fuel in the kiln system (this will vary from fuel to fuel).
Monitor combustion air by continuously monitoring the O 2 and CO percentages in the
exit gases. Adjust the draught in the kiln system as needed to maintain the volume of
combustion air.
During start-up of the kiln system, ensure that the combustion air temperature
exceeds the solid fuel meal’s ignition temperature before introducing the fuel to the
kiln system.
The solid fuel must be ground to a fineness that will ensure combustion of the fuel in
the kiln system.
WARNING!
Variations in the flow of solid fuel meal to the kiln system can lead to formation of
explosive gases. Maintain a constant flow of solid fuel meal to minimize this risk.
5.2 Interlocking
To reduce the risk of fires and explosions, routinely verify that all sensors,
thermocouples, set points and other parts of the interlocking system are fully
functional and operating properly. In particular, ensure that:
• The operation of the burner is conditional on the pyro processing induced draft
fan and primary air fan being in operation.
• Starting a burner is conditional on high tension to the electro-static precipitator
of the existing kiln being interrupted.
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6 Plant conditions
Solid Fuel Safety:
ATTENTION!
For e.g. the complete plant must be inspected for leaking solid fuel dust at
least daily. Solid fuel dust that lies on or in the vicinity of overheated bearings
can ignite or explode.
Be sure that all personnel are instructed on applicable laws and regulations regarding
dust explosion hazards and how and when dust build-ups or accumulations must be
eliminated. At a minimum, they should be made aware that:
• A dust layer of as little as 0.8mm can create a dust explosion hazard.
However, for especially explosive solid fuels (for example, Powder River Basin
coal), a layer of dust averaging as little as .127 mm can produce a minimum
explosive concentration.
ATTENTION!
Some solid fuels are unusually combustive and explosive, and you should not
assume that the precautions in this document will be adequate to prevent or
minimize the risk of fires, explosions and other safety hazards that are
associated with handling, storing or using all solid fuels. Know and understand
the particular characteristics of the actual solid fuels that are being used at the
solid fuels mill plant and employ such additional, different and/or more
repetitive precautionary measures as may be needed to prevent or minimize
the risk of fires, explosions and other safety hazards that may be associated
with those fuels.
• Whirled-up dust can create dust clouds and may result in a dust explosion.
• If solid fuel dust is deposited on structures in a building, solid fuel dust may
fall or be whirled up, with the risk of a serious explosion in the building.
Removal of dust should be done daily at the end of each shift or (as and whenever
circumstances may require) even more frequently to ensure that the accumulated
dust levels on walls, floors and any other surfaces where does may accumulate (for
example, equipment, ducts, pipes, ledges, beams and above suspended ceilings and
interior of electrical enclosures) are removed or at least kept below 0.8 mm.
Arrange spaces in a way that facilitates cleaning. Vacuum cleaning of dust should be
established with connection to the individual spaces wherever possible.
To minimize the potential for whirling up dust, avoid vigorous sweeping, use of
compressed air or steam as compressed air to blow down equipment in dusty areas,
and other housekeeping methods that may lead to the formation of dust clouds.
The use of steam or compressed air to remove dust should be permitted only when:
a) the area and equipment have been vacuumed before blow down;
b) electrical power and other sources of ignition have been shut down or
removed;
c) the steam or air pressure is limited to 15 psig;
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d) there are no hot surfaces in the area capable of igniting dust.

In such instances, a fixed-pipe (house) system with a remotely located exhauster
and dust collector (properly protected against explosion) or a portable vacuum
cleaner listed for use in Class II hazardous locations should be used.
The building structure must not have any inaccessible horizontal faces.
Faces at sectional irons, girders, stiffeners, ledges, cornices, etc., must be made at an
angle of at least 60° to horizontal in order that solid fuel dust cannot accumulate in
these places.
Wherever possible, cable trays must be built into cable ducts in the walls, or be
placed outside the building.
Cable trays inside the building must be enclosed.
Inaccessible plane surfaces must be made at an angle of at least 60º to horizontal.
All equipment in the solid fuel grinding installation must be potentially neutralized and
earthed as specified so as to avoid static electricity which may cause sparking and
resultant fires or explosions.
Electrical equipment in classified areas must meet the requirements for those areas.
All unclassified equipment should only be placed in unclassified areas.
The plant must be able to operate around the clock. It is important that the necessary
illumination should be established and maintained.
Holes into which the personnel may fall must be fenced properly.
Elevations over which the personnel may trip must be marked properly.
Platforms and stairways must be provided with banisters.
The place of work must always be kept tidy.
Escape routes must be marked clearly with signs
Smoking and use of open fire must be prohibited. Such prohibitions must be shown
clearly by signs.
6.1 Zone Classification

