3 Aluminum Processing Operations

8/14/2019 3 Aluminum Processing Operations

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Safety for Aluminum Processing andFinishing Operations Involving

Combustible Dust

in the

Die Casting Industry

Unit 3

NADCANorth American Die Casting Association


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Enabling Objectives

Explain procedures for housekeeping, dust collection,

fire prevention, prevention of accumulation of

fugitive dusts, proper storage, and safety

procedures for aluminum and magnesium.

After completing this section

of the course studentsshould be able to:

Discuss aluminum dust

producing operations andthe precaution for carrying

out these operations safely


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Two recognized methods to

capture aluminum dust: Wet collectors located near the point

of generation

Dry collectors located outdoors as

near as possible to the point of

generation

Machines fitted with hoods and

capture devices able to capture and

transport al l the dus t that is

produced

Dust Producing Operations


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Design system so all dust

moves into the hoods, into

the ducts and is collected

Connecting ducts must

be kept as straight and

short as possible



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Ductwork

Duct runs as short &straight as possible!


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Metal dust-air

suspension can pass

into the explosive

range in the

collector!



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Dry-type provided with

barriersor other protection

Area around collector

posted with Caution Sign

Personnel outside of

marked area when

operating

CAUTION:

This dust collector can

contain explosible dust.

Keep outside the

marked area while

equipment is

operating.

CAUTION

CAUTION

This d tcollec

torcan c


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Dedicated equipment not to

be used with other types of

metals

Grinders, buffers posted

with warning sign!

Warning:

Aluminum Metal Only

Fire or Explosion CanResult with Other Metals.

!

Warning:

Aluminum Metal

OnlyFire or

Explosion Can

Result with

Other Metals.

Hi Aluminum!

Im another type

of metal!

Kaboom


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Practice Quiz

1. Duct runs for dust collectors should be: A. As far away from the machine feeding into it as possible.

B. Build with curves and turns to slow down the movement

of dust.

C. As short and straight as possible. 2. When dry-type dust collectors are operating:

A. They should be indoors near the point of generation.

B. Barriers should be established and personnel should stay

away.

C. Maintenance personnel should open them up to ensure

they are working properly.



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Practice Quiz

3. Grinders and buffers used for aluminum must be: A. Dedicated equipment.

B. Used for all types of metal including stainless steel

C. Disconnected from dust collection units when used for

other metals.



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Practice Quiz

1. Duct runs for dust collectors should be: A. As far away from the machine feeding into it as possible.

B. Build with curves and turns to slow down the movement

of dust.

C. As short and straight as possible. 2. When dry-type dust collectors are operating:

A. They should be indoors near the point of generation.

B. Barriers should be established and personnel should

stay away.

C. Maintenance personnel should open them up to ensure

they are working properly.



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Practice Quiz

3. Grinders and buffers used for aluminum must be: A. Dedicated equipment.

B. Used for all types of metal including stainless steel.

C. Disconnected from dust collection units when used for

other metals.



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Cyclones are less

hazardous than bag-

or media-type

Exhaust discharge to

atmosphere away

from other operations!

Portable Dust Collectors


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Fixed Media

Type Dust

Collector

NOT the best choice!

Material

Discharge

Filtration Media

Build a

barrier

around the

equipment!


Dry collectorsrequired to be

located outdoors

(exception: small

portable units

Dry co l lecto rs

prov ided w i th

barr iers


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Dust Collection, Ducts and

Ductwork

Collector area is to bemarked and a sign

posted

NFPA 68: length of afireball from a vented

collector

Collection system

dedicated to

aluminum only!

This dust collector can

contain explosive dust,

keep outside the marked

area while equipment is

running

20'


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Experts indicate an eventual explosion can

be expected from bag collectors use for

aluminum fines!

Multiple-series cyclone with final liquid stageis

a better choice

Not so good

Can lead to Im a better choice
http://en.wikipedia.org/wiki/Image:Multiclone.jpghttp://en.wikipedia.org/wiki/Image:Image_005.jpg


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Ductwork

If the collectionsystem used for

combustible

aluminum dust isused for other

materialsit should

be disassembled

and cleanedbefore

and after.


