FLACS-Based Simulation of Combustible Gases Leaked from the Pressure Device for the Optimizing of Gas Detectors’ Setup

The leakage and diffusion of hazardous gases from steam methane reforming (SMR) equipment are investigated by Flame Acceleration Simulator (FLACS) software to optimize the layout of combustible gas detectors. A typical accident scenario, with the gases leaked from converter tubes with leak apertures of 5 mm, 25 mm, and 100 mm and medium pressure of 0.1 MPa, 1 MPa, and 10 MPa, is established. At the same time, the influence of the environment wind speeds from 0.2 m·s−1 to 6 m·s−1 on the diffusion process is also investigated. The research results show that the leakage source concentration and diffusion distance positively correlate with the leakage aperture. Suggestion on the distance between combustible gas detectors and possible leak point is within 5 m, 10 m, and 15 m in the scenario of the leak aperture of 5 mm (small-hole leak aperture), 25 mm (middle-hole leak aperture), and 100 mm (big-hole leak aperture). The most dangerous scenario is at the static ambient wind speed, and the diffusion process strengthens with the raising of wind speed. The turning point scenario occurs at a wind speed of 1 m·s−1, where the flammable area is minimal. The medium pressure relates to the jet speed of the combustible gases. The wind speed should be comprehensively determined when considering the layout of the combustible gas detectors affected by this factor. The orthogonal experimental design shows that the most significant influence factor on the diffusion process of the combustible gas is the leak aperture, followed by the medium pressure and, finally, by the ambient wind speed. Recommendations are listed for the optimization of the layout of gas detectors in related enterprises.