Zone Classification: Doc. No. 50068905 Ver.1.0

Zone Classification
Plant: NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

Contract: 13-45327
Approved date: 6-Oct-2014

Created by: OJ
Approved by: NEA
Doc. No. 50068905 ver.1.0
Zone classification
Doc. No.
50068905 ver.1.0
Plant:
NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC
1. Introduction
1.1 Object of the zone classification
Zone classification is needed where explosive atmospheres may be present in order to
minimized explosion risks based on the correct equipment categories being used or
installed in these hazardous areas.
The responsibility for the required plant zone classification rests primarily with the plant
owner because the obligation is rooted in workplace legislation.
In order to facilitate this task, FLSmidth has elaborated this generic zone classification
which can be tailored to a specific plant/project, based on available customer input
and/or FLSmidth default values.
1.2 Explosion risks
Fire and explosion hazards/risks are closely related, but while fire hazards require the
simultaneous presence of the first three (the fire triangle) of the following elements,
explosion hazards require the simultaneous presence of all five elements (the explosion
pentagon):
Fuel (dust, gas, vapour or mist)

Air (oxygen)
Effective ignition source
Premixing of fuel and air with fuel concentration between LEL and UEL
Sufficient confinement to allow for high temperature and pressure increase
LEL: Lower explosion limit (the lowest concentration of the flammable substance
in air capable of being ignited)
UEL: Upper explosion limit (the highest concentration of the flammable
substance in air, capable of being ignited)
Several areas on cement plants, e.g. the firing systems, entail explosion risks due to
the possible presence of flammable dust, gas, oil, vapour or mist, sufficiently mixed
with air (oxygen) to form an explosive mixture ready to react violently by ignition
sources, such as sparks.
An area (volume) in which explosive mixtures is or may be expected to be present
requiring special precautions, is named a hazardous area which must be zone
classified in order to minimize explosion risks.
1.3 EU regulatory approach
Explosion risks are regulated in EU by the ATEX directives:
Directive 1999/92 demanding the Plant owner (the employer) to prepare

workplace risk assessments and zone classifications, identifying zones where
explosive mixtures (atmospheres) may occur, and to procure equipment
categorized to fit the zone classifications.
Directive 94/9 demanding the equipment manufacturer to categorize equipment

for use in hazardous areas (zones) in order to facilitate the user's selection of
appropriate equipment in compliance with the legislation.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
2/23
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Plant:
The zone classification must take into consideration the type of explosive mixture and
the likelihood of its occurrence according to the following zone definitions:
Zone
Zone 0
Definition
A place in which an explosive atmosphere consisting of a
mixture with air of flammable substances in the form of
gas, vapour or mist is present continuously or for long
periods or frequently
gas, vapour or mist is likely to occur in normal operation
occasionally.
gas, vapour or mist is not likely to occur in normal
operation but, if it does occur, will persist for a short period
only.
A place in which an explosive atmosphere in the form of a
cloud of combustible dust in air presents continuously, or for
long periods or frequently
cloud of combustible dust in air is likely to occur in normal
operation occasionally
cloud of combustible dust in air is not likely to occur in
normal operations but if it does occur, will persist for a short
period only
Zone 1
Zone 2
Zone 20
Zone 21
Zone 22
The following (universal) guideline can be used at the zone classification task
concerning the duration (t) of the occurrence of an explosive atmosphere:
Zone
Zone 0 and 20
Zone 1 and 21
Zone 2 and 22
Guideline
t > 1000 hours/year or t > 1 hour/shift
10 < t < 1000 hours/year
1 < t < 10 hours/year and t < 1 min/shift
Note: The zone classification takes into consideration the type of explosive mixture
and the likelihood of its occurrence (determined by the frequency and duration of its
occurrence, which outside equipment is influenced by the degree of ventilation of the
area). The zone classification does not include considerations regarding the presence of
possible ignition sources and the consequences of an explosion.
Regarding releases of flammable dust, gas, vapour or liquid from a point source into
the atmosphere (for example through vents and failure leaks), and closely connected
to the zone classification conception, one finds the Grade of release (which is not
influenced by the degree of ventilation) definition:
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50068905 ver.1.0
Plant:
Grade
Continuous
grade of release
Primary grade of
release
Secondary grade
of release
Definition
A release that is continuous or nearly
so, or that occurs frequently and for
short periods
A release that is likely to occur
periodically or occasionally in normal
operation, i.e. an anticipated release
A release that is unlikely in normal
operation and, in any event, only
infrequently and for short periods
Guideline
(hours/year)
t > 1000
10 < t < 1000
1 < t < 10
In general, a continuous, primary and secondary grade of release under unrestricted