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Ductwork

Use separate collection

systems for grinding

and buffing operations

The dust collector

should dissipate static

electricity


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For bag-house shake-out

design to minimize sparking

Pulse-types less likely tocreate a spark because there

are no moving parts

Attach ground wires to

bagsand securely ground


Ductwork

Mechanical Shaker Baghouse


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For baghouse an alarm sounds

for pressure drop across bags

Locate baghouse or mediatype collector > 50 feet from

other operations and

buildings!

Keep personal > 50 feet away

when shaking!


Ductwork

At least Im outside!
http://www.dshayairsystems.com/images/Projects/Vermont%20Hospital/2005_VADC_505001_LG.jpghttp://www.dshayairsystems.com/images/Projects/Vermont%20Hospital/2005_VADC_505001_LG.jpghttp://www.dshayairsystems.com/images/Projects/Vermont%20Hospital/2005_VADC_505001_LG.jpg


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Avoid letting aluminum

impact oxidized iron!

Thermite reaction possible

for impact with aluminum &

rusted iron or steel

Enough heat to produce

molten iron!

Thermite Reaction

Laboratory created

thermite reaction


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Practice Quiz

1. Baghouse collectors for aluminum: A. Are both economical and efficient.

B. Are considered better than cyclone collectors.

C. Have been associated with fires when used for aluminum.

2. If aluminum impacts iron oxide:

The material produced is inert.

A dangerous thermite reaction can be initiated.

It makes a valuable by-product that is a commodity.

Dust Collection, Ducts and Ductwork


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Practice Quiz

3. If a baghouse type collector is used: A. A pulse-type is better than a mechanical shaker.

B. The collector should be located outdoors at least 50 feet

away from buildings and other equipment.

C. Barriers and warning signs should be posted around theequipment.

D. All of the above

4. Dust collection for grinding and buffing operations

should be: A. A single unit with adequate capacity for the amount of

dust generated.

B. Located between the grinder and buffer.

Served by separate dust collection systems.



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Practice Quiz

1. Baghouse collectors for aluminum: A. Are both economical and efficient.

B. Are considered better than cyclone collectors.

C. Have been associated with fires when used for

aluminum.

2. If aluminum impacts iron oxide:

The material produced is inert.

A dangerous thermite reaction can be initiated. It makes a valuable by-product that is a commodity.



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Practice Quiz

3. If a baghouse type collector is used: A. A pulse-type is better than a mechanical shaker.

B. The collector should be located outdoors at least 50 feet

away from buildings and other equipment.

C. Barriers and warning signs should be posted around theequipment.

D. All of the above

4. Dust collection for grinding and buffing operations

should be: A. A single unit with adequate capacity for the amount of

dust generated.

B. Located between the grinder and buffer.

Served by separate dust collection systems.



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Explosion vents are usually

built into the system

If not a retrofit is a good idea!

Locate Explosion Vents

away from personnel!

Explosion vents for dust collectors

Explosion Venting

located away from personnel

Its a good thing!


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Ductwork

Ducts short and straight

to maximize free airflow

No dead ends or

unused caps in ductsthat could trap

accumulations of dust

Ducts grounded &

bonded to dissipate

static electricity


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Particles are suspended

Air velocity at least 4500 ft/min

Build-up of dust particles

Air velocity less than 3500 ft/min

Entrainment! is what you need!

Bad!


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Duct Construction Ducts made of

conductivematerial

Lap joints face

airflow direction

No unused or

capped outlets Duct seams

away from

personnel!

Smells

like

somethingsburning!


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Duct Construction

No add-ons without

engineering redesign of

system and the impact the

add-ons will have

Collectors and machines

that generate combustible

dust properly bonded &

grounded

Copper wire is securely fastened

to the equipment and then

grounded to earth, for example by

attaching it to a metallic water

pipe or other object connected

with earth.

Prevents

buildup

of staticcharges!


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Dust Collection & Ductwork Practice Quiz

1. Explosion vents:A. Should be built into collectors for combustible

aluminum dust.

B. Located away from personnel.

C. Not necessary under normal circumstances.

D. Both A & B.

2. Ducts for dust collectors should have:

A. Dead end sections to help collect dust at the

point of generation.

B. Unused caps to maintain duct velocity pressure.

C. No dead ends or unused caps.


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Dust Collection & Ductwork

Practice Quiz

3. Dust collectors and machines:A. Isolated from ground to prevent conducting

electricity.

