(55ci) Using Lab Test Data to PREVENT DUST EXPLOSIONS

Industrial dust explosions pose a significant threat to personnel, equipment, and the environment within various processing industries. To effectively mitigate these hazards, a comprehensive understanding of the factors influencing dust ignition sensitivity and explosion severity is essential. This paper presents a study that showcases the successful integration of ignition sensitivity and explosion severity test data in the investigation of two actual dust explosions. The aim of the investigation was to diagnose the root causes of these incidents and subsequently adapt plant design and practices to prevent their reoccurrence.

The study details two contrasting, real-world dust explosion incidents; one in a pharmaceutical plant and the other in a metal spray coating facility. By analyzing ignition sensitivity data, the investigating team was able to identify, validate, and eliminate candidate ignition sources under various conditions. Furthermore, explosion severity test data was utilized to examine these incidents in terms of blast pressure, flame propagation, and thermal effects and compare to the damage caused.

The investigations demonstrate the importance of a holistic approach to dust explosions analysis, encompassing not only incident response but also proactive prevention strategies. The collected data enabled the identification of specific process areas where ignition sources were prevalent, and modifications to equipment and operational procedures were proposed accordingly. Additionally, the explosion severity data informed the design of mitigation measures, including blast relief systems and isolation methods, to minimize the impact of any future explosion.

The success stories highlighted in this paper offer practical insights that can be adopted by safety and engineering professionals in industries seeking to prevent dust explosions, protect plant against explosion effects and ensure the safety of their operations. In particular, they highlight the practical application of scientific data in addressing the critical dust explosion safety concern within industrial settings. The cases thus bring to life the basic principles and requirements for identifying and managing fire and explosions hazards of combustible dusts and particulate solids as outlined in NFPA 652 ‘Standard on the Fundamentals of Combustible Dust.’