A complete safety survey for the solid fuel mill plant should be prepared before
commencement of delivery and stockpiling of solid fuels to eliminate or (at a
minimum) reduce the risks posed by the handling or use of solid fuels and ensure the
safety of all personnel. FLSmidth will provide such information as may be requested.
In particular, areas where there is a hazard of explosion should be marked as a
restricted area. The hazards should be categorized. For example:
Zone_20: A place in which an explosive atmosphere in the form of a cloud of combustible
dust is present continuously or frequently.
Zone_21: A place in which an explosive atmosphere in the form of a cloud of combustible

dust is likely to occur occasionally under normal operating conditions.
Zone_22: A place in which an explosive atmosphere in the form of a cloud of

combustible dust is not likely to occur under normal operating conditions but if it does
occur, will persist for a short period only.
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6.2 Dust Escape

All conveying equipment that transports solid fuel must work at negative pressure to
avoid escape of solid fuel dust. However, this may not be necessary when
pneumatically conveying solid fuel meal, provided that:
1. there will be no more than a slight excess pressure during filling of a fuel meal
bin or raw fuel bin corresponding to the pressure loss across the bag filter, and
2. Remedial steps are taken as quickly as possible to repair wear, openings,
cracks or other deformations of pipes or joints through which solid fuel meal
can escape.
Solid fuel dust escape from the grinding installation may result from: incorrectly
adjusted valves, maladjustments and when emptying segregated foreign objects and
solid fuel from a vertical solid fuel mill.
Solid fuel dust may leak from seals and bearings, depending on operation and
maintenance. This subject is dealt with in various instruction manuals in the
maintenance section. Leaks must be repaired immediately. Worn seals must be
replaced.
Solid fuel dust that has leaked out should be removed immediately to eliminate or
reduce the risk of fire and/or explosion.
6.3 Pressure Relief

Machines integrated into the solid fuel mill plant for storing or grinding solid fuel meal
are designed to be explosion-proof in accordance with applicable design standards
and regulations and to minimize the risk of or contain fires or explosions generated
inside.
A pressure wave, if any, from inside the storage bins or grinding mill will be relieved
and vented to atmosphere through pressure relief flaps.
During operation, the areas around the pressure relief flaps must be cordoned or
barricaded and marked by no admittance signs. Checking and maintenance of
explosion relief flaps is described in the applicable equipment instruction manual. This
service work must only be done while the solid fuel mill plant is shut down.
Pressure waves containing live materials and un-burnt solid fuel dust or fire may burst
out if the pressure relief flaps are opened manually during operation. The result could
be a short-term excessive generation of heat.
Ducts, expansion joints, separators, cyclones, filters and solid fuel bins must be
pressure relieved for protection of personnel and the plant.
7 Inspection, Maintenance and Repair

Inspection and maintenance work should be carried out when and as stated in the
applicable equipment manual or more frequently as circumstances may require. Such
work should be performed only by personnel who are experienced and trained in
installation and operation of the equipment used. Follow applicable United States
or European regulations and generally recognized industrial safety practices
for cutting/welding operations and other types of maintenance work.
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ATTENTION!
Before working on or around a solid fuel mill plant, , (i) the plant must be
brought to a state below the lower explosion limit where solid fuel cannot
ignite or (ii) solid fuel must be washed down with water or vacuum
cleaned to be sure solid fuel dust cannot ignite.
Follow the applicable maintenance schedules and procedures for the equipment in the
solid fuel mill plant. In addition:
• Ventilate the equipment prior to and during inspection, maintenance and repair
work to prevent the accumulation of dangerous gases in the equipment.
ATTENTION!
Inhalation of gas with insufficient O2 content will cause asphyxiation in a very

