che_february-2025 - 37

Environmental Manager
Fire and Explosion Safety: Going Beyond
Traditional Protection
A sophisticated approach to fire and explosion safety requires one that expands
conventional protection strategies to comprehensively consider storage, containment
and tool compatibility
Steve Eyer
DENIOS U.S.
I
ndustrial fires and explosions
are a serious risk to chemical
processing facilities worldwide,
threatening significant harm to
personnel, assets and the environment.
Despite advancements in
safety practices, root causes continue
to pose persistent challenges.
Managing these hazards means addressing
volatile chemicals, ignition
sources and the safety demands of
modern processes.
This article examines risks, explores
essential safety measures
and provides actionable insights for
improving fire and explosion safety,
with special focus on storage considerations
for flammable, combustible
or otherwise hazardous materials
(Figure 1).
Keeping facilities up to date
Complexity in the chemical processing
industries (CPI) is increasing
due to process intensification,
automation and the introduction of
novel chemical pathways. Modern
facilities must evaluate and upgrade
their safety infrastructure regularly,
including advanced containment
systems, intentional storage solutions,
advanced tools and integrated
safety operations.
Facility updates occur within a
comprehensive regulatory framework
that includes the Process
Safety Management (PSM) standard
put forth by the U.S. Occupational
Safety and Health Administration
(OSHA; www.osha.gov),
the Risk Management Program
(RMP) requirements developed by
the U.S. Environmental Protection
Agency (EPA; www.epa.gov), and
international standards such as the
European Union's ATEX directives.
In Canada, the
Process Safety
Management
standard generally
aligns closely
with the PSM
standard from
OSHA. Globally,
the International
Labor Organization's
(ILO; www.
ilo.org) Chemicals
Convention has
been ratified by
many countries to
establish guidelines
for the safe
use of chemicals.
Ensuring compliance
with these
regulations demands
an integrated
approach,
beginning with
proper material
FIGURE 1. When developing site-safety plans to mitigate the risks of handling
flammable materials, storage considerations should never be overlooked
classification and extending through
storage, handling and emergencyresponse
protocols.
Classifying material hazards
Effective fire and explosion safety
starts with understanding the specific
hazards in a facility. Safety datasheets
(SDS/CAS) provide critical
information on a substance's flammability,
reactivity and toxicity, along
with handling, storage and disposal
guidelines. They also specify personal
protective equipment (PPE)
requirements, safety precautions
and emergency response measures.
Chemical processing facilities
rely on SDS details to inform storage
infrastructure and emergencyresponse
plans, ensuring proper
hazard management.
The distinction between flammable
and combustible materials
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lies in their ignition temperatures, a
key part of safe handling and storage.
Flammable materials - those
with flash points below 100°F
(37.8°C) - demand the most stringent
storage and handling protocols.
Examples include solvents
and petroleum-based liquids commonly
used in chemical processing
facilities. Combustible materials
-with flash points between
100°F and 200°F - require different,
but equally specific, safety
measures. Examples of combustible
materials often include hydraulic
fluids and lubricating oils.
Bio-based hydraulic fluids offer an
added safety advantage because
they generally have a higher flash
point than petroleum-based alternatives.
The classification of materials
as flammable or combustible
determines storage requirements
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