"open air" conditions of dust will give rise to a Zone 20, 21 and 22 respectively (and for
gases, correspondingly to Zone 0, 1 and 2).
The zone classification obligation is limited to atmospheric conditions (be it inside or
outside process equipment) which are generally regarded as areas having a pressure
between 0.8 Bara and 1.1 Bara, and a temperature between -20 C and +60 C.
The zone classification obligation does not extend to catastrophic failures, but the
normal operation concept includes all conditions within the design parameters of the
plant, including start-up, shut-down and failure of fragile components (foreseeable
events).
According to the ATEX directive 94/9 the following equipment categories must be used
or installed in zones classified as:
In Zone 20 and Zone 0: Equipment of category 1 must be used,

In Zone 21 and Zone 1: Equipment of category 1 or 2 must be used,
In Zone 22 and Zone 2: Equipment of category 1, 2 or 3 must be used.
Provided, the equipment is suitable for gases, vapours or mist and/or dust, as
appropriate (indicated by "G" or "D").
Note: Zone classification is only one part of the obligatory (workplace) explosion risk
assessment, which also includes the likelihood of ignition sources to be present and the
anticipated effects caused by an explosion. Above-mentioned combinations of zone
types and equipment categories may therefore be deviated when determined by the
actual risk assessment.
The zone representation on drawing makes use of the symbols shown on the next
page.
Although not of any special relevance concerning coal dust, the gas (gases, vapours or
mists) zones 0, 1 and 2 are included here for the sake of completeness.
4/23
Zone classification
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50068905 ver.1.0
Plant:
Key to symbols
Dust zones
Zone 20
Zone 21
Zone 22
Areas outside zone classification: No signature
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Plant:
2. FLSmidth approach to coal dust safety

The explosiveness of coal depends primarily on the coal type and its physical properties
such as particle size, size distribution and the content of volatile matters and moisture.
Particles exceeding a diameter of about 0.5 mm do not form explosive dust
atmospheres. Maximum ignitability occurs with sizes of 0.075 mm or smaller.
Table I below lists the different coal types, their characteristic explosibility parameters:
Kst, Pmax, Tig, Tig,layer and the FLSmidth default values for LEL and UEL (fixed on a rather
conservative level).
In contrast to gases and vapours, the release of coal dust will form a cloud initially,
which will settle on to floors, ledges, etc. from where it could be stirred up again to
form an explosive cloud. Therefore, avoiding areas where the dust may settle and
providing good house-keeping - regularly monitored - are of key importance.
Furthermore, FLSmidth design prevents dust accumulations by:
Maintaining transport speed above 20 m/s in pipes and ducts
Avoiding horizontal pipe lines
Avoiding measuring orifices
Avoiding dust built-up in cyclone outlet cones or filters, so that coal meal is
collected solely in the bins provided.
2.1 Avoiding explosive coal dust atmospheres
Theoretically, explosive coal dust atmospheres could be prevented by requiring coal
meal being at concentrations below the LEL value of about 30 g/m 3 or above the UEL
value of about 2 kg/m3 in the air, but that is not technically possible.
The only other way (besides avoiding layers of coal dust which may become airborne)
of preventing the presence of explosive coal dust atmospheres, is the partial (or
complete) substitution of the air by an inert gas, such as Flue gases (from the rotary
kiln or a hot gas generator), Carbon Dioxide (CO2) and Nitrogen (N2). This preventive
method is called inerting)
Coal dust explosions will be avoided when the oxygen concentration is lowered (from
the 21 % level in atmospheric air) to 12 % for lignite and 14 % for other coal types.
For optimum safety with inert operation, the following procedures should be adhered
to:
Action
Alarm
Mill cut-out
O2
(% by volume on wet basis)
Lignite
Coal
10
8
12
10
Areas where it is not possible to avoid the occurrence of an explosive coal dust
atmosphere (defined as hazardous areas) must, as mentioned above, be zone
classified, and the avoidance of possible ignition sources must have first priority for the
elimination of explosion risks.
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2.2 Avoiding ignition sources