short time.
• After inertization of process plant or coal meal bins has taken place with CO2 or N 2,
it is very important that the machine be ventilated thoroughly prior to being
entered by personnel.
• The solid fuel mill must be ventilated moderately as long as it is open.
• CO is lethal in even very small concentrations. Maintain sufficient blow-through
and ventilation to eliminate or minimize the risk of CO poisoning when entering
the machine.
• Only one manhole must be open at a time if personnel are to stay in any part of
the solid fuel mill plant.
Correct ventilation can only be ensured in this way.
ATTENTION!
Opening a door or cover before the equipment has been ventilated
sufficiently can admit air to incandescent solid fuel dust in the system.
This can create an explosion hazard and risk of a secondary explosion, as
the pressure wave from an explosion may whirl up explosive solid fuel
dust elsewhere in the system.
• Do not open bin bottom or bottom hoppers on cyclones or filters until the
equipment has been emptied of solid fuel and solid fuel meal and all equipment for
conveying solid fuel meal has been deactivated.
• If inspection or maintenance work is to be carried out inside equipment in a solid
fuel mill plant, position a watchman immediately outside the opened cover.
• Inspections should be made routinely as often as circumstances may require
detecting and preventing or minimizing solid fuels dust leakage, accumulation and
dust clouds.
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• If such leakage is detected, the condition should be corrected as quickly as

possible and the area vacuum-cleaned or washed to eliminate the potential for
fire, explosion or other safety hazards.
• If the leakage is not stopped immediately, determine whether:
o The solid fuel mill plant must be shut down to repair the leak; or,
o The plant can be safely operated while vacuum-cleaning with such
frequency as needed to minimize dust accumulation and taking other steps
to eliminate safety hazards caused by the leak.
If the solid fuel mill plant can be safely operated, schedule permanent repairs for
the first available shut-down.
ATTENTION!
Prior to entering solid fuel mill plant equipment to perform inspections,
maintenance or repairs, follow all applicable regulations and industrial safety
practices to assure that proper safety conditions exist.
In all cases, use extreme caution when opening an inspection door.

When shutting down the solid fuel mill plant, minimize the potential for combustion
and fire by feeding solid fuel meal or filter dust or other incombustible material into
the mill system.
FLSmidth recommends mounting a centralized vacuum cleaning installation with
connections in all relevant solid fuel dust escape locations. Alternatively a mobile
vacuum cleaning unit can be used.
All vacuum cleaning equipment must be suitable for the actual solid fuel that is being
fed to the plant and comply with relevant standards and codes.
Empty solid fuel meal only after it has been soaked with water.
Before emptying grinding media out of a ball mill, remove the solid fuel meal with a
vacuum cleaner
ATTENTION !
If solid fuel meal has ignited spontaneously, it must be soaked with water
until extinguished before removing the solid fuel meal and grinding media.
Equip all personnel who perform inspections, maintenance or repairs of solid fuel mill
plant equipment with portable gas analyzers and all other sensors and testing
equipment necessary to measure and alert the personnel of the presence of
combustible, explosive, noxious and other dangerous gasses. . The equipment should
also be able to give alarms at either CO-max. and O2 -min.
A ball mill can be stopped for brief control of the solid fuel charge or while samples
are being drawn.
Power tools must be of spark-proof design complying with United States or
European standards, whichever is applicable.
Do not perform welding if solid fuel dust is present.
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Thoroughly remove solid fuel dust from the repair area before starting repair work to
minimize the risk from spark formations from mechanical work.
Any changes in machines and ducts must be made so that no pockets are created in
which solid fuel dust may accumulate. However, if such changes are made, avoid
changing the inclination of ducts.
8 Deactivating Machines during Repair

Before beginning repairs, comply with all relevant lock out and tag out procedures.
Take any other steps that are necessary to ensure that the equipment to be repaired,
(all auxiliary equipment (for example, motors) and all conveying equipment to and
from the equipment to be repaired, and all applicable electric, pneumatic and other
power sources) have been shut off and deactivated.
9 Monitoring Equipment
Keep all monitoring equipment in service during operation, shutdown and standstill of
the solid fuel mill plant.
ATTENTION !
Ensure that at all times (i) the magnetic separator and metal detector are
operating, (ii) temperature and gas analyzer are properly calibrated and
(iii) all essential interlocks are in place and functioning properly.
10 Machines and Equipment

In General:
• Inspection doors for field inspection in belt conveyor discharges and chutes, lids
over screw conveyors, and drag chains must be in place and attached securely.
• Protective guards must be installed in proper position on V-belts, couplings, chain
drives and other rotary parts.
• Ensure motion detectors for moving equipment, such as, belt conveyors, screw
conveyors, airslides, etc. are installed and operational to warn of a potentially
hazardous situation.
• Perform preventive maintenance in accordance with the applicable Operation and
Maintenance Manuals.
• Replace wear components before they are worn.
• Check temperature of bearings and be sure they are properly aligned.
ATTENTION !
Overheated bearings or misalignment can cause fire and explosion
• Keep insulation on equipment in good condition. Be sure it is intact and prevent

penetration of rainwater, solid fuel, dust or other contaminants into the insulation.
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ATTENTION !
Condensation can lead to a build-up of solid fuel meal and increase the
risk of fire or explosion. The equipment is insulated to minimize
condensation which can cause build-up of fuel or corrosion.
• Ensure all electrical grounding of equipment is in place and in good condition.

