What is a Dust Explosion?
Combustible dust explosions are violent and often devastating events that occur when fine, dry, particles of combustible materials become suspended in the air and then ignite, leading to a rapid release of energy. Dust particle size influences any explosion. The fire triangle key three elements necessary for a dust explosion include fuel (the combustible dust), oxygen (present in the air), and ignition sources (typically a spark, open flame, static electricity, or even hot surfaces). The addition of small particle dust dispersion in a confined space, generates the Five factors (oxygen, heat, fuel, dispersion, and confinement) are known as the dust explosion pentagon. If one element of the pentagon is missing, an explosion cannot occur. Source: OSHA Combustible Dust Explosion
The process that leads to a dust explosion involves the dispersion of dust particles in the air, the creation of a dust cloud, ignition, and the subsequent rapid combustion of the cloud, which results in pressure waves, fireballs, and potential damage. Source: https://www.nfpa.org/codes-and-standards/6/5/4/nfpa-654
This primary combustion process is called deflagration and produces a high-pressure airwave. As the airwave bursts from its enclosed space, it is likely to displace or stir up build up combustible dust and dust particles in a high surface area of the manufacturing facility, such as a dust collection system, roof trusses and beams, confined spaces and enclosed spaces, other dust collectors, electrical equipment, and HVAC ductwork ventilation systems. This dust explosion pentagon process will mix the dust with the oxygen in the air, intensifying the explosion with a flash fire, and pressure wave, and potentially fueling a secondary or several explosions. Source: https://www.sciencedirect.com/topics/chemical-engineering/dust-explosion
Some of these secondary explosions may occur inside other production or processing machines, and on pipes and beams along a high surface area, with a build up of dust and dust accumulation, as the pressure wave and fire propagate through the entire manufacturing facility. Knowledge of the dust explosion pentagon is the key strategy, with dust accumulations. At this point, the risk of harm to human life, equipment, or entire buildings is catastrophic. Source: https://en.wikipedia.org/wiki/Dust_explosion
What industries are affected by Dust Explosions?
Many industries worldwide produce the threat of combustible dust, but certain sectors are particularly susceptible to this hazardous concern. Understanding the industries affected by combustible dusts as fine particles, and explosions is vital for proactive risk management.
A wide variety of industries are affected, including:
- Agriculture
- Food Processing
- Wood and paper products
- Textiles and clothing industries
- Pharmaceuticals
- Furniture Manufacturing
- Metal processing
- Rubber Manufacturing
- Pulp and Paper Industries
- Polymer and Plastic Manufacturing
- Automotive and Aerospace manufacturing
Regarding statistics, industries, industrial processes, process equipment, and dust explosions, the US Chemical Safety Board, CSB, released its Combustible Dust Hazard Study that summarized 281 major dust explosions between 1980 and 2005 in the United States (CSB, 2006). Among the list of industries most prone to dust issues are woodworking and sawmills, where wood dust is prevalent, agricultural products, food processing, and grain handling facilities, where grain dust, sugar and flour dust pose significant risks. Grain dust explosions are extremely common in agricultural facilities. Chemical manufacturing facilities handling materials like coal and sulfur are also at high risk. The metalworking industry, dealing with aluminum and magnesium, must remain vigilant. Agriculture and grain handling, feed mills, grain elevators, pharmaceutical production, recycling facilities, and many others also contend with dust challenges. Source: Dust Safety Science Combustible Dust Incident Report
In 2023, understanding the materials most frequently implicated in dust explosions and dust fires is crucial for workplace safety. Combustible dusts and materials like food, metals, grain dust, and wood can all present significant risks if not handled properly. These materials resulted in 82% of the injuries and 52% of the fatalities. Source: Dust Safety Science Combustible Dust Incident Report
Coal was the most deadly material, accounting for 44% of this year’s fatalities. In reviewing the global incident data, food and wood products made up 79% of the dust fires and explosions recorded. Source: Dust Safety Science Combustible Dust Incident Report
In 2023, The largest fatal Combustible Dust Explosion occurred on March 14, 2023, in Sutatausa, Cundinamarca, Colombia, resulting in 21 Fatalities, which accounted for 44% of the fatalities: 21 Miners Killed in a Combustible Dust, Coal Explosion (Sutatausa, Cundinamarca, Colombia) Source: Dust Safety Science Combustible Dust Incident Report
On 1 January 1, 2023, a Dust Explosion, at Jindal Poly Films, had a Boiler explosion and had 17 injuries. This incident resulted in 24% of all total, combustible dust injuries: 17 Workers were Injured during a Combustible Dust Boiler Explosion (Nashik, India) Source: Dust Safety Science Combustible Dust Incident Report
In the year 2023, industries like wood processing, food production, and metal manufacturing continue to be at the forefront of dust explosions and dust fires. Industries such as wood, food, and metal processing are among the most common sectors prone to dust explosions and dust fires. Source: Dust Safety Science Combustible Dust Incident Report
Understanding the risk factors associated with combustible dusts in these industries is crucial for ensuring workplace safety. As shown in the historical data (see the full report), wood processing, wood products, agricultural activity such as grain dust, grain dust hazards, and food production comprise a large portion of the overall fire and explosion incidents, where dust explosions occur. Since 2017 wood and wood products have ranged from 19% to 28% of the incidents, while agricultural activity and food production have ranged from 33% to 50% Source: Dust Safety Science Combustible Dust Incident Report
Conclusion
Understanding combustible dusts and preventing dust explosions is an ongoing and crucial endeavor for industries worldwide. Safety compliance and a proactive approach are imperative, as these measures protect lives, assets, and the environment. In addition, proactive measures to prevent dust is a top strategy, to prevent primary and secondary dust explosions. By staying informed on combustible dust, and any combustible material, while adopting best practices, and increasing combustible dust awareness, organizations can effectively reduce the risk of dust clouds, and primary and secondary explosions in an enclosed space, and contribute to safer workplaces globally.
Sources and References
Here is the list of sources and references that can be consulted for further information on dust explosions and combustible dust:
Chemical Safety Board (CSB) website: “Combustible Dust Safety,” https://www.csb.gov/recommendations/mostwanted/combustibledust/#:~:text=In%202006%2C%20after%20investigating%20three,and%20extensively%20damaged%20industrial%20facilities
Dust Safety Science 2023 Incident Summary: https://dustsafetyscience.com/combustible-dust-incident-report/
NFPA 652: Standard on the Fundamentals of Combustible Dust, National Fire Protection Association, 2019 Edition https://www.nfpa.org/codes-and-standards/6/5/2/nfpa-652
NFPA 654: Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids, National Fire Protection Association, 2020 Edition https://www.nfpa.org/codes-and-standards/6/5/4/nfpa-654
Occupational Safety and Health Administration, (OSHA), website: “Combustible Dust: An Explosion Hazard,” https://www.osha.gov/combustible-dust
Occupational Safety and Health Administration, (OSHA), website: “Combustible Dust Poster,” https://www.osha.gov/sites/default/files/publications/combustibledustposter.pdf
Occupational Safety and Health Administration, (OSHA), website: “Safety and Health Topics: Combustible Dust,” https://www.osha.gov/combustible-dust
ScienceDirect, “Dust Explosion – Dust explosion propagation through ductwork connected to a process vessel,” https://www.sciencedirect.com/topics/chemical-engineering/dust-explosion
Wikipedia, Wikimedia Foundation, Inc., website: “Dust Explosion,” https://en.wikipedia.org/wiki/Dust_explosion
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