B. Properly grounded and bonded. C. Designed and installed to dissipate static

electricity.

D. Both B & C.


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Dust Collection & Ductwork Practice Quiz

1. Explosion vents:A. Should be built into collectors for combustible

aluminum dust.

B. Located away from personnel.

C. Not necessary under normal circumstances.

D. Both A & B.

2. Ducts for dust collectors should have:

A. Dead end sections to help collect dust at the

point of generation.

B. Unused caps to maintain duct velocity pressure.

C. No dead ends or unused caps.

D C ll i & D k


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Dust Collection & Ductwork

Practice Quiz

3. Dust collectors and machines:A. Isolated from ground to prevent conducting

electricity.

B. Properly grounded and bonded. C. Designed and installed to dissipate static

electricity.

D. Both B & C.

Wet Type Dust Collector


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Wet-Type Dust Collector Exhaust to the outside of

building

Exhaust duct as short &

straight as possible

Ducts designed to

withstand same explosion

pressure as wet-type

collector

http://www.wynnenv.com/NewPhotos/Wet%20Collector.jpghttp://www.wynnenv.com/NewPhotos/Wet%20Collector.jpg


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Wet-Type Dust Collector

Aluminum and water canproduce hyd rogen gas

Extremely flammable and

easy to ignite

Dont trap in unventilated

areas of the building or

equipment!



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Wet-Type Dust Collector Return air tested and approved for recirculation

Exhaust vent inspected and cleaned frequently Particles can collect on the walls of the exhaust

duct and can be highly combustible

Particles Collecting on

exhaust duct

Im forming a highly combustible cake!



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Water level

sludge

Liquid level control w/ interlock

Non-sparking work surface

Liquid Precipitator Collector For Portable Dust Collector

Mist eliminator packs

Expanded metal aluminum mesh

Wet-Type Dust Collector

Sl d & C ll t S V ti


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Sludge & Collector Sump Venting

Wetted dust ishighly

flammable!

Sludge removed

regularly

Collector sump

vented!

H2H2

H2

H2

H2

H2H2

H2

H2

H2

H2H2

H2

H2

H2 H2

H2H2

H2

P S l


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Power Supply Inter locked with the

exhaust blower and

the liquid-level

controller

Time delay on dust

producing equipment

prevents motor

starting until collector

is operating

To dust producing

equipment

Power to dust-

producing eq. motor

cutoff by low liquid level

or

low airflow

Inspection/

Cleanout door

Water level

Overflow/Drain Piping

Liquid level

control w/

interlock

Sludge in tank

Mist Eliminator

Packs

My power supply is dependent on

my proper functioning

Sl d R l


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Sludge Removal

Sludge removed daily

Covered vented containers for transport

Containers filled to < 50 lbs

Sl d R l


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Sludge Removal

NO SMOKING

ALLOWED!

Mix with inert at 5:1

ratio & dispose of

properly

Hot Work

requires a Permit

use one!

W t T C ll t


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Wet-Type Collectors

Practice Quiz

1. Wet aluminum dust:A. Is inert

B. Is easily removed with steel shovels

C. Can generate explosive hydrogen gas

2. Exhaust air:

A. Should be vented to the outside

B. Should be tested if it is to be returned to thebuilding.

B. Both A & B.

W t T C ll t


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Wet-Type Collectors

Practice Quiz

3. Sludge from wet-type dust collectors for

combustible aluminum dust should be:

A. Emptied daily.

B. In containers of less than 50 lbs.

C. Covered in vented containers for disposal

transport.

D. All of the above.


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W t T C ll t


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Wet-Type Collectors

Practice Quiz

3. Sludge from wet-type dust collectors for

combustible aluminum dust should be:

A. Emptied daily.

B. In containers of less than 50 lbs.

C. Covered in vented containers for disposal

transport.


D T D t C ll t


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Dry-Type Dust Collectors

Use only where permitted

Collection containers covered to

prevent airborne fugitive dust

Collector designed and

maintained to ensure internal

cleanliness!

No accumulation of material allowed

except discharge container

D T D t C ll t


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Dust-collecting filter medium conductive

with enmeshed noninsulated wire

woven or fastened to it

Not fool proof:

No force passes charge across nonconductive

areas of the fabric

Broken wires can hold or build-up a charge!