• Ensure auxiliary power is available to operate key equipment in the event of a
power failure.
11 Solid Fuel Stores

The storage site must be located away from any heat source, well drained, free from
standing water.
ATTENTION !
Solid fuel stores can create a risk of spontaneous ignition. Steam or smoke
indicates that spontaneous ignition has occurred.
• Keep the storage cooled by ventilation or water spraying
• Store the solid fuel in smaller lots of stock pile
• Reduce the storage site’s access to air. For example, store in closely covered,
air-tight enclosure or store in compressed piles by packing solid fuel tightly and
compacting it with Dozer/Loader compactor over stock pile).
• Reduce the fine powder content in the solid fuel.
• Follow the practice of first in-first out in stock pile management.
• Regularly check the pile’s temperature with long portable thermocouple

temperature indicator.
• Avoid feeding hot solid fuel from the storage pile. Once cooled, the solid fuel
should be used as soon as possible. The operator must show special attention
while the solid fuel is ground. Refer to the Operating Instruction for the solid
fuel plant for maximum inlet gas temperature guidelines.
12 Rubber Belt Conveyors

Run rubber belt conveyors empty of material before stopping the mill.
Some rubber belts have a high heat resistance that can withstand temperatures up to
150 ºC. For e.g. Oil resistant rubber to be used for petcoke.
When working with pet coke it may be necessary to use oil-resistant rubber.
Ensure that the rubber belt conveyor is in good condition and properly aligned and
that the conveyor bearings are properly lubricated.
12861-09-3.0
ATTENTION !
Belt slippage, improper alignment, and/or un-lubricated bearings can
cause combustion of solid fuel that is being conveyed.
13 Raw Solid Fuel Bins

All surfaces will have a slope of at least 70° to the horizontal sphere for bins
and filters.
ATTENTION!
The solid fuel may emit gases which, when mixed with air, will form inflammable
and explosive gases.
Prior to entering a solid fuel bin for inspection, maintenance or repair, be sure the bin
has been vented in addition to complying with applicable safety regulations (for
example, testing the air for noxious or explosive gasses, confined space procedures,
etc.). The bin should be emptied before longer shut-down periods.
For precautionary measures during inspection, see Section 7 Inspection and Repair.
In the event of an outbreak of fire in the solid fuel bin, or if there is an indication that
combustion has occurred in the bin, take immediate steps to:
(i) stop feeding solid fuel from the bin;
(ii) stop all conveyors from the bin to the mill; and,
(iii) if this can be done safely, discharge the solid fuel from the bin to a safe
location. .
14 Solid Fuel Mill Plants and Solid Fuel Drying Plants