The ignition of an explosive coal dust atmosphere requires an ignition source
possessing sufficient energy (in general above 1 mJ for dust), such as a static electrical
charge or a hot surface in the coal grinding installation. Charges exceeding 1 mJ can
also occur in the mill through the entry of metal fragments together with the raw coal,
collision between grinding media, impact against rollers or grinding tables, hot
conveyer bearings, metal friction in fans etc.
Ignition risks are e.g. minimized by appropriate earthing of the equipment and by
having metal separators installed. And surface temperatures above the ignition
temperature of layers of coal dust must be avoided - see Table I below.
Coal oxidizes slowly at temperatures below 50 C, and fires can occur by spontaneous
ignition in bins and filters, which means that it is very important for equipment to be
on hand for inerting.
2.3 Mitigation explosion risks
When it is not possible to prevent the formation of explosive coal dust atmospheres
and avoid the possible presence of effective ignitions sources, the possibility of an
explosion must be accepted, and mitigation measures must be implemented to ensure
the safety of persons in exposed areas.
In these circumstances the FLSmidth equipment is relief-vented so as to release and
deflect explosions into the atmosphere outside buildings and thus minimize the danger
of secondary explosion inside buildings - especially when good house-keeping has not
been complied with. The relief venting systems allow the equipment design pressure
(Pdes) to lie substantially below the max explosion pressure (P max).
Inside building, coal dust does not cause unacceptable risks as the process system is
designed never to allow leaks to outside locations - except at defined explosion reliefs,
which are located outside buildings or in areas inside buildings where safe steel walls
separate internal parts of the building around explosion vents on bag filters, and guide
safely possible explosions from inside filters to areas outside the buildings.
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Plant:
Table I:
Explosibility parameters of coal dust and FLSmidth default values for
LEL and UEL
1
No.
2
Flammable
material
3
Volatility
4
Kst
5
Pmax
6
LEL
Name
vol. %
bar x
m/s
bar
g/m3
36 < VC
150
9.3
30
7
UEL
8
Dust
cloud
Ignition
Tig
C
9
Dust
layer
Ignition
Tig,layer
C
2000
440
230
g/m3
Lignite
High
volatile
bituminous
coal
26 < VC
36
120
9.3
30
2000
550
240
Low volatile
bituminous
coal
11 < VC
26
90
8.6
30
2000
600
260
Pet coke
8 < VC 11
60
6.9
30
2000
690
280
Anthracite
VC 8
0.6
30
2000
700
340
Kst
10
Any other
information or
remarks
Explosion constant = Max rate of pressure rise
Pmax
Max explosion pressure
LEL
Lower explosive limit
UEL
Upper explosive limit
Tig
Minimum dust cloud ignition temperature
Tig,layer Minimum dust layer (5 mm) ignition temperature
8/23
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Plant:
None
Zone classification for coal dust

