Safety and risk Management

Assignment on
Dust Explosion

By,
Vishal M. Mahamuni
M.Chem.Engg.
ICT,Mumbai

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Dust Explosion
1. Definition
Combustible dusts are fine particles that present an explosion hazard when suspended in air in
certain conditions. A dust explosion is the rapid combustion of fine particles suspended in the air,
often but not always in an enclosed location. Dust explosions can occur where any dispersed
powdered combustible material is present in high enough concentrations in the atmosphere or
other oxidizing gaseous medium such as oxygen. Dust explosions are a frequent hazard in
underground coal mines, in grain elevators, and other industrial environment.
Any oxidisable fine powdered material can form a flammable dust cloud in air. (When dispersed
in appropriate concentration).Most powder handling industries are at risk : Agricultural,
Pharmaceutical, Chemical, Textile, Metal processing, Wood working, Paper works, recycling
operations almost anywhere that dust is generated.
2. Factors for dust explosion
When dealing with flammable gases and vapors, the generally accepted major requirements for a
fire or explosion are fuel, oxygen and ignition. In chemical industry they try to eliminate or
reduce one or more of the sides of the triangle i.e. the major factors.
In addition to the familiar fire triangle of oxygen, heat, and fuel (the dust), dispersion of dust
particles in sufficient quantity and concentration can cause rapid combustion known as a
deflagration. If the event is confined by an enclosure such as a building, room, vessel, or process
equipment, the resulting pressure rise may cause an explosion. These 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.
3. How dust explosion can occur?
An initial (primary) explosion in processing equipment or in an area where fugitive dust has
accumulated may dislodge more accumulated dust into the air, or damage a containment system
(such as a duct, vessel, or collector). As a result, if ignited, the additional dust dispersed into the

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air may cause one or more secondary explosions. These can be far more destructive than a
primary explosion due to the increased quantity and concentration of dispersed combustible dust.
Many deaths in

past incidents, as well as other damage, have been caused by secondary

explosions.

4. Prevention of Dust Explosions

To identify factors that may contribute to explosion, OSHA recommends a thorough hazard
assessment of the following things.

All materials handled;

All operations conducted, including by-products;
All spaces (including hidden ones); and
All potential ignition sources.

4.1 Dust control recommendations

Implement a hazardous dust inspection, testing, housekeeping, and control program

Use proper dust collection systems and filters
Minimize the escape of dust from process equipment or ventilation systems;
Use surfaces that minimize dust accumulation and facilitate cleaning;
Provide access to all hidden areas to permit inspection
Inspect for dust residues in open and hidden areas at regular intervals;
If ignition sources are present, use cleaning methods that do not generate dust clouds;
Use only vacuum cleaners approved for dust collection; and
Locate relief valves away from dust deposits

5. Case study 1.
On October 9, 2012, at approximately 1:15 pm Eastern Standard Time (EST), a flash fire caused
burn injuries to seven workers, including three who sustained third degree burns at the US
Ink/Sun Chemical Corporation ink manufacturing facility in East Rutherford, New Jersey.
This situation caused ignition and a pressure rise in the dust collector, which was already filled
with the blend of Gilsonite, carbon black, and clay. The increase in the total suppression
pressure occurred because of the higher rate of pressure rise of the dust mixture compared to the
expected design of 165 bar meters per second.
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Lessons learned from the incident

1. Inadequate Project Oversight and Misrepresentation of MOC Exemption
2. Ineffective Hazard Communication and Emergency Response Planning
3. Ineffective Employee Training on Dust Collection Mechanism

Re-commendations
Revise the Capital Appropriations /Asset Request (CAR) Form procedure for new installations
and modifications to existing equipment to require at a minimum the following
1. Process hazard analysis
2. Management of change (MOC)
3. Review of engineering drawings for permits
4. Safety Management of Contractors
5. Training Of plant operators based on applicable dust collection system guidelines

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