The precondition for a solid fuel dust explosion is as follows:
Adequate solid fuel dust concentration, a spark for ignition and an air mixture
containing sufficient O 2 are the conditions for an explosion. This condition will often
be present inside the closed process plant.
The first explosion usually inside the equipment is called the primary explosion.
Subsequently fast spreading of ignited solid fuel dust can entail one or more
explosions of fuel dust in the surroundings. These are called secondary explosions.
A distinction is made between:
1. The potential solid fuel dust explosion taking place inside the process plant or
inside equipment’s with or without explosion relief and
2. The serious explosion which may occur in open and closed buildings where
personnel are present.
12861-09-3.0
Re. 1:
If an explosion should occur inside closed vessels and process plants supplied by
FLSmidth, an explosion will always be trapped in the machine/vessel if not provided
with explosion relief. If the machine/vessel is designed with external explosion relief,
a pressure rise will always escape the closed section through an explosion relief.
Re. 2:
This type of personal risk depends entirely on the cleanliness inside buildings and
around machines and equipment.
Moreover, practice has shown that solid fuel dust explosions very much depend on the
property of the type of solid fuel to ignite spontaneously. , unless removed on a daily
basis. Spontaneously ignited solid fuel is a serious ignition source which must be
removed immediately. SOP’s should be plant specific to prevent any variation and
application and be readily available to all operating personnel. Containing necessary
information for system checkout, warm up, shut down, including short and long term
emergency operating conditions and to be review regularly. Procedures should cover
emergency actions and firefighting from the stock pile through to firing. They should
also cover housekeeping and general operation.
ATTENTION!
Daily cleaning of the solid fuel meal plant spaces is required, if daily inspection has
revealed that solid fuel dust has leaked from glands or elsewhere.
Grinding of solid fuel into solid fuel meal involves danger of explosion in several
places in the plant. Drying and grinding for the purpose of preparing solid fuel dust
for combustion causes, at the same time that the final product is explosive. If drying
exceeds the limits specified by FLSmidth, there is moreover a latent risk of
spontaneous ignition in the solid fuel meal and an increasing risk of an explosion
inside the plant and in the solid fuel meal bins.
Operational considerations for initial start-up, normal operation, normal shutdown as
well as emergency shut down, see plant specific Operating/Process Instruction.
15 Separator
In vertical mills, the separator is an integrated part of the mill. Therefore, all the
safety precautions shall be taken as considered for the complete mill system.
A solid fuel dust explosion inside the separator is relieved by an explosion relief valve
in the closest possible location after the outlet from the separator.
Ensure that the explosion relief valves are fully operational, in good condition,
unobstructed and have not been altered. For further details, refer to the separate
instruction manual for explosion relief flap valves.
16 Cyclone
Solid fuel meal cyclones in solid fuel grinding plants are pressure-relieved.
Ensure that the pressure relief valves are fully operational, in good condition,
unobstructed and has not been altered. A pressure sensor is mounted in the bottom
cone to monitor if the cyclone is becoming blocked.
12861-09-3.0
• If the under pressure decreases or disappears, it is an indication that the cone

is becoming blocked or is full of solid fuel. Take immediate action to remove
the blockage and, if necessary stop operation of the mill.
Do not discharge blocked-up solid fuel meal from the cyclone into the open without
having soaked the material in water.
ATTENTION!
Discharging dry solid fuel meal from the cyclone can create an explosion
hazard.
17 Solid Fuel Mill Filter

Solid fuel mill filters ordinarily are jet pulse filters specially designed to handle
explosion-prone solid fuel meal. Review the operation and maintenance manual for
the mill to determine the type of filter that is being used and follow the operation and
maintenance manual’s inspection, maintenance and repair provisions.
Immediately replace filter bags in a jet pulse filter that are found to be defective.
ATTENTION!
Properly designed earthing straps should be installed whenever electrostatic charges
can develop.
The solid fuel mill filters are pressure-relieved. Ensure that the pressure relief valve is
fully operational, in good condition, unobstructed and has not been altered or
changed.
If solid fuel meal is found to have accumulated in the filters’ bottom hoppers,
immediately take steps to remove the material.
Inspect the clean side in the filter as and when required.
ATTENTION!
Condensation may occur in a filter if the difference between the exit gas
temperature and the dew point temperature is too small. This can cause
dust accumulations, which can block the filter and/or lead to spontaneous
combustion.
The clean side of the mill filter is provided with a dew point meter. Check the meter
routinely to safeguard against the formation of condensate in the mill plant during
operation.
12861-09-3.0
ATTENTION!
If the filter has not been heated sufficiently before start-up, dust
accumulations can develop, which can block the filter and/or lead to
spontaneous combustion.
Any heating elements in the filter installation must be cut in at a suitable time before
start-up in order to avoid the risk of condensation in the filter.
ATTENTION!
Ventilation inside the filter during stoppage increases the risk of
spontaneous ignition.
During lengthy stops, shut off the filter inlet and outlet and inspect the inside of the
filter.
The valves must be closed when the solid fuel mill plant is stopped. Check all valves
in the filter inlet and outlet pipes to ensure they close tight. Test their performance
annually.
ATTENTION!
Too high and increasing temperatures are indicative of combustion and a
risk of fire.
Routinely monitor the temperature of the filter. If an increase in temperature is

detected, stop the supply of solid fuel meal to the mill and shut the mill down to
determine the cause of the temperature increase and whether solid fuel material
inside the filter is on fire.
If solid fuel meal inside the filter is on fire, discharge the material into a separate
waste system bypassing the solid fuel meal bins.
Ensure that the transport system after the solid fuel dust filter has an extractor for
dust and embers.
Comply with the cleaning interval requirements in the operation and maintenance
manual. Use a timer when cleaning with compressed air.
17.1 Fire fighting
Ensure that adequate firefighting systems and materials are in place to put out
fires in the filter. Use inert fire suppressants (for example, CO 2 or N 2 gas).
ATTENTION!
Use water only in an emergency. Water suppression may make it
difficult to restart the plant quickly and expose personnel to injury.
Regularly check the inert fire suppression systems to ensure there is a
sufficient supply of inert gas for at least two inertizations.
12861-09-3.0
In the event of a filter fire follow the following inertization procedures:
ATTENTION!
Ensure that all operating personnel are trained thoroughly in the operating
principles and uses of the inertization equipment and fire suppression
gasses.
1. Stop the solid fuel grinding mill.

