che_february-2025 - 40

FIGURE 4. In some applications, specialized tools must be used to further reduce
fire and explosion risks. Such tools are designed so that no sparks are formed during
maintenance or repair tasks
or defective batteries should be
stored in quarantine containers until
they can be professionally disposed
of. Combined with proper handling,
these solutions help reduce fire and
explosion risks from batteries.
Facility-wide integration
Storage solutions must align with
facility-wide systems for grounding
and ventilation. Electrostatic discharge
is a major risk during material
transfers, so modern facilities
use grounding systems with continuous
monitoring. Active grounding
systems with LED indicators allow
quick connection verification. For
highly flammable materials or combustible
dust, this provides better
protection than passive methods,
especially during transfers.
The effectiveness of storage systems
also depends on how well they
work with emergency-response
capabilities. Strategic placement
ensures emergency access while
supporting safe separation distances.
Some materials, including
volatile dusts, require specialized
extinguishing agents, so fire suppression
systems should match the
specific hazards present. For example,
Class D fire extinguishers may
be necessary for combustible metal
dusts like aluminum or magnesium.
Carbon dioxide systems are often
used for extinguishing fires involving
flammable solvents or chemicals
where water could cause a hazardous
reaction. Foam suppression
systems are needed for handling
fires involving
large quantities
40
flammable liquids, such as toluene
or
acetone, because they help
smother the
flames and
prevent any
re-ignition.
Emergency
showers and
eyewash stations
should
be readily
accessible
with clear
access paths
from storage
areas.
Ventilation
systems play
a vital role as
they manage
both routine emissions and
potential emergency scenarios.
Technical ventilation requirements
vary based on stored materials but
typically include both high-level
and low-level extraction points to
manage vapors of varying densities.
Modern systems often
add monitoring capabilities that
allow users to verify proper airflow
and provide early warning of
system failures.
of
Specialized tools to reduce risks
In chemical processing facilities,
flammable gases, vapors and dust
make the risk of ignition ever-present.
Preventing sparks during routine
maintenance or emergency
repairs is necessary for fire and explosion
safety. Non-sparking tools
are designed for hazardous environments
like these (Figure 4).
Non-sparking tools are made from
non-ferrous metals, such as aluminum
bronze, phosphor bronze,
beryllium copper and brass. These
materials do not produce sparks
when struck or rubbed against other
surfaces, which reduces the chance
of ignition in environments where a
single spark could cause an explosion.
These tools are indispensable
for working around flammable substances
like solvents, gases and
combustible dust.
Beyond spark prevention, nonsparking
tools are often corrosionresistant,
making them suitable for
environments where chemicals,
moisture or extreme conditions
could degrade standard tools. Their
durability ensures effectiveness in
harsh chemical or humid conditions.
Non-sparking tools are available in
a variety of forms to support different
maintenance needs, including
wrenches, hammers, screwdrivers,
pliers and scrapers. These tools are
designed for safe use in situations
where traditional steel tools pose a
risk. Non-sparking tools help chemical
processing facilities reduce the
risk of fires and explosions, making
them a part of a comprehensive
prevention strategy.
Continuous improvement
As hazards evolve and new safety
technologies emerge, facilities
must upgrade monitoring systems,
enhance containment measures,
and integrate solutions that boost
safety and efficiency. This involves
maintaining documentation, frequent
inspections and responsible
equipment management. Comprehensive
training programs covering
routine operations and emergency
response are essential to this effort.
By building and maintaining
a robust safety system, facilities
can stay compliant, reduce risks
and protect employees, assets
and the environment. Continuous
improvement is the foundation
of effective fire and explosion
hazard management.
■
Edited by Mary Page Bailey
Acknowledgement
All images provided by author
Author
Steve Eyer is an engineered systems
sales manager at the DENIOS
U.S. (1152 Industrial Blvd.,
Louisville KY 40219; Phone:
1-800-216-7776; Email: seyer@
denios-us.com.) Eyer has over 25
years of experience within the
safety industry with a focus on
design and engineering of flammable
combustible products. He
has worked for many leading manufacturers and is a
three-time patent recipient. Throughout his career, Eyer
has contributed to industry regulations and given influence
for engineered judgments to third party insurers.
He holds a mechanical engineering degree from Vincennes
University and is currently pursuing his M.S. in
technology from Eastern Illinois University.
Further reading
1. Design for Safety: Tips for Proactive Risk Reduction,
Chem. Eng., Feb. 2023, pp. 30-33.
2. Steps to Improve Safety Challenges in Hazardous
Environments, Chem. Eng., Aug. 2022, pp. 42-46.
3. Process Changes: Understanding and Mitigating
Fire- and Life-Safety Risk Factors, Chem. Eng.,
Sept. 2020, pp. 50-53.
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM
FEBRUARY 2025
http://WWW.CHEMENGONLINE.COM
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