CSB Publishes Major Concerns About Hoeganaes

PLEASE NOTE:  I'll be quoting extensively from the U.S. Chemical Safety Board's statements on their investigations of 3 fire/explosion incidents in the first 5 months of this year. The conference was held in Nashville, TN on June 3, 2011. You can read the entire statement by going to the "CSB Investigation" tab on this blog site. To download a copy of the statement in pdf format go to: http://www.csb.gov/assets/news/document/Final_Statement_6_3_2011.pdf

Major Concern #1: A Buildup of Combustible Dust
Quotes from Rafael Moure-Eraso, Chairperson of the U.S. Chemical Safety Board: "Combustible dust is an insidious workplace hazard when it accumulates on surfaces, especially elevated surfaces. Since the CSB was established in 1998, three of the four deadliest accidents we have investigated were determined to be combustible dust explosions."

"It is a finely powdered iron dust. It is similar to material we previously tested, which was shown to cause flash fires or explode when suspended in air, confined, and brought into contact with an ignition source."

Quote from CSB Team Lead Johnnie Banks, the investigator-in-charge for this case: "During all three of our trips to the Hoeganaes plant my team observed alarming quantities of metal dust within close proximity to the incident locations. This was of particular concern as metal dust flash fires present a greater burn injury threat than flammable gas or vapor flash fires. Metal dust fires have the potential to radiate more heat and some metals burn at extremely high temperatures in comparison to other combustible materials. In addition to visible dust particles in the air, 2 to 3-inch layers of dust were observed on flat surfaces, rafters, and railings throughout the facility."

The photo below is from the CBS's Investigation of 2 deadly flash fires. The photo shows combustible, atomized iron powder buildup on surfaces throughout the plant.

The photo blow shows atomized iron powder buildup several inches thick in some places.

Quote from Rafael Moure-Eraso, Chairperson of the U.S. Chemical Safety Board: "...As you can see, there are a number of serious safety problems at this plant that need to be immediately addressed before production resumes. No one should underestimate the scope of the task. Far more than a one-time cleaning is required. Without design and engineering improvements, dust will quickly accumulate back to its former levels..."

After showing a video of fires produced during the CSB's extensive tests, the CSB Team Lead Johnnie Banks stated; "...the small sample of just over one ounce of fine iron powder produces an intense flash fire when dropped onto a gas flame. If this size fire can result from just an ounce of iron powder, you can imagine the magnitude of the fire and explosion hazard from the estimated tons of dust accumulated in the Hoeganaes plant."

Major Concern #2: Rusted piping carrying hydrogen gas. The CSB observed combustible dust all over the plant and estimated TONS of it on elevated surfaces.  The company uses hydrogen gas in the annealing process to make atomized iron powder. They have 12 ovens that melt iron scrap at a temperature of 3000 degrees F and the pipes carrying the hydrogen gas were in this condition.

Note: Hoeganaes had a clean record with TOSHA.... No safety violations reported prior to the incidents this year.

Why This Blog Was Created

This blog has been created solely for the purpose of compiling and centralizing information and to build awareness about the dangers of living in a community near the world's largest "atomized" iron powder producer which has been reported to have serious combustible dust issues as evidenced by three separate deadly fire/explosion incidents at the plant in the first 5 months of this year in which the CSB reported combustible dust as a factor. Equally concerning is that the most recent explosion at the Hoeganaes Corporation in Gallatin, TN involved "inadequate maintenance of hydrogen gas piping," as also reported by the U.S. Chemical Safety Board Investigation Team.

I urge you to educate yourself on these issues by visiting the videos section where you will find coverage of some freightening combustible dust and chemical explosion disasters at other plants in the U.S. Even more concerning is that the CSB stated; "... metal dust flash fires present a greater burn injury threat than flammable gas or vapor flash fires. Metal dust fires have the potential to radiate more heat and some metals burn at extremely high temperatures in comparison to other combustible materials." Add some hydrogen gas into the mix and you have the recipe for a disaster of catastrophic proportions.

Take a look at the video below of an explosion at Pepcon Chemical, a rocket fuel ingredient manufactuer in Henderson, NV on May 4, 1988. The fire started from a welding accident inside the plant. The explosion registered 3.5 on the richter scale 600 miles away. Keep in mind as you watch this that, as I stated above, the CSB said; "metal dust flash fires radiate more heat than flammable gas." What would happen if tons of atomized iron powder exploded at Hoeganaes due to the combustible dust and hydrogen gas piping issues? Would our community look like the H bomb had been dropped on it?

Note: The video begins by saying: "...industrial factory explosions are not that common..." However, in 2006, a pattern of industrial mishaps in the U.S. prompted the CSB to launch a comprehensive study of combustible dust explosions which uncovered 281 fires and exlosions that had occurred over the previous 25 years. The study revealed what the "CSB called a significant industrial problem.

Destroyed in Seconds...

While you are here, you definitely should read the CSB's investigation report on Hoeganaes located under the "CSB Investigation" tab. In the report, the CSB stated; "...three of the four deadliest accidents we have investigated were determined to be combustible dust explosions."

The main message here is that these types of disasters are preventable! The question is, will the right people make the right decisions to stop something like this from happening here in Gallatin, TN?