2. Stop the dust transport after the filter.
3. During the stoppage procedure, the valves before and after the filter has
been closed. Before injecting inert gas, the valves on the discharge side
after the filter must be opened 5-10% to allow the displaced gas to
escape.
• If the material cannot be removed in this manner, wash the material
out with water.
• Discharge the water and solid fuel to the waste container using the
screw conveyor after the filter.
4. The filter is inertized by replacing the gas containing O 2 with a fire-
extinguishing type of gas such as CO 2 or N 2 .
2 kg CO2 per m3 volume is estimated for CO2 inertization.
1 kg N 2 per m3 volume is estimated for N2 inertization.
5. Injection of inert gas must not be done too fast.
ATTENTION!
If the pressure in the receiver exceeds 0.1 bar, the pressure relief flaps will
be activated and gas containing O2 likely will flow into the filter. This can
create a risk of a solid fuel dust explosion.
6. Close the dampers to the filter when the filter has been filled with inert
gas. If the filter bottom hopper is equipped with vibrators, operate them a
few times after inertization has finished shaking off any solid fuel meal
accumulations from the walls down to the bottom.
7. Empty the filter via the alternative discharge channels, by-passing the
solid fuel meal bins.
8. When the filter is assumed to be emptied of solid fuel meal, inspect the
filter from the outside through the inspection hatches (situated on top of
the bottom hopper).
12861-09-3.0
Mandatory!
Inspection must never be done through the manhole door in the bottom
hopper, because of the risk of dust slides.
Before conducting the inspection, follow all applicable lock out/tag out
procedures, safety regulations and laws and generally accepted industrial
safety practices (for example, testing the air inside the filter for noxious or
explosive gasses).
When using artificial light, use spark-proof lamps suitable for placing in
zones 21 and 22 with the following marking requirements: єx II 1 D T4.
9. If there are still dust caking present, repeat the procedure described in
item 7.
10. If it is difficult to find ones way inside the filter, a few buckets of raw meal
may be thrown into the bottom hopper. This will contribute to improve the
reflection of light. In this way a better general view of any solid fuel dust
accumulations is obtained. This method is the last resort!
11. If the filter inspection shows that incandescent particles are still present in
the filter, repeat all the preceding inertization procedures.
12. When the filter has been emptied of solid fuel dust, open the inspection
hatch and the damper and then start the filter fan to remove the inert gas
from the filter.
13. Enter the filter to inspect for fire damage.
Mandatory!
Do not enter the filter if there is any detectable presence of CO2 or N 2 .
Before entering the filter, follow all applicable lock out/tag out procedures,
safety regulations and laws and generally accepted industrial safety
practices (for example, test the air inside the filter for noxious or explosive
gasses, comply with confined space procedures and requirements, etc.).
When using artificial light, use spark-proof lamps suitable for placing in
zones 21 and 22 with the following marking requirements: є.g. II 1 D T4.
14. After repairing any fire damage, close the filter and prepare it for
operation.
12861-09-3.0
17.2 Special precautionary measures for electrostatic precipitators

This section contains special conditions relating to electrostatic precipitators.
For fire and explosion hazards, see Sections 3 and 4
Before start-up:
• Check the earthing system to ensure it is in good operating condition.
• Check all inspection doors on precipitator and insulator cubicles to ensure
they have been closed and locked properly.
• Check protective guards to be sure they are in place and in good condition
and there is no risk of persons getting into contact with live parts.
• Check all warning signs to ensure they are in place, unobstructed and plainly
visible.
• Keep all keys to high-tension rooms, inspection hatches, insulator cubicles
and similar equipment in a safe, readily accessible location.
Operation:
During inert operation the mill filter must be interlocked by the O2 and the CO
meter of the mill plant.
Maintenance
Mandatory!
Before entering the precipitator, follow all applicable lock out/tag out
procedures, safety regulations and laws and generally accepted industrial
safety practices (for example, de-energize all power sources, comply with
confined space procedures and requirements, etc.).
Before work is started inside the precipitator, check the high tension plant to ensure
it is interrupted and connected to earth and in good condition.
Earthing must also be arranged inside the precipitator at the point where the work
is to be done.
During inspection and maintenance work, station a watchman immediately outside
the entrance door.
Post notices in the high-tension room and at the control board warning that work on
the precipitator is in progress.
18 Solid Fuel Meal Bins

