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Author:
Nikulin V, Head of Engineering
Nikulin V, Head of Engineering
During the processing, grinding, or cutting of aluminum products, fine aluminum dust particles may be generated. It is a significant nuisance in production facilities, as it creates a health hazard for workers and is potentially explosive.
Sources
Operations involving significant mechanical impact on metal with specialized tools—such as crushing, sawing, turning, burning, or melting of aluminum—can generate fine material. Harmful impurities are present in the air during technological processes associated with the use of pyrotechnic aluminum powder, PAP powder for metal working aluminum dust (silver paint). During the casting process, aluminum fumes dust may be formed.
Aluminum powder
Flammable Metals in Industrial Settings | PODCAST
Occupational Hazards
Aluminum dust hazard to employees of enterprises health is confirmed by scientific research. The respiratory and immune systems are most susceptible. Aluminum grinding dust hazards consists in the fact that inhaling can lead to pulmonary emphysema, diffuse pneumosclerosis, bronchitis, and liver cell degeneration. Central nervous system and kidneys may also be affected.
Workers who weld aluminum are at risk for aluminum dust health effects. Inhaling its vapors for several hours daily can cause connective tissue growth in the lungs, impeding ventilation.
Aluminosis, a common occupational disease, is characterized by progressive shortness of breath and coughing. The disease is caused by aluminum oxide dust sanding, when it accumulates in the internal organs.
The maximum permissible concentration of aluminum powder in the air of the premises is 2 mg/m³. If this value is exceeded, it is required to take additional measures to maintain indoor air cleanliness.
Workers who weld aluminum are at risk for aluminum dust health effects. Inhaling its vapors for several hours daily can cause connective tissue growth in the lungs, impeding ventilation.
Aluminosis, a common occupational disease, is characterized by progressive shortness of breath and coughing. The disease is caused by aluminum oxide dust sanding, when it accumulates in the internal organs.
The maximum permissible concentration of aluminum powder in the air of the premises is 2 mg/m³. If this value is exceeded, it is required to take additional measures to maintain indoor air cleanliness.
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Properties
Along with (Al), the composition contains minor quantities of copper, manganese, silicon, iron, etc. The basic properties of dust — density, dispersion, adhesive, electrical, chemical, and abrasive characteristics — are important factors to consider when selecting a collector.
The density of aluminum dust can be true particle density and bulk density. The second takes into account the air gaps between particles. The bulk density of the powder (aluminum dust flammable) is about 0.15–0.30 g/cm³, aluminum oxide - 3.5–3.97 g/cm³. The density of the material and its bulk density affect the hydraulic resistance of the cleaning system and the duration of its operation without regeneration.
Dispersion also affects cleaning ability. Dispersion may be less than 0.1 microns (smoke), from 0.1 to 10 microns (cloud), and over 10 microns. In rolling mills, air pollution is primarily caused by fine particles up to 50 microns in size. These particles can account for up to 85% of the air pollution, with the remainder being pollutants up to 10 microns in size. Tiny metallic matter measuring up to 5 microns poses the greatest risk to human health.
Aluminum conducts well of electricity, ranking fourth in conductivity after silver, copper, and gold. This high electrical conductivity remains intact even in fine solid form, as long as the small metal components are in contact with each other and an external power source. However, in dust form, its properties change, making it explosive when mixed with atmosphere (aerosol) and fire hazardous when settled (aerogel) due to its chemical properties.
Adhesive properties: poor adhesion to smooth surfaces without prior preparation.
Abrasive properties: Not considered an abrasive material in itself, although it can cause an abrasive effect due to its mechanical nature and the sharp angled shape of its particles.
The density of aluminum dust can be true particle density and bulk density. The second takes into account the air gaps between particles. The bulk density of the powder (aluminum dust flammable) is about 0.15–0.30 g/cm³, aluminum oxide - 3.5–3.97 g/cm³. The density of the material and its bulk density affect the hydraulic resistance of the cleaning system and the duration of its operation without regeneration.
Dispersion also affects cleaning ability. Dispersion may be less than 0.1 microns (smoke), from 0.1 to 10 microns (cloud), and over 10 microns. In rolling mills, air pollution is primarily caused by fine particles up to 50 microns in size. These particles can account for up to 85% of the air pollution, with the remainder being pollutants up to 10 microns in size. Tiny metallic matter measuring up to 5 microns poses the greatest risk to human health.
Aluminum conducts well of electricity, ranking fourth in conductivity after silver, copper, and gold. This high electrical conductivity remains intact even in fine solid form, as long as the small metal components are in contact with each other and an external power source. However, in dust form, its properties change, making it explosive when mixed with atmosphere (aerosol) and fire hazardous when settled (aerogel) due to its chemical properties.
