Preventing explosions: Resolved measurement of turbulent flow electrification

Project Information

MefiX

Grant agreement ID: 101179931

DOI

10.3030/101179931

Project closed

EC signature date 12 August 2024

Start date 1 January 2025

End date 30 June 2026

Funded under

• European Research Council (ERC)

Total cost

No data

EU contribution

€ 150 000,00

Coordinated by

PHYSIKALISCH-TECHNISCHE BUNDESANSTALT
Germany

Periodic Reporting for period 1 - MefiX (Preventing explosions: Resolved measurement of turbulent flow electrification)

Reporting period: 2025-01-01 to 2026-06-30

Summary of the context and overall objectives of the project

Electrostatic charging is one of the least understood and most difficult-to-control ignition sources in industrial processes involving powders and liquids. During pneumatic conveying, fueling, or other transport operations, static electricity can accumulate unexpectedly and trigger explosions, leading to injuries, fatalities, and major economic losses. Existing measurement technologies can only determine the average charge of a flowing powder and therefore fail to detect dangerous local charge concentrations.

The objective of the MefiX project was to advance a novel laser-based measurement technology developed in ERC-funded frontier research towards commercial application. MefiX is the first system capable of measuring the spatial distribution of electrostatic charge in turbulent powder flows under industrially relevant conditions. By identifying hidden regions of high electrostatic charge, the technology enables early detection of potential ignition sources and provides the basis for improved explosion prevention and safer industrial processes.

The project aimed to validate the technology under realistic operating conditions, increase its level of automation, strengthen its intellectual property position, and engage with industrial stakeholders to prepare future commercialization. In the long term, MefiX is expected to improve process safety across sectors such as the chemical, pharmaceutical, food, and energy industries while supporting the safe deployment of new industrial processes and energy technologies.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project focused on advancing the MefiX measurement technology from an experimental laboratory setup towards a technology suitable for industrial applications. The main scientific effort was devoted to validating and extending the measurement method for industrially relevant powder flows.

A new measurement methodology was developed that reconstructs the complete spatial distribution of electrostatic particle charge in turbulent flows. The method combines high-speed optical particle tracking with a mathematical reconstruction framework and was validated using direct numerical simulations and laboratory experiments. The technology was successfully demonstrated for particle systems of increasing complexity, including monodisperse, tridisperse, and polydisperse irregularly shaped particles representative of industrial powders. The results show that MefiX can resolve local charge concentrations that remain undetected by conventional charge measurement techniques.

The measurement workflow was further automated through dedicated software, substantially improving the efficiency and reproducibility of data acquisition and analysis. The project thereby established the technological foundation for future integration into a compact prototype.

Overall, the project advanced MefiX from an experimental proof of concept towards a technology validated under industrially relevant powder-flow conditions (TRL 4, approaching TRL 5). The outcomes provide the first experimental access to spatially resolved electrostatic charge distributions in turbulent powder flows and establish a solid basis for future industrial deployment and further technology development.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The MefiX project has established the first technology capable of reconstructing the spatial distribution of electrostatic charge in turbulent powder flows. Unlike conventional charge measurement methods, which only determine the average charge of a powder stream, MefiX reveals local charge concentrations that can act as hidden ignition sources. This capability represents a significant advance in process safety and provides experimental data that were previously inaccessible.

The project validated the technology under industrially relevant powder-flow conditions and demonstrated its applicability to complex, polydisperse and irregularly shaped powders. These results considerably reduce the technical risks associated with future commercialization and provide a solid basis for developing a compact industrial prototype.

The project also strengthened the commercial potential of the technology through international patent protection in Europe and the United States. Discussions with industrial stakeholders confirmed strong interest in applications in the chemical, pharmaceutical, food and energy sectors.

The next steps are the integration of the technology into a compact prototype, validation in industrial environments, extension to liquid flows, and preparation for market entry through industrial partnerships or licensing. These activities are expected to increase the technology readiness level towards commercial deployment.