Solid fuel meal bins are provided with explosion relief flaps to protect the receiver in
case of an inside solid fuel dust explosion. For further details, refer to the separate
instruction manual for explosion relief flaps.
During operation, it is recommended that the solid fuel meal bins are constantly as
full as possible.
12861-09-3.0
For planned prolonged kiln stops, run the solid fuel meal bin until it is empty before
the kiln is stopped.
Stop the bin extraction when it is empty.
ATTENTION!
The bin must under no circumstances be emptied of solid fuel meal unless it
is fired directly into the kiln system.
ATTENTION!
CO is developed during oxidation, and the chemical reaction develops heat.
Thus, the bin must be inertized after it is stopped.
18.1 Fire Monitoring

Spontaneous ignition of certain types of lignite can occur after standstill of 8
hours.
Certain types of bituminous solid fuel will only ignite spontaneously after weeks
of standstill.
The time elapsing before an incandescent fire can be said to be developing can,
therefore, not be stated in advance.
18.2 Temperature monitoring

Coal meal bins are equipped with thermo sensors at the top of the bin and in
the outlet cone.
Thermo sensors normally have two alarm levels called Max.I and Max.II.
• Max.I is typically an alarm indicating a temperature increase to a level re-

quiring attention
• Max.II is an alarm indicating a serious risk of bin fire. The supply of coal
meal to the bin will stop automatically.
18.3 CO-monitoring
The CO concentration in the gas inside a bin depends on the type of coal meal
and the exchange of gas in the bin.
The CO concentration can, therefore, only be determined during normal
operation.
For a given plant, the level of the normal CO concentration must be determined
during normal operation.
CO measurements give a very safe warning of a developing incandescent fire,
and when adjusted correctly, the CO alarm will trip before the thermo sensors
give alarm.
12861-09-3.0
19 Fans
Ensure that fans are maintained in good operating condition and are properly
lubricated.
ATTENTION!
Badly aligned fans and inadequately lubricated bearings can cause

combustion of solid fuel, leading to fire or an explosion.
20 Air Sluices
Air sluices are used in the solid fuel mill plant between two machines with different
pressures, used partly under normal operating conditions and partly in the event of an
explosion.
The air sluice prevents transfer of explosion from one machine to another.
Air sluices with chain drive are equipped with a motion detector to report chain drive
failure.
If an alarm is given, stop the installation and inspect the air sluices to determine the
cause of the alarm. Repair any damage that is found before re-starting the sluice
gates.
ATTENTION!
If the damage is not repaired, solid fuel meal may accumulate in the
machine and cause fire and explosion.
Regularly maintain all bearing seals and other seals by adjusting or replacing them as
needed.
21 Screw Conveyors
Keep all screw conveyors well-lubricated and in good repair and operating condition.
ATTENTION!
Badly aligned conveyors and inadequately lubricated bearings can cause

combustion of solid fuel on the conveyors or spillage, leading to fire or an
explosion. Material movement against others or moving parts may produce
sufficient heat and sparks that can cause a fire or explosion.
Regularly maintain bearing seals and other seals by adjusting or replacing them as
needed.
Do not use hanger bearings in screw conveyors.
22 Pipe Connections, Flexible Hoses, Expansions Joins

• Routinely check pipe connections, flexible hoses, expansion joints and similar
equipment connecting machines in which solid fuel meal is conveyed for wear,
damage, cracks or other disrepair that may enable solid fuel meal to escape.
12861-09-3.0
Flexible hoses should be inspected at least monthly and should be replaced every
6 to 12 months, depending on their condition, the type of solid fuel
• If such conditions are found, consider whether the extent of the disrepair is
significant enough to stop the plant or if temporary repair can be made.
ATTENTION!
Solid fuel dust can create a risk of fire or explosion.
• Do not weld-repair or use any other form of repairs that generate heat before
first stopping the plant, the area surrounding the machine has been completely
cleaned and all solid fuel dust has been removed. Vacuum clean the entire
area thoroughly before beginning repairs by welding or other heat generating
means. Flexible hoses must be replaced following a plan. Depending on their
condition they may be worn from the inside. In solid fuel mill plant hoses must
be inspected on a monthly basis. Spare hoses must always be available for
flexible hoses fitted in pneumatic excess pressure conveyors. Replacement
should be made every 6 to 12 months, depending on the type of solid fuel and
user intervals.
Secondary dedusting filters
22.1 Bunker Filters

