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STORAGE

Dust explosion

#2

Is suppression the solution

in grain hammer mills?
by Kevin Spiess, EMEA Sales Manager for Explosion Protection, BS&B Safety Systems, UK

here have been newsworthy examples of

grain mill fires around Europe in recent
years: 2010 Verdelot in France saw
the destruction of Moulins Bourgeois
mill; in 2014 a major fire broke out in
Chancelot Mill in Edinburgh. Recently
in 2015 a fire consumed Allied Mills at
Tilbury Docks, London.
The originating causes of grain
mill fires may be varied; a spark, a carelessly discarded match,
electrical fault, or grinding and milling friction. However, the
fuelling and propagation of a possibly fatal explosion is almost
always caused by grain dust.

because they pulverize raw materials against a surface at high

impact. When surfaces contact in this way, the impact and friction
causes sparks and hot spots, which are ideal ignition sources for
dust accumulations or dust clouds.
According to the UK Health and Safety Executive (HSE)
guidance on Prevention of Dust Explosions in Food Industry
(Milling and Grinding):
Hammer mills are often engineered to be strong enough to
contain a dust explosion, but sparks or smouldering particles may
spread from the mill to other more vulnerable equipment.
However, what are the consequences when a hammer mill fails
to contain such an explosion?
The very nature of the materials being processed and
handled turn a hammer mill into a potential tinder box.
Explosions are caused by the trinity of ignition, fuel and
oxygen. When these three elements come together in an
enclosed area, with rising pressure and rapid increases
in temperature, a deflagration can occur. This primary
explosion can cause a pressure wave carrying with it a flame
that disturbs accumulated grain dust. Nearby personnel and
property are now at great risk of harm.

Why are hammer mills an explosion risk?

Post ignition hazards

Devastating mill explosions pose one of the most

significant safety risks in the grain and feed industry.
The milling, handling and storage of grain and feed
- whether wheat, rice and barley, or sugar and corn constitute explosion risks in spite of their innocuous
nature.

Among the locations commonly identified for primary dust

explosions, hammer mills sit as a leading contender for explosion
initiation. Hammer mills are sources of explosion ignition
58 | Milling and Grain

Unfortunately, once the agitated dust is in suspension, this

is where the extremely dangerous secondary explosion risk is
created. The secondary explosion has the ability to spread to other

F
parts of processing equipment risking its complete destruction. It
travels through pipes, ductwork and silos until no part of the mill
is safe from the mobile explosion risk - including the mill building
structure.
In theory, when one element of the incendiary trinity is
interrupted or controlled, an explosion can be averted. This
invites different methods of protection to mitigate against fire
risk ranging from better housekeeping to reduce or eliminate
dust accumulation, to venting systems and explosion suppression
devices.

Figure1: The explosion suppression

system is designed to detect the start of
an explosion and deliver dry chemical
extinguishing agents into a developing
internal deflagration. In this way it
suppresses further flame propagation
and protects interconnecting process
equipment from any spreading
explosion damage.

Early detection

BS&B have taken explosion suppression methods to a new level

of efficiency with the new the System V. System V is designed
to detect the start of an explosion and deliver dry chemical
extinguishing agents into a developing internal deflagration via a
Cannon. In this way it suppresses further flame propagation and
protects interconnecting process equipment from any spreading
explosion damage.
In environments where the by-product of bulk handling and
processing is highly combustible dust, this system detects danger
at the first suggestion of risk. It is made up two main elements.
The Cannon, which delivers the extinguishing agent, is a
modular design consisting of five components:
the Cannon body
extinguishing agent canister
actuation mechanism
pressurized nitrogen tank
Cannon electrical enclosure
The second element is the Smart Controller Unit with sensors
that detect the slightest temperature fluctuations and indicate a
potential deflagration forming. This timely detection is the key to

avoiding a potential explosion disaster.

When the Cannon deploys, it releases sodium bicarbonate to
suppress a dust explosion. Deployment is prompted by a low
voltage electrical signal generated from sensors in the Smart
Controller Unit, which activates actuators in the Cannon.
The actuators release pressurized nitrogen gas at the sodium
bicarbonate canister, which in turn, fires its contents at high speed
in just a few milliseconds. A possible explosion travelling through
connected equipment is safely and quickly averted. The result: no
persons injured by a spreading explosion and untold damage to
equipment is avoided.

July 2015 | 59

STORAGE

The originating causes of

grain mill fires may be varied;
a spark, a carelessly discarded
match, electrical fault, or
grinding and milling friction.
However, the fuelling and
propagation of a possibly fatal
explosion is almost always
caused by grain dust
User flexibility and regulatory compliance

The System V is lightweight and modular, enabling easy

shipping, fitting and maintenance, making it user friendly at each
stage of the supply chain.
BS&B are very aware of a need to make protection systems

simpler to use for the end-user. Therefore, the Cannons critical

circuits are continuously monitored and any events are reported
at a controllers touch screen. To ensure personnel and
property safety, there are equipment failsafe features. The dual
lockout mechanism prevents accidental discharge of a Cannon
into the protected equipment
when client operatives may be
conducting internal work in the
vicinity.
The end-user has full control
over refit and maintenance. With
appropriate training from BS&B,
an appointed operative can refit the
system using simple replacement
parts after it has been activated.
This reduces interruption on
production time and any ensuing
economic loss.
As employers are required
to adhere to DSEAR 2002 and
ATEX 95, the System V has
been designed to be a flexible,
cost effective and efficient
means to help them meet those
requirements. It is recommended
that before installation, correct
specification of the dust likely
to cause an explosion hazard is
identified. In this way the client
can install the appropriate size of
Cannon for optimal protection of
staff, equipment and property.

Protecting your business

The appeal of applying

explosion suppression as a
protective measure, is that it
pre-empts explosion danger
via sensitive detection and
prompt action. The accuracy of
response means that lives are
not unnecessarily endangered,
equipment is saved from
destruction and in the worst case,
the entire milling business is not
rendered inoperable due to an
explosion-induced fire.
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60 | Milling and Grain