Combustible Dust: An Explosion Hazard

What is Combustible Dust?

Combustible dust is any solid material that is divided into fine or distinct particles, which under certain conditions and concentration, can rapidly catch fire or become explosive once exposed to air and other elements. It can be found in a wide variety of materials in various industries and created when items are handled, transported, processed, or stored. Workplaces and facilities that generate dust are all potentially at risk.

Why is it a Hazard?

According to the latest report released by Dust Safety Science, a combustible hazard research organization, there’s a yearly average of 28 dust explosions, 25 injuries, and a range from one to six fatalities.

One of the notable incidents of dust explosions in the United States is the sugar dust explosion that happened in Georgia in 2008. 14 people were killed in the incident, while 40 people sustained injuries.

These numbers show that dust explosion is still an increasing safety issue in industrial and workplace settings. Businesses should always put safety systems in place to proactively address any issues and prevent these types of incidents that lead to damage to property, injury, and even fatality from ever happening.

The Dust Explosion Pentagon

A dust explosion can occur when all of the following five elements are present:

1. Combustible dust – These are solid materials with fine particles that are susceptible to fire or explosion. This element is often referred to as the fuel.

2. Ignition source – These are processes or scenarios that can cause fire or explosion, such as electrical sparks, static electricity, hot surfaces, friction, etc.

3. Oxygen in the air – This is the oxidizing agent in the air. Along with the previous two elements, it’s enough to create a dust fire.

4. Confinement of dust cloud – For a dust explosion to occur, the dust elements should be confined in an enclosed space where pressure builds and expands.

5. Dispersion of dust particles – A dust explosion finally happens when all four elements are present and the dust particles are dispersed or distributed in an enclosed area.

Combustible Dust Examples

Workplaces utilize various materials daily and many of these can potentially be combustible dust. Examples of materials include:

• Agricultural products such as sugar, powdered milk, corn starch, flour, rice, etc. This puts not just the agricultural industry at risk of dust explosion, but the food production industry as well.

• Chemical dust such as coal, sulphur, etc. These types of materials are often present in the pharmaceutical industry.

• Textile products such as silk, wool, synthetic fibers, etc. This puts the fabric manufacturing industry at enormous risk of explosion if not regularly monitored.

• Wood materials can lead to combustible dust, especially those that are stored and used to manufacture new products.

• Metal substances such as aluminum, bronze, magnesium, etc. The businesses that are often at risk with this type of dust hazard are the metal processing and metal manufacturing industries.

How to Prevent Combustible Dust Explosions

The Occupational Safety and Health Administration (OSHA) released a Hazard Communication Guidance for Combustible Dusts that gives businesses and employers a guide in implementing their control measures for dust explosions.

These are some preventive measures to proactively maintain a safe working environment for employees and in facilities concerning combustible dust:

Identify hazardous dusts present in your workplace.

Recognize all potential combustible materials within your site. Conduct regular inspections to uncover hidden or overlooked substances that could generate hazardous dust. Document every finding to determine how best to manage and eliminate each dust hazard effectively.

Use proper dust collection systems.

Maintain strict housekeeping standards to minimize fire and explosion risks. Use an industrial-grade vacuum designed for combustible dust to collect and safely remove particles from the site. Avoid sweeping or using compressed air, as these can disperse dust into the air and increase ignition risk. Always ensure all dust collection equipment complies with industrial safety standards and is regularly inspected for functionality.

Implement good control measures.

Establish a comprehensive dust control strategy that prevents accumulation and reduces ignition sources. Integrate safety procedures into daily operations, outlining clear steps for monitoring, containment, and removal of dust. Standardize these measures across departments so all employees follow consistent safety protocols.

Conduct regular employee training.

Train all employees regularly on recognizing and handling combustible dust hazards. Include hands-on sessions for operating safety equipment, using extinguishing systems, and managing fire or explosion incidents. Reinforce awareness through refresher courses and visual reminders throughout the facility to maintain safety-conscious behavior.

Assess confined space risks.

Evaluate confined spaces, ducts, silos, and other enclosed areas where dust clouds may accumulate. Perform proactive risk assessments to detect potential explosion hazards and implement control systems before issues escalate. Establish permit systems and ventilation protocols to ensure safe entry and maintenance in confined environments.

Perform regular inspections.

Inspect all work areas, dust collection systems, and equipment regularly. Verify that housekeeping procedures are being followed and that preventive measures remain effective. Record inspection results, identify weak points, and implement corrective actions promptly to sustain compliance and continuous improvement.