Adhesive properties: poor adhesion to smooth surfaces without prior preparation.
Abrasive properties: Not considered an abrasive material in itself, although it can cause an abrasive effect due to its mechanical nature and the sharp angled shape of its particles.
Baghouse Cyclone Decoded: Overview, Working Principles, System Selection, Industries of Use, FAQs
Explosion Risk
Aluminum dust is classified as an explosive pollutant (Group E, Class II). Under normal conditions, there is no risk of ignition. Suspended combustion occurs with prolonged exposure to a high-temperature source. When combined with moisture, aluminum dust forms aluminum oxide, emitting a lot of heat. This can cause spontaneous combustion in areas with significant pollutant concentrations.
Aluminum dust explosion depends mainly on its dispersion characteristics. Metals crushed to particles smaller than 50-100 microns can exploding even at temperatures as low as 20°C.
Pieces smaller than 100 microns are considered hazardous. Large pieces are no less dangerous: their ignition rate is higher. When large metal fragments mix with pieces around 100 microns, the risk of explosion is high, along with a rapid combustion rate.
The most common causes of explosions are the following factors:
The higher the concentration of oxygen, the higher the probability of an explosion.
Contact with water produces heat in the metal, meaning even tiny fragments can trigger an explosion.
To prevent explosions in production, it is necessary to ensure the following:
Aspiration Equipment
The following types of equipment are used to remove from the air and disposal of aluminum dust:
Table – Comparison of equipment characteristics
Aluminum dust explosion depends mainly on its dispersion characteristics. Metals crushed to particles smaller than 50-100 microns can exploding even at temperatures as low as 20°C.
Pieces smaller than 100 microns are considered hazardous. Large pieces are no less dangerous: their ignition rate is higher. When large metal fragments mix with pieces around 100 microns, the risk of explosion is high, along with a rapid combustion rate.
The most common causes of explosions are the following factors:
- failure to observe safety precautions during metalworking;
- insufficient personnel qualifications;
- improper work organization;
- malfunctions in equipment operation, because of failure to comply with maintenance rules, repair and replacement schedules.
The higher the concentration of oxygen, the higher the probability of an explosion.
Contact with water produces heat in the metal, meaning even tiny fragments can trigger an explosion.
To prevent explosions in production, it is necessary to ensure the following:
- Safety valves must be installed in rooms and flues where uncontrolled processes leading to explosions may occur.
- Aluminum powder production areas must be free from sparks. Floors in these areas must be constructed of materials that prevent sparks.
- Use only containers and equipment made from non-sparking materials.
- Production areas and warehouses must be kept free of dampness and moisture to prevent oxidation and spontaneous combustion, which could lead to an explosion.
- All metal residues must be cleaned from the floor and equipment before the beginning of each work shift. Walls, ceilings, and metal structures must be cleaned of dirt once a week.
Aspiration Equipment
The following types of equipment are used to remove from the air and disposal of aluminum dust:
- mobile local dust collection machines – it allows to get rid of aluminum grinding dust in work area;
- filtration units with cartridges - it may be assembled into a single whole by combining modules;
- industrial baghouses – capable of removing solids of any size from the air.
Table – Comparison of equipment characteristics
To select the appropriate cleaning system, you need to consider the specifics of your production process, the concentration of contaminants in your premises, and your budget.
In addition, cyclone designs such as a filtering machine Torch Cyclone or a modular air cleaning cartridge "AKMAN Cyclone", which can be found on our website. Both types of equipment use a combined cleaning method, including preliminary cyclonic separation and subsequent deep filtration through special elements (bag or cartridge). The main difference lies in the design of the filter elements: bag filters are applied in the first device, while the second has cartridge filters. Both methods ensure effective purification of air flows from solid impurities of various sizes.
Safety Measures
To reduce the risk of fire and minimize occupational risks, it is recommended to observe this aluminum dust safety measures.
The Blizzard Bag Filter MOBIL
Work areas must be well-ventilated and surfaces must be regularly cleaned of accumulated contaminants. Personal protective equipment (goggles, respirators, special proof clothing) must be used to protect the eyes and respiratory system. Smoking and using open fire in the place of work are strictly prohibited. Position air purification systems at the points of emission. Ground all process equipment to prevent static buildup. Do not let the fine solids come into contact with water, as this can trigger spontaneous combustion.
By following these recommendations, you can significantly reduce the risk of explosion when handling combustible powders.
By following these recommendations, you can significantly reduce the risk of explosion when handling combustible powders.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
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