Minimizing the Severity of Consequence

http://www.inmaricopa.com/NEWS/NewsArticleDetails.aspx?ArticleID=6798&&mid1=390

Early morning fire and explosion at Pinal Energy ethanol plant. This is an excellent example of NFPA combustible dust standards best engineering practices minimizing the severity of consequence of combustible dust related fires and explosions. In reality, combustible dust explosions cannot be totally prevented, only the probability of occurrence reduced and the severity of consequence minimized.

Malt Silo Explosion in Germany kills 1, injures 7

http://www.iht.com/articles/ap/2008/11/30/europe/EU-Germany-Factory-Explosion.php

Here in the USA we all pray for the families and emergency responders that experienced a tragic event quite similar to the Imperial Sugar Refinery dust explosion at Port Wentworth, Georgia in Feb. 2008. The German news account stated, "There was a first explosion at 07.00 AM causing the fire fighters to rush in, then at 09.00 AM there was in the midst of firefighting activities a second explosion, fatal for one fire fighter, injuring 7 others." Sounds eerily familiar, a more deadly secondary explosion.

Combustible dust related fires and explosions are a constant threat to fire-fighters responding to such events. In many instances the hazards of seemingly harmless combustible particulate solids that generate combustible dust are unknown.

The explosion severity of many combustible dusts are quite similar to flammable vapors, liquids, and gases. Currently many national manufacturing industries in the USA have not acknowledged this fact.

This catastrophic event in GLOBAL MALT GMBH & CO KG, in Germany should be a wake up call for stakeholders in the USA in following similar process safety management (PSM) programs that are required by OSHA at petrochemical refineries where a thorough process hazard analysis is conducted, which identifies, evaluates, and institutes control measures in lessening the occurrence and reducing the severity of future events.

Note: You can easily translate from German to English if add the Google Toolbar to your browser. Click the link for free download

Photo Credit: SWR

Resources:

Brewing Process-
Dave Statter's Blog: STATter 911
German News Article
Aftermath Pictures http://is.gd/9Dd6

Flare-up Combustible Dust Explosions/Fires

Over the past nine days a multitude of combustible dust related explosions and fires have occurred across eight states on both sides of the Mississippi in a myriad of manufacturing industries. Recent incidents include paper, wood, textile, chemical, and plastic manufacturing sectors.

The equipment involved includes a silo, oven, dryer, electrical panel , external burner, auger, and ductwork. Luckily, injuries have been limited to a burn victim in last week's unfortunate wood fiber silo explosion. Prayers still go out to the family and worker for a speedy recovery.

Overall economic damage is in the tens of thousands of dollars. Over 50% of the incidents are reoccurences with combustible dust as the culprit causing a repeat of a dust fire or explosion. For three days last week there was two combustible dust explosions and fires/day, totaling six incidents in three days.

Hopefully after the rash of 14 combustible dust fires and explosions for the month of May, no additional incidents will occur. So lets all cross our fingers for the next two days and pray that the dragon takes a much needed rest. If it keeps up at this pace, 2008 will accumulate a dismal scorecard of over 160 reported combustible dust fires and explosions.

This is in stark contrast to the average of 12 combustible dust explosions and fires/year that the Chemical Safety Board submitted in their Combustible Dust Hazard study with recommendations to OSHA for the period of 1980-2005, which included 281 incidents.

The problem with only acknowledging 281 incidents, is that over 90% of the complex issue concerning combustible dust has not been recognized by industry, governmental regulatory agencies, trade associations, safety professionals, and state/federal legislators. Until all stakeholders recognize and acknowledge that over 3,000 combustible dust explosions and fires have occurred in the past three decades then an understanding of the depth and breadth of the problem will be absent.

In the meantime incidents will occur throughout the nation's manufacturing industries with the explosive atmospheres generated daily in the workplace without precautionary preventative, mitigative, administrative, and technical control procedures.

