(193c) Combustible Dust Explosion Case History

This paper deals with a combustible dust explosion that occurred in 2003 at the CTA manufacturing facility in Corbin, KY. The explosion and subsequent fires resulted in multiple fatalities, widespread injuries, and damage to the processing area of the facility. The majority of the damage associated with the explosions was caused by secondary dust explosions, which resulted from the widespread accumulation of hazardous levels of combustible dusts throughout the processing area of the facility. The primary combustible dust involved in the explosion was phenolic resin, although similar damage would have been caused by any typical combustible dust allowed to accumulate in a similar manner. Although a number of potential initiating events have been postulated, the most likely initiating event was a gas explosion inside an oven associated with the manufacturing operation; several safety systems related to the oven burner controls had been bypassed.

This event clearly demonstrates that allowing combustible dust to accumulate to hazardous levels within a building, room, or similar enclosure creates the risk of a secondary dust explosion. The accumulation of hazardous levels of combustible dust within an enclosure coupled with a competent initiating event can result in a dust explosion. The hazards associated with combustible dusts are widely discussed in the literature and addressed by national codes and standards (e.g., NPFA 654). Nevertheless, combustible dust explosions, such as the one described in this paper, continue to occur. It is therefore important to continue to disseminate information regarding combustible dust explosion hazards and case history information that illustrates the nature of these hazards.