General notes:
1) House keeping and inspection, see 12861-09 Precautions when using coal and lignite (ref. EN 61241-10 Annex C)
2) Precautions during maintenance, see 12861-09 Precautions when using coal and lignite: In connection with maintenance is
important that working area must be cleaned thoroughly of coal dust. This is done by using a vacuum cleaning installation. The coal
dust may possibly be neutralized by flushing with water at very low pressure. Use a low-velocity spreader nozzle so as to avoid
swirling, which may initiate a coal dust explosion
3) Preventive exchange of wear components, see 12861-09 Precautions when using coal and lignite and the equipment instructions
manual. Wear parts, e.g. gaskets, glands, flexible connections, joints and hoses, are preventive exchanged before they are worn
out
4) Preventive maintenance, see 12861-09 Precautions when using coal and lignite and the equipment instruction manual.
5) 30001378 Civil design precautions to be taken when handling inflammable dust
6) Pressure chok resistant according to EN 14460.
Definitions:
Non-hazardous area (NC)
area in which an explosive gas atmosphere is not expected to be present in quantities such as to require special precautions for the
construction, installation and use of apparatus
Extent of zone
distance in any direction from the source of release to the point where the gas/air mixture has been diluted by air to a value below the
lower explosive limit
N/A: Not applicable
See also the flow diagrams following the table.
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Plant:
None
Installation
Internal
zone
Raw coal intake department.

Reception hopper
Apron feeder
Rubber belt conveyors
Secondary filters
Fan for secondary filter
Dedusting pipes
Building
External
zone
Extent of
external
zone
m
Explanation
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Coarse and humid

Coarse and humid
Coarse and humid
Coarse and humid
Coarse and humid
Coarse and humid
See note 1 and 5
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
N/A
N/A
N/A
N/A
N/A
N/A
See notes
See notes
Coarse and humid dust load below LEL
Pdes = 3.5 bar
21
NC
N/A
Separator RTKA
21
NC
N/A
Below grinding table

Reject box
Hydraulic pump station, mill
Roller pressure
Mill roller lubrication
Gear unit mill
21
22
NC
NC
22
NC
N/A
2
N/A
Category in accordance to ATEX Guidelines August 2008 4.1.2.4. Additional safety

by explosion relief.
Restricted access in flame reach area during operation
Pdes = 3.5 bar
Pdes = 3.5 bar, Pressure relieved
Pdes = 3.5 bar
Pdes = 3.5 bar
Placed in a room separated from the dust handling
NC
NC
NC
NC
N/A
N/A
Coal mill department

Coal mill building, open
Coal mill building, closed
Rubber belt conveyor
Raw coal silo
Raw coal feeder
Mill sluice
Atox coal mill.
Coal mill, VRM ATOX
dust.
dust.
dust.
dust.
dust.
dust.
Dust
Dust
Dust
Dust
Dust
Dust
load
load
load
load
load
load
below
below
below
below
below
below
LEL
LEL
LEL
LEL
LEL
LEL
10/23
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Plant:
None
Installation
Gear unit oil cooler

Motor mill
Drive, separator
Water injection unit
Internal
zone
External
zone
NC
NC
NC
NC
NC
NC
NC
NC
Extent of
external
zone
m
N/A
N/A
N/A
N/A
Coal mill filter, Duct to stack. Coal meal from filter.

Duct from separator to filter
21
NC
Shut-off valve in inlet to mill

filter
Coal mill bag filter, dirty side
N/A
22
NC
N/A
21
NC
N/A
Explanation
Restricted access in flame reach area during operation.

Regarding internal zone classification: The product is not covered by ATEX as the
product is not
a) a equipment, as defined in Article 1.3.(a); or
b) a protective system, as defined in Article 1.3.(b); or
c) a component, as defined in Article 1.3.(c); or
d) a safety, controlling or regulating device as defined in Article 1.2.
Pdes = 2 bar
Category in accordance to ATEX Guidelines August 2008 4.1.2.4. Additional safety
by explosion relief.
Pdes = 0.2 bar
11/23
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Plant:
None
Installation
Internal
zone
External
zone
Extent of
external
zone
m
N/A
Explanation
Coal mill bag filter, clean side
22
NC
Coal mill bag filter, pent

house
Mill filter screw conveyor
Mill filter air sluice
Shut-off valves in outlet from
mill filter
Throttle valve at filter fan
Filter fan
NC
NC
N/A
21
21
22
NC
NC
NC
N/A
N/A
N/A
Pdes = 0.2 bar

