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Blenders
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001713
EISBN: 978-1-62708-220-4
... Abstract On 21 April 1995, the contents of a large blender (6 cu m) reacted and caused an explosion that killed and injured a number of workers at a plant in Lodi, NJ. A mixture of sodium hydrosulfite and aluminum powder was being mixed at the time of the accident. This report focuses...
Abstract
On 21 April 1995, the contents of a large blender (6 cu m) reacted and caused an explosion that killed and injured a number of workers at a plant in Lodi, NJ. A mixture of sodium hydrosulfite and aluminum powder was being mixed at the time of the accident. This report focuses on evaluations of the blender to determine if material or mechanical failures were the cause of the accident. The results indicate that the mixing vessel was metallurgically sound and did not contribute to the initiation of the failure. However, the vessel was not designed for mixing chemicals that must be isolated from water and excessive heat. Water leaking into the vessel through a graphite seal may have initiated the reactions that caused the accident.
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 2 A blender at the accident site that was not damaged. This blender is similar to the blender involved in the accident.
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 1 Drawing of a blender typical of the one involved in the accident, showing the approximate size and mounting configuration. The blender involved in the accident had a working capacity of about 3.5 m 3 and an actual volume near 5.7 m 3 (125 ft 3 working capacity; 200 ft 3 actual
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 3 The damage to the blender in the accident was extensive. This photograph shows the 2 top loading ports on the blender, the shredded water jacket, and the hold-down tabs for the access covers.
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 4 This photograph of the blender shows the flange and support tube for the vacuum assembly (left), the shaft to which the Gear drive was attached to (right), and the damage to the off-load port at the bottom of the blender.
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 5 A port on the top of the blender showing erosion markings.
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in Failure Analysis of a Large Blender in a Chemical Plant
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 7 The inside of the blender shell showing the 2 top loading ports (photograph taken through the bottom, off-load port). The vertical seam in the figure is the seam where the 2 lobes meet to form the Vee on the blender. Erosion markings are visible on both sides of the seam, near
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