Bunker filters are monitored and protected by the machine or bin they de-dust.
22.2 Central Filters

Central filters for machines handling solid fuel meal are explosion-relieved, also have
closing valves in front of and after the filters in order to reduce air circulation during
stand still periods.
23 Inertization Equipment
The inertization equipment at cement plants is normally of the CO 2 or N 2 type. Other
industries may use steam or other gas types.
2 kg of CO 2 per m3 free volume is estimated for CO2 inertization.
1 kg of N 2 per m3 free volume is estimated for N 2 inertization.
Ensure that sufficient inert gas is always kept in reserve for at least two volume
inertizations for each system.
Ensure that inertization equipment can be activated locally and from the central
control room.
24 Hot Gas Generators

For start-up and operating purposes, the mill may be equipped with a hot gas
generator.
Routinely check the hot gas generator to ensure it does not have any hot surfaces
that may ignite a fire or explosion.
12861-09-3.0
25 Written Incident Investigation Report Should Include the

Following:
• Date of incident
• Location of the incident and equipment/process affected
• Description of the incident, contributing factors and the suspected cause including
records of operation parameters
• Operation of the automatic/manual fire protection systems and emergency
response
• Recommendations and corrective actions taken, or to be taken, to prevent a
reoccurrence
• Lessons learned from the investigation
This report and lessons learned from the incident must be shared with all affected
personnel operating, maintaining and supervising the facility.

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Safety Precautions When Using

Approved date: 03-Dec-15

Doc. No.: 12861-09-3.0

1 General Notes .............................................................................................. 4

22 Pipe Connections, Flexible Hoses, Expansions Joins ............................................ 25

• safety training is repeated as needed or required; and,

• Design basis Identification of danger and preparation of procedures to

• Preparation of explosion protection document.

• Preparation of fire and warning instructions.

o oxygen (O 2 ) is above the lower explosion limit, e.g. atmospheric air,

o Solid fuel dust is in suspension in concentrations between the upper and

o There is an ignition source with sufficient energy.

4 Solid Fuel Dust Explosions

ii. A sufficiently high temperature called the ignition temperature exists,

4.1 Reducing the Risk of Explosions

4.2 Precautions against Fire

Solid fuel piles

Solid fuel meal bins

• the inertization system is in good operating condition at all times;

5 Solid Fuel Meal Firing

d) there are no hot surfaces in the area capable of igniting dust.

6.1 Zone Classification

Zone_21: A place in which an explosive atmosphere in the form of a cloud of combustible

Zone_22: A place in which an explosive atmosphere in the form of a cloud of

6.2 Dust Escape

6.3 Pressure Relief

7 Inspection, Maintenance and Repair

Inhalation of gas with insufficient O2 content will cause asphyxiation in a very

• If such leakage is detected, the condition should be corrected as quickly as

In all cases, use extreme caution when opening an inspection door.

8 Deactivating Machines during Repair

10 Machines and Equipment

• Keep insulation on equipment in good condition. Be sure it is intact and prevent

• Ensure all electrical grounding of equipment is in place and in good condition.

11 Solid Fuel Stores

• Keep the storage cooled by ventilation or water spraying

• Store the solid fuel in smaller lots of stock pile

• Reduce the fine powder content in the solid fuel.

• Follow the practice of first in-first out in stock pile management.

• Regularly check the pile’s temperature with long portable thermocouple

12 Rubber Belt Conveyors

13 Raw Solid Fuel Bins

14 Solid Fuel Mill Plants and Solid Fuel Drying Plants

• If the under pressure decreases or disappears, it is an indication that the cone

17 Solid Fuel Mill Filter

Routinely monitor the temperature of the filter. If an increase in temperature is

17.1 Fire fighting

In the event of a filter fire follow the following inertization procedures:

1. Stop the solid fuel grinding mill.

5. Injection of inert gas must not be done too fast.

17.2 Special precautionary measures for electrostatic precipitators

18 Solid Fuel Meal Bins

18.1 Fire Monitoring

18.2 Temperature monitoring

• Max.I is typically an alarm indicating a temperature increase to a level re-

Badly aligned fans and inadequately lubricated bearings can cause

Badly aligned conveyors and inadequately lubricated bearings can cause

22 Pipe Connections, Flexible Hoses, Expansions Joins