Pdes = 2 bar
Pdes = 3.5 bar
22
22
NC
NC
N/A
N/A
Stack
22
NC
N/A
Recirculation duct to mill
22
NC
N/A
Pdes = 3.5? bar

A cloud of combustible dust in air is not likely to occur in normal operation but, if
it does occur, will persist for a short period only. Zone 22 during bag failure only.
Pdes = 0.4 bar
product is not
Pdes = 0.4 bar
product is not
Pdes = 2.5 bar
A cloud of combustible dust in air is not likely to occur in normal operation but, if
it does occur, will persist for a short period only. Zone 22 during bag failure only
Pdes = 0.2 bar
12/23
Zone classification
Doc. No.
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Plant:
None
Installation
Internal
zone
External
zone
Extent of
external
zone
m
N/A
Hot gas side of mill
22
NC
Sampler below filter
22
NC
N/A
Screw conveyor below filter
22
NC
N/A
Chute to air sluice
22
NC
N/A
Air sluice above pneumatic

screw pump
Pneumatic screw pump
22
NC
N/A
21
NC
N/A
Pneumatic transport to coal

meal bin
21
NC
N/A
Explanation
product is not
Pdes = 2 bar
product is not
Pdes = 2 bar
Dust load is above UEL in normal operation. No turbulence due to low peripheral
velocity.
Pdes = 2 bar
product is not
Pdes = 2 bar
Pdes = 10 bar
Dust load 4 kg/kg air is above UEL in pipeline
Pdes = 10 bar
Dust load 4 kg/kg air is above UEL
Pdes = 10 bar
13/23
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Plant:
None
Installation
Secondary filters, central

type RC, dirty side
Secondary filters RC, central
type, clean side
Fan for secondary filter
Slide gate below screw
conveyor
Container for reject
Coal meal dosing

Change over valves in
pneumatic transport pipeline
Slide gate below screw

conveyor
Internal
zone
External
zone
Extent of
external
zone
m
N/A
21
NC
NC
NC
N/A
NC
NC
N/A
NC
NC
N/A
22
NC
N/A
Explanation

Dust load below LEL also during bag failure
Pdes = 2.5 bar
product is not
Pdes = 10 bar
Pdes = 10 bar
14/23
Zone classification
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Plant:
None
Installation
Internal
zone
External
zone
Extent of
external
zone
m
N/A
Coal meal bin
20
NC
Dedusting filter, bunker type,

dirty side
20
NC
N/A
Dedusting filter, bunker type,

clean side
Dedusting filter fan
Agitator for multiple outlets
NC
NC
N/A
NC
22
NC
NC
N/A
N/A
Rotary feeder below the coal

meal bin
22
NC
N/A
Explanation
Restricted access in flame reach area during operation.

product is not
Pdes = 2 bar, Pressure relieved
Pressure relief through the coal meal bin explosion relief.
product is not
Pdes = 2.5 bar
When there is meal in the bin the dust load is above UEL. Applicable only with
empty bin, which is not likely to occur in normal operation but, if it does occur, will
persist for a short period only. Explosion pressure relief through the coal meal bin
explosion relief
Pdes = 10 bar
Dust load above UEL (100 % filling)
Pdes = 10 bar
15/23
Zone classification
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500xxxxx
Plant:
None
Installation
Internal
zone
External
zone
Prehopper (Pfister)
20
NC
Rotor scale (Pfister)

Pneumatic transport to
burner
20
21
NC
NC
Extent of
external
zone
m
N/A
N/A
N/A
Separate rooms and central vacuum cleaner system