D T D t C ll t


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Hoods regularly cleaned

Dry collectors for

aluminum dust provided

with deflagration vents

Air from dry dust

collectors is not to be

recycledback into the

building

Courtesy of

Fenwal SafetySystems

D T D t C ll t


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Dry-Type Dust Collectors Selection of type and location

of weak sections or vents

designed to minimize injury to

personnel and minimizedamage to nearby equipment &

structures

Explosion venting is a very

important consideration!

Al: high explosion pressure

Courtesy of

Fenwal Safety

Systems

Dry Type Dust Collectors


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Dry Type Dust Collectors Practice Quiz

1. Air from dry-type dust collectors: A. Should be vented back into the plant to balance negative

pressure.

B. Should be used to provide warmth around grinding

operations. Should not be recycled back into the building.

2. Grounding cartridge filters with wires built into the

cartridge :

A. Is a fool proof way of ensuring static charges will becontrolled.

B. Does not ensure that static charges will move across the

filter.

C. Never done.



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Practice Quiz

3. Dry type dust collectors should:A. Have their hoods regularly cleaned.

B. Be fitted with deflagration vents.

C. Allow for no accumulation of dust exceptfor in discharge containers.



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Practice Quiz

3. Dry type dust collectors should:A. Have their hoods regularly cleaned.

B. Be fitted with deflagration vents.

C. Allow for no accumulation of dust exceptfor in discharge containers.


Additional Considerations


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Additional Considerations Cutting tools sharp & sufficient

coolant flow to prevent ignitionof turnings

Cutting & grinding eq. grounded

Chips, swarf, turnings, etc.

collected in closed-top

containers

Removed daily to safe storage

or disposal



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Coolant non-flammable & filtered

Collected solids max accumulation 5

gallons



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All electrical wiring conforms to NEC

Collection systems bonded &

grounded

Metallic jumpers installed when

continuous contact is interrupted

NEC

NFPA 70

Ho sekeeping


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Housekeeping

No accumulation of

fugitive combustible dust

Ignition of a dust cloud or

layer will likely result inan explosion

Often followed by a more

violent explosion

Good housekeeping is

extremely important!

Housekeeping


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Housekeeping Regular cleanup using

conductive non-sparkingtools

Soft brooms with natural

bristles Bulk of cleanup done with

scoops, shovels & brooms

Vacuum only small residualamounts

Non-sparking

Housekeeping


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Housekeeping

Compressed air blow down is

generally not to be permitted

Only allowed in areas otherwise

impossible to clean Only allowed under carefully

controlled conditions

All potential ignition sources

eliminated

All equipment shut down

Vacuum Cleaners


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Vacuum Cleaners Vacuums only for too small,

dispersed or inaccessibledust

Bonded & grounded

Listed or approved for usewith combustible dust

Periodic continuity tests

performed Dusts from fixed vacuums

collected to outside of

building

Fixed Vacuum Systems


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Fixed Vacuum Systems If possible locate

vacuum collectionoutside facility

50 feet from building

If closer enclose in

open-top steel shield

Fit suction lines withexplosion vents and

anti-flash back valves

50 ft

.

Water Cleanup Considerations


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Water Cleanup Considerations Wet aluminum fines can evolve

hydrogen gas!

Keep hydrogen at or below 1%

concentration in air usingventilation (H2LEL = 4%)

Inform management of risks

Competent person has

determined wet cleaning is

safest method availableApplies to Aluminum

Dross: Wet or Hot

Cleaning Frequency


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g q y

Avoid excessive accumulation of dust on any

portion of building that is not cleaned during

regular daily operations

Regular cleaning of buildings and machinery asneeded

Machines idle and

power off

Housekeeping


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p g

Practice Quiz

1. Cleanup of aluminum dust should be done

with:

A. Non-combustible conductive tools.

B. Brooms with soft natural bristles.

C. Mostly scoops, shovels and brooms.


2. Compressed air blown for aluminum dust:

A. Is a fast and safe way to clean up.

B. Is a common practice.

C. Should only be done under controlled

procedures when no other method is feasible.

Housekeeping


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p g

Practice Quiz

1. Cleanup of aluminum dust should be done

with:

A. Non-combustible conductive tools.

B. Brooms with soft natural bristles.

C. Mostly scoops, shovels and brooms.


2. Compressed air blown for aluminum dust:

A. Is a fast and safe way to clean up.

B. Is a common practice.

C. Should only be done under controlled

procedures when no other method is feasible.