Map Combustible Dust Explosions 2007 & 2006

Here are a few helpful links of Google Maps regarding combustible dust related explosions and fires during 2007 and 2006.The data included in the Google Maps was obtained from Chemical Safety Board incident data. The Combustible Dust Policy Institute did not start collecting incident data until after the Imperial Sugar Refinery dust explosion in February 2008.

Google Map 2007

Google Map 2006

Here at the Combustible Dust Policy Institute, we will continue to provide updated information on the extent of combustible dust incidents throughout the process manufacturing industries. With knowledge of the prevalence of such incidents, all stakeholders can take appropriate preventative measures in protecting life and property.

Multitude Combustible Dust Incidents in One Day

Thursday started out as a normal day at many workplaces across the nation. After the lunchtime break, things would begin to change and heat up real quick in a span of two hours across three states. Prior to the clock striking 2:00 P.M. CST, a combustible dust fire consisting of titanium dust flared up in the dust collector at a dental equipment manufacturing facility in Pennsylvania.

In the Midwest, at approximately 2:30 P.M, as firefighters were responding to the titanium combustible dust fire at the Den-Tal-Ez Inc dental facility in Lancaster, Pa, a combustible dust explosion rocked the Farmer's Co-op Society grain elevator in Sanborn, Iowa.

An hour and a half later as events were just getting heated up, the afternoon turned into a leapfrog event as Baldwin Feed and Seed grain elevator in Baldwin, Wisconsin became engulfed in flames. This is very unusual for so many combustible dust related explosions and fires to occur with a span of two hours on the same day. Luckily there were no injuries only heavy economic damage to the businesses.

It's All the Same
Combustible dust is combustible dust. It doesn't matter if it's grain , metal, rubber, plastic, wood, coal, etc. All this dust is generated from a raw product of combustible particulate solids. The only difference in the dusts is the heat of combustion (oxidation), which is a measure of the rate of combustion. Which could range from 1200 KJ/mole O2 for magnesium all the way down to 470 KJ/mole O2 for starch. Proper preventive and costly mitigative measures needs to be instituted with all classes of organic, synthetic, coal, and metals. Until a comprehensive combustible dust standard is instituted more events will occur on a daily and weekly basis.

Since the OSHA grain facility combustible standard was instituted in 1988, occurrences of grain dust explosions have been reduced 30 %, with an average of 14 events annually. Have we reached an acceptable level now with the grain facility standard ? Or should a review of current procedures be in order?

Dust Explosion Research Institute
A Dust Explosion Research Institute (DERI) facility in the United States would be a good move. The time has arrived for all stakeholders in industry, academia, and cooperation with governmental agencies in facilitating the planning stages for a combustible dust research institute. This is not a novel idea, as Norway has done so decades ago at it's CMI facility in close collaboration with the University of Norway.

The results have led to the exciting field of combustible dust computational fluid dynamic (CFD) studies in conjunction with computer aided design. GEXCON, a leading Norwegian research and consultancy in explosion scenarios took over the work of CMI in 2000 and now provides a revolutionary FLame ACceleration Simulator (FLACS) in modeling the dust explosion process.

Combining physical properties of minimum explosive concentrations, minimum ignition temperatures, minimum ignition energy, and deflagration index's into the computer application of CFD will provide a cross spectrum of industries the intricate nature of combustible dusts. Much more research needs to be done as this is only the tip of the iceberg. Question is, will, the industrial powers of our nation be up to the challenge?

For others who are up to the challenge be sure to stop by the GEXCOM booth at the 2008 AIChE Spring National Meeting April 6-10, 2008 Ernest N. Morial Convention Center
New Orleans, La. . Olav Roald Hansen and Kees van Wingerden will be there with demo programs of FLACS and the Dust Explosion Simulation Code, which is the awesome CFD code for simulating the course of industrial dust explosions in complex geometries such as we experience here in the U.S. . Click here for brochure

Click here for FLACS video