Energy release and countermeasures for sand casting explosion accidents

Xu, Qingwei; Xu, Kaili; Li, Li; Xu, Xiaoyan; Yao, Xiwen

doi:10.1080/10807039.2019.1650327

Cited by 16 publications

(14 citation statements)

References 40 publications

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“…is accident occurred because the residual cooling water (approximately 0.3 tonnes) in the cooling pipe of the OL flowed into the bottom of the converter, leading to contact between the water and hot slag in the bottom, thereby causing an explosion. It can be seen that in the process of metal smelting, once the high-temperature molten metal is in contact with water, the accident consequences are extremely critical [1,2]. However, only a few domestic and foreign scholars have investigated the risk of converter device failures, and most of them concentrated only on the methods to increase production or reduce energy consumption [3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Risk Assessment of Oxygen Lance Burning Loss Using Bow-Tie Analysis Based on Fuzzy Theory

Fan

et al. 2020

Mathematical Problems in Engineering

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Oxygen lances (OLs) are important devices used in converter steel making. However, the occurrence of OL burning loss (OLBL) failure may lead to explosion accidents. To better prevent OLBL failure, it is necessary to perform a probabilistic assessment. Bow-tie analysis based on fuzzy theory was proposed to assess OLBL, which represents a hazardous event. In this paper, fuzzy theory based on triangular fuzzy numbers (TFNs) was applied to calculate the failure data. Fuzzy fault tree analysis (FFTA) in combination with the improved similarity aggregation method (ISAM) was employed to reduce the error generated due to the subjective judgement of experts. Furthermore, a comprehensive importance analysis method was developed to rank the importance of basic events (BEs), facilitating the adoption of the corresponding safety decisions. When performing fuzzy event tree analysis (FETA), the occurrence probability of outcome events (OEs) was determined by conducting a layer of protection analysis (LOPA). Finally, safety measures were proposed based on the assessment results to achieve safe production. The results indicated that the use of bow-tie analysis is appropriate to perform qualitative and quantitative assessment. Through bow-tie analysis based on fuzzy theory, the occurrence probability of OLBL was determined to be in the interval (5.34E − 02, 2.69E − 01). By adding independent protective layers (IPLs), the occurrence probability of OEs caused by OLBL can be effectively reduced.

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Section: Introductionmentioning

confidence: 99%

Risk Assessment of Oxygen Lance Burning Loss Using Bow-Tie Analysis Based on Fuzzy Theory

Fan

et al. 2020

Mathematical Problems in Engineering

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“…Severe heat conduction phenomena occur when molten alloy is poured into the cavity of the foundry [15], resulting in the temperature of the casting mould rapidly rising. For sand casting, as the temperature of the casting mould rises, materials such as adhesives, curing agents, and coatings in the sand quickly vaporize and pyrolyze to produce gas [4,27].…”

Section: 7mentioning

confidence: 99%

“…For sand casting, as the temperature of the casting mould rises, materials such as adhesives, curing agents, and coatings in the sand quickly vaporize and pyrolyze to produce gas [4,27]. If the gas cannot be discharged out of the cavity in time, there may be a blowhole defect or even an explosion accident [15]. erefore, investigating the thermal decomposition behaviour of foundry sand is helpful for obtaining an in-depth understanding of the change trends in casting mould temperature and cavity gas during the pouring process.…”

Section: 7mentioning

confidence: 99%

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Thermal Decomposition Behaviour of Foundry Sand for Cast Steel in Nitrogen and Air Atmospheres

Chen

Zhang

et al. 2020

Mathematical Problems in Engineering

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Sand casting is the most widely used casting technique, known for ages, even since ancient times. The main goal of this study was to determine the thermal decomposition behaviour of foundry sand for cast steel. We first tested the basic properties of foundry sand, including its proximate analysis, chemical composition, and particle size characteristics; we next monitored the thermal decomposition behaviour of foundry sand for cast steel via simultaneous thermal analysis. We focused on the mass loss of foundry sand for cast steel at different heating rates in nitrogen and air atmospheres. We adopted a novel method to calculate the volatile release characteristic index of foundry sand. The volatile content of foundry sand for cast steel was very low, so the volatile release characteristic index of the sand could not be strictly calculated according to this concept. We calculated the thermal decomposition kinetics parameters of foundry sand, namely, the activation energy and preexponential factor, under kinetics theory. To thoroughly test the fitting effect, we conducted a single-factor analysis of variance on the source of error. The results showed that the independent variable has a significant influence on the dependent variable and that the fitting equation we selected is feasible and effective.

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“…With continued economic growth, China's foundry industry has achieved considerable development, making great contributions to the basic industry and machinery industry [4]. The casting process is used to obtain a part or workblank by pouring liquid metal into a cavity corresponding to the shape of the part, and then gradually cooling and solidifying it [5,6]. However, there are negative effects of the growing foundry industry, such as environment pollution [7][8][9] and casualties [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Safety Assessment of Casting Workshop by Cloud Model and Cause and Effect–LOPA to Protect Employee Health

Fang

2020

IJERPH

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Safety assessment of a casting workshop will provide a clearer understanding of the important safety level required for a foundry. The main purpose of this study was to construct a composite safety assessment method to protect employee health using the cloud model and cause and effect–Layer of Protection Analysis (LOPA). In this study, the weights of evaluation indicators were determined using the subjective analytic hierarchy process and objective entropy weight method respectively. Then, to obtain the preference coefficient of the integrated weight more precisely, a new algorithm was proposed based on the least square method. Next, the safety level of the casting workshop was presented based on the qualitative and quantitative analysis of the cloud model, which realized the uncertainty conversion between qualitative concepts and their corresponding quantitative values, as well as taking the fuzziness and randomness into account; the validity of cloud model evaluation was validated by grey relational analysis. In addition, cause and effect was used to proactively identify factors that may lead to accidents. LOPA was used to correlate corresponding safety measures to the identified risk factors. 6 causes and 19 sub-causes that may contribute to accidents were identified, and 18 potential remedies, or independent protection layers (IPLs), were described as ways to protect employee health in foundry operations. A mechanical manufacturing business in Hunan, China was considered as a case study to demonstrate the applicability and benefits of the proposed safety assessment approach.

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Energy release and countermeasures for sand casting explosion accidents

Cited by 16 publications

References 40 publications

Risk Assessment of Oxygen Lance Burning Loss Using Bow-Tie Analysis Based on Fuzzy Theory

Risk Assessment of Oxygen Lance Burning Loss Using Bow-Tie Analysis Based on Fuzzy Theory

Thermal Decomposition Behaviour of Foundry Sand for Cast Steel in Nitrogen and Air Atmospheres

Safety Assessment of Casting Workshop by Cloud Model and Cause and Effect–LOPA to Protect Employee Health

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