Housekeeping


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p g

Practice Quiz

3. Cleaning dust from the facility should:

A. Include additional cleaning on all parts of the

building where dust can accumulate that is not

cleaned during normal operations.

B. Be done as often as necessary. C. Be done with machines idle with the power off.


Fire Prevention & Protection


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Fire Prevention & Protection Large scale fires in

aluminum dust are verydifficult to extinguish

DO NOT create a dust

cloud in an attempt to fight

an aluminum dust fire!

Attempt to control asquickly as possible with

minimum disruption to the

pile

Fire Extinguishers
http://www.asia.ru/ProductInfo/938369.html


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Fire Extinguishers

Ample Class D fire

extinguishers should be

available to fight incipient

stage fires

Available within 75 feet of

metalworking areas.

Required where dust is

generated at least once every

two weeks

Fire Extinguishers


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Fire Extinguishers

Install signsso other

types of extinguishers are

not used by mistake!

Extinguishing Agent


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g g g

Ring incipient fires with

dry sand, or a Class D

powder

Properly ringed will form ametal oxide crust

Apply with non sparking

utensils

Eliminate drafts, etc.

Extinguishing Agent
http://upload.wikimedia.org/wikipedia/commons/2/21/Bucket_in_the_sand.svg


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g g g

Dry sodium chloride is very effective

Check for caking

Flux made of potassium and magnesium

chloride and calcium fluoride Avoid Class B agents for dry powder aluminum

fires, they will accelerate

fires or cause an explosion!

Aluminum Slurry Fires


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Aluminum Slurry Fires

Incipient stage fires

involving a slurry

(wetted) of aluminum

powder can be foughtusing a Class B type

extinguisher as long

as the agent is not

halogenated.

Sprinkler Systems


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p y

No automatic

sprinklers where dryaluminum powder is

produced or handled

Consider the hazards

associated with

aluminum and water in

considering sprinkler

systems

Fire Prevention and Protection


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Practice Quiz

1. Large aluminum fires:

A. Can be easily controlled with class D fire extinguishers.

B. Are extremely difficult to extinguish.

C. Are best handled with class B fire extinguishers.

2. Incipient stage aluminum fires:

A. Should be ringed with a Class D extinguishing agent.

B. Should have extinguishing material applied with non-

sparking scoops.

C. Should be protected from drafts.




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Practice Quiz

3. Class D fire extinguishers

A. Are optional for aluminum dust processing

areas.

B. Only needed by the dust collector.

C. Are required where combustible dust is

produced at least once every two weeks.



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Practice Quiz

1. Large aluminum fires:

A. Can be easily controlled with class D fire extinguishers.

B. Are extremely difficult to extinguish.

C. Are best handled with class B fire extinguishers.

2. Incipient stage aluminum fires:

A. Should be ringed with a Class D extinguishing agent.

B. Should have extinguishing material applied with non-

sparking scoops.

C. Should be protected from drafts.




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Practice Quiz

3. Class D fire extinguishers

A. Are optional for aluminum dust processing

areas.

B. Only needed by the dust collector.

C. Are required where combustible dust is

produced at least once every two weeks.

Employee Training & Emergency Evacuation


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Train employees in

evacuation procedures

Only trained

employees are al lowed

to attempt to f igh t f ires

All others must

evacuate!

Fire Safety Training


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Familiarize fire departments

with the special potential

hazards present

Plant safety officer to

provide instruction or direct

the efforts of fire personnel

Scrap metal fire

Will burn until it

runs out of fuel

Fire Safety Training


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Job hazard analysis

should be conducted

and safe work practices

developed

Employees trained on

hazard recognition,

elimination and control

Dont let this happen to you!

Fire Prevention & Control


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Set up test fires for f i re

department train ing

Cover foreseeable

scenarios and plan and

prepare accordingly

Train employees for thedifferent types of fires

possible



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Fire Prevention & Control Train employees on the

hazards present

Focus on proper actions,

decisions & procedures Train on location of

controls, emergency

supplies and fire

extinguishers

The stuff you NEED!



