The ALVAK Mixer Helps Prevent ATEX Hybrid Atmospheres
Even today, in many industries, the incorporation of solids into reactors or tanks is still carried out in the traditional way: liquids are added to the tank, the manway is opened, and the solids are loaded from above.
This method of adding solids to liquids has several disadvantages in terms of proper dispersion and dissolution. However, it also creates a much more serious issue when both the liquid and solid raw materials are flammable or explosive.
Loading solids through the tank manway inevitably 𝗶𝗻𝘁𝗿𝗼𝗱𝘂𝗰𝗲𝘀 𝗮𝗶𝗿 𝗶𝗻𝘁𝗼 𝘁𝗵𝗲 𝘃𝗲𝘀𝘀𝗲𝗹. At the same time, it can generate 𝗮 𝗰𝗹𝗼𝘂𝗱 𝗼𝗳 𝗱𝘂𝘀𝘁 𝗽𝗮𝗿𝘁𝗶𝗰𝗹𝗲𝘀 above the vapours or gases released by the liquid inside the tank. If the process involves flammable vapours or solvents together with combustible or 𝗲𝘅𝗽𝗹𝗼𝘀𝗶𝘃𝗲 𝗱𝘂𝘀𝘁, the three elements required for a potentially explosive atmosphere may be present at the same time: fuel in gas form, fuel in dust form and an oxidising agent.
These so-called 𝗵𝘆𝗯𝗿𝗶𝗱 𝗺𝗶𝘅𝘁𝘂𝗿𝗲𝘀, where an explosive or flammable gas atmosphere can coexist with an explosive or flammable dust atmosphere, represent one of the most demanding scenarios from an ATEX safety point of view.
A key point is that the minimum ignition energy, or MIE, of a gas-dust mixture is mainly determined by the amount of gas or vapour present and is usually lower than the MIE of the pure dust. This means that a dust which may be difficult to ignite on its own can become much easier to ignite when vapours are present. In the same way, residual solvent contained in a powder can generate a hybrid mixture that is far more dangerous than the dust cloud alone.
So, how can explosive solids be added to flammable liquids without creating the significant risk associated with hybrid mixtures?
The ALVAK Mixer Helps Prevent ATEX Hybrid Atmospheres
At Vak Kimsa, we believe that the best way to protect people and installations is to design the process so that the hazardous situation does not arise in the first place.
This is precisely the principle behind our ALVAK in-line mixers for the incorporation of solids into liquids.
With the ALVAK solid incorporation system, powdered products are introduced directly into the pipework, in a completely closed circuit filled with liquid, without the need to open the tank during the manufacturing process. By adding the required safety instrumentation to the ALVAK system, the incorporation sequence can be controlled so that the oxidising agent does not coincide simultaneously with potentially flammable or explosive substances.
In other words, we do not fight the risk once it has been created; we prevent it from appearing.
Operating with the ALVAK mixer helps prevent the formation of a hybrid gas and dust atmosphere, simplifying both the ATEX design of the installation and its operating conditions.
In addition to the clear improvement in safety, the process offers other major advantages: dust emissions to the outside are reduced, tank inertisation can be maintained when applied, operator exposure to the product is minimised, and solids can be incorporated in a faster, more homogeneous and more repeatable way. The final result is also a better process in terms of dispersion quality or dissolution of the solid into the liquid.
This approach is especially valuable in chemical, pharmaceutical, cosmetic and food processes where combustible ingredients, organic solvents or high value-added products are handled.
But the real added value does not lie only in the equipment.
At Vak Kimsa, we do not simply supply a solid incorporation system. We study each process, analyse the associated risks and develop a solution adapted to each customer’s needs. Our experience in mixing, dispersion and dissolution processes allows us to integrate production requirements with ATEX safety demands, always seeking the safest, most efficient and economically viable solution.
Because when it comes to safety, the best technology is not necessarily the one designed to withstand an explosive atmosphere, but the one that prevents that atmosphere from forming in the first place.
This is Vak Kimsa’s commitment: transforming a complex safety challenge into an intelligent, reliable and future-ready process solution.
Do not hesitate contacting our specialists for further information!
