Prevention of fires and explosions in production of dispersed zirconium powder from potassium fluorozirconate by sodium reduction

The relevance of the problem is governed by a growing demand of industry for dispersed zirconium powders manufactured using different technologies from zirconium concentrates of ore produced in the country. Parameters of decomposition and hydrotreatment of zirconium concentrate are selected so that to ensure high rate of removal of impurities, as well as preset coarseness and morphology of potassium fluorozirconate. The fire hazard of production of zirconium powder by sodium reduction in a melting furnace without a pan burner is examined. It is shown that aside from determination of process steps, a final product to be manufactured requires the fire and explosion safety conditions. A series of tests is carried out with different samples of zirconium powders. In particular, we determined the self-ignition temperature, the linear velocity of flame front in a sample layer depending on the sample moistness, and the water content of the samples; and we evaluated the ignition energy and possibility of fire extinction by fire-extinguishing powders. The mechanisms which have effect on self-ignition of wet and frozen powder of zirconium are analyzed. It is shown to be necessary to treat zirconium powder under a layer of water, including storage of a final product. The influence of freezing of zirconium powder produced by sodium reduction on the fire hazard of the product is discussed. The measures of technical protection to ensure safety of process flows are proposed. 

Shtutsa M. G., Toporkov A. V., Chibisov A. L., Fedotkin D. V., Inchikov A. P. Prevention of fires and explosions in production of dispersed zirconium powder from potassium fluorozirconate by sodium reduction . MIAB. Mining Inf. Anal. Bull. 2026;(1):16-26. [In Russ]. DOI: 10.25018/0236_1493_2026_1_0_16.

M.G. Shtutsa¹, Dr. Sci. (Eng.), Deputy Technical Director — Project Manager for Advanced Products, e-mail: shtutsa-mg@yandex.ru,
A.V. Toporkov¹, Chief Engineer of Project, e-mail: AVToporkov71@yandex.ru,
A.L. Chibisov, Dr. Sci. (Eng.), Professor, Chief Researcher, Non-profit Partnership National Academy of Fire Safety Sciences (NANPB), Balashikha, Russia, e-mail: chibisov2@mail.ru,
D.V. Fedotkin, Dr. Sci. (Eng.), Professor, NUST MISIS, Moscow, Russia, e-mail: fdv982@mail.ru,
A.P. Inchikov, Cand. Sci. (Eng.), Deputy Head of Department, Federal State Budgetary Establishment All-Russian Research Institute for Fire Protection of the Ministry of the Russian Federation for Civil Defense, Emergencies and Elimination of Consequences of Natural Disasters (FGBU VNIIPO EMERCOM of Russia), Balashikha, Russia, e-mail: apinchikov@mail.ru,
¹ Joint Stock Company «Chepetsk Mechanical Plant» (JSC «CHMZ»), Glazov, Russia.

D.V. Fedotkin, e-mail: fdv982@mail.ru.

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