New England Wood Pellet Dust Explosion

On June 23, 2020, a dust explosion occurred at the New England Wood Pellet facility in Jaffrey, New Hampshire, leading to significant damage and injury. An OSHA investigation revealed the presence of combustible wood dust, inadequate dust control measures, and a lack of proper safety protocols.

How the Incident Began

The production of wood pellets in the facility generated wood dust as a byproduct of its manufacturing process. This dust accumulated and became suspended in the air, creating a highly explosive environment. The absence of adequate ventilation systems allowed the dust to remain suspended, increasing the likelihood of an explosion. Through an unknown ignition source, possibly sparks, heat, or electrical equipment, the dust detonated.

Firefighters spent two and a half hours combating the resulting fire. When they first arrived, they found heavy smoke conditions in the pellet mill manufacturing area. Although the area where the explosion had occurred was severely damaged, all employees had been evacuated and accounted for. After the primary fire was put out, secondary fires on the roof were discovered and quenched. The Monadnock Ledger-Transcript reported one employee was transported to the hospital with minor injuries.

OSHA Investigation

The facility had experienced fires and explosions in the past and had not taken substantial steps to stop these events from occurring. OSHA had cited the company for violations of workplace safety standards in connection with the first incident of explosions and fires in 2011. An inspection conducted in response to that incident identified numerous fire and explosion hazards resulting from the absence of protective devices, which were complicated by a build-up of sawdust on surfaces throughout the plant.

As a result of the 2020 explosion, the company was fined $100,000, which it contested. OSHA and New England Wood Pellet agreed that measures would be implemented to prevent, detect, and suppress any potential fires or explosions. A third-party expert would be involved to determine if the measures implemented were effective.

Lessons Learned

Learn what steps were taken to reduce process safety risk, maintain compliance and substantially increase peace of mind.

Administrative Controls

Proper housekeeping procedures should be implemented to regularly clean and remove combustible dust from all areas of the facility. This includes regular vacuuming, sweeping, and ensuring that dust does not accumulate on surfaces, equipment, or ventilation systems.

Furthermore, the installation and maintenance of effective dust collection and ventilation systems are vital. These systems should be designed to capture and remove dust from the air, preventing it from accumulating and becoming a hazard. Regular inspections and maintenance of these systems are essential to ensure their proper functioning.

Process Safety Training

Employee training and awareness are also critical. All personnel should receive comprehensive training on the hazards associated with combustible dust, including how to identify and report potential issues. They should be educated on safe work practices, such as the use of appropriate tools and equipment to minimize the generation of sparks or heat in areas where dust may be present.

Hazards Analysis

To prevent such incidents, a comprehensive approach to dust