Building around feeder,
NC
NC
N/A
closed
Compressor room/ Rotary
NC
NC
N/A
blower room
CO2-bottle room
NC
NC
N/A
Central vacuum cleaner pipes
21
NC
N/A
Dedusting filter for vacuum
21
NC
N/A
cleaner
Explanation
product is not
Pdes = 10 bar
Pdes = 10 bar
Dust load 4 kg/kg air is above UEL
product is not
Pdes = 10 bar
See note 1 and 5
Pdes = 10 bar
Pressure relieved
Burner platform , preheater- and kiln departments

16/23
Zone classification
Doc. No.
500xxxxx
Plant:
None
Installation
Internal
zone
External
zone
Extent of
external
zone
m
N/A
Flexible joints to burner pipe
NC
Kiln burner
NC
N/A
Calciner burner
NC
N/A
Burner platform building,

open
Burner platform building,
closed
Explanation
product is not
Pdes = 10? Bar,
product is not
product is not
See note 1 and 5
See note 1 and 5
17/23
Zone classification
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Plant:
None
Flow diagram
Note: Actual equipment configuration can deviate from the diagrams.
Coal Intake, coal mill feed
18/23
Zone classification
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Plant:
None
ATOX coal mill
19/23
Zone classification
Doc. No.
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Plant:
None
Coal meal bins
20/23
Zone classification
Doc. No.
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Plant:
None
Outline drawings
ATOX coal mill reject box
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None
Container
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Zone classification
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Plant:
None
List of General Arrangement drawings
Plant department
211.Coal intake
241 Coal transport

Error! Unknown document property name. - Error! Unknown document
property name.
465 Coal Dosing
421.Preheater
441.Cooler
Drawings
13079942
13079943
13079945
13079939
13079940
13080387
50062849 (legend)
13082729
10365974
13082731
13082732
13082733
13082734
13082735
13082736
13082737
13082738
13082739
13082740
13082741
13084179
10365976
10345561
Error! Unknown document property name. (legend)
13077341
13078616
23/23

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Zone Classification

Plant: NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

Approved date: 6-Oct-2014

Doc. No. 50068905 ver.1.0

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

Fuel (dust, gas, vapour or mist)

Directive 1999/92 demanding the Plant owner (the employer) to prepare

Directive 94/9 demanding the equipment manufacturer to categorize equipment

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

In general, a continuous, primary and secondary grade of release under unrestricted

In Zone 20 and Zone 0: Equipment of category 1 must be used,

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

Areas outside zone classification: No signature

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

2. FLSmidth approach to coal dust safety

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

2.2 Avoiding ignition sources

NYUMBA YA AKIBA-CEMENT PLANT 3000 TPD, SONGOLOLO DRC

Explosion constant = Max rate of pressure rise

Zone classification for coal dust

Raw coal intake department.

Coarse and humid

Below grinding table

Category in accordance to ATEX Guidelines August 2008 4.1.2.4. Additional safety

Coal mill department

Placed in a room separated from the dust handling

Gear unit oil cooler

Coal mill filter, Duct to stack. Coal meal from filter.

Shut-off valve in inlet to mill

Placed in a room separated from the dust handling

Placed in a room separated from the dust handling

Restricted access in flame reach area during operation.

Coal mill bag filter, clean side

Coal mill bag filter, pent

Pdes = 0.2 bar

Recirculation duct to mill

Pdes = 3.5? bar

Hot gas side of mill

Sampler below filter

Screw conveyor below filter

Chute to air sluice

Air sluice above pneumatic

Pneumatic transport to coal

Secondary filters, central

Coal meal dosing

Slide gate below screw

Restricted access in flame reach area during operation

Coal meal bin

Dedusting filter, bunker type,

Dedusting filter, bunker type,

Rotary feeder below the coal

Restricted access in flame reach area during operation.

Rotor scale (Pfister)

Separate rooms and central vacuum cleaner system

Burner platform , preheater- and kiln departments

Flexible joints to burner pipe

Burner platform building,

Coal Intake, coal mill feed

ATOX coal mill

Coal meal bins

List of General Arrangement drawings