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Fire Prevention & Control Train on proper

method for fighting

incipient stage

aluminum dust fires

Warn employees

regarding the creation

of a dust cloud or using

liquids on combustible

metal fires



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Practice Quiz

1. If you have not been trained you should:A. Only fight a major fire with coworkers who haveexperience.

B. Only attempt to extinguish incipient fires.

C. Not attempt to put out combustible dust fires.

2. Your training should focus on hazard:

A. Recognition.

B. Elimination.

C. Control.




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Practice Quiz

1. If you have not been trained you should:A. Only fight a major fire with coworkers who haveexperience.

B. Only attempt to extinguish incipient fires.

C. Not attempt to put out combustible dust fires.

2. Your training should focus on hazard:

A. Recognition.

B. Elimination.

C. Control.




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Practice Quiz

3. It is important not to:A. Put liquids on aluminum dust fires.

B. Use a high pressure extinguisher that will create

a dust cloud.

C. Use the wrong type of fire extinguisher.


E. None of the above.



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Practice Quiz

3. It is important not to:A. Put liquids on aluminum dust fires.

B. Use a high pressure extinguisher that will create

a dust cloud.

C. Use the wrong type of fire extinguisher.


E. None of the above.

Controlling Ignition Sources


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No smoking, cutting or

welding in areas where

wet sludge is present

Any area where hotwork takes place must

be free of all

accumulations of dust

Comply with NFPA 51B

Employees and visitors

should not carry smoking

materials in any areas wherecombustible dust is present!



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No propellant-actuated

tools unless machinery

is shutdown and

cleaned Only non-sparking tools

used on machines

where combustible dust

is present



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Do not dress grinding

wheels when the

collection ventilation is

on!

Cleaning Tools


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Brooms & brushes

natural fiber bristles

No synthetic bristles

Scoops and dustpans,

etc. to conductive & non-

sparking Do not return dry

sweepings to processing

Proper PPE around Combustible Metal Dust


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p

Except for working around

electricity, safety shoes

should be worn with

Soles and heels attached bysewing

No nails or metal plates

Safety toes composite or

covered

Shoes static dissipating

Specialstatic

dissipating

shoe

Proper PPE around Combustible Metal Dust


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p

Clothing clean, flame

retardant and non-staticgenerating

Tight fitting, smooth fabrics

from which dust can easilybe should be used

No cuffs or other folds

where aluminum couldcollect

No wool or silk


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Compressed air & inert gas


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Dont mistake plant

air for inert gas!

Fittings for both shall

not be

interchangeable!

Safety Inspections


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y p

Inspection program

for operations that

produce dust!

Performed on a regular

interval

Skilled inspectors

Reports filed

Deficiencies corrected!



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Practice Quiz

1. No smoking, cutting or welding in areas:A. Accumulations of dust are present.

B. Where wet aluminum is present.

C. Where powder actuated tools are approved. D. All of the above.

E. A & B only.

2. Do not dress grinding wheels if:A. If the ventilation system is turned off.

B. If the ventilation system is still turned on.

C. Neither A nor B.



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Practice Quiz

1. No smoking, cutting or welding in areas:A. Accumulations of dust are present.

B. Where wet aluminum is present.

C. Where powder actuated tools are approved. D. All of the above.

E. A & B only.

2. Do not dress grinding wheels if:A. If the ventilation system is turned off.

B. If the ventilation system is still turned on.

C. Neither A nor B.

Emergency Procedures


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Practice Quiz

3. Emergency procedures:A. For clothing fires needs to be implemented

B. Include fire blankets and their use where water is

not permitted. C. Are often overrated and usually not necessary

D. A & B only.


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PPE


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Practice Quiz

4. Clothing should be:A. Clean.

B. Non-static generating.

C. Flame Retardant. D. All of the above.

E. B & C only.

PPE


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Practice Quiz

4. Clothing should be:A. Clean.

B. Non-static generating.

C. Flame Retardant. D. All of the above.

E. B & C only.

Summary


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In this section we discussed safe practices for

machining and finishing aluminum. We identified the importance of safe meansof dust collection We looked at housekeeping issues Fire prevention and fire protection were also

discussed

We also examined proper cleaning tools andthe correct PPE to wear when working around

aluminum where combustible dust is present

Date post:	04-Jun-2018
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3 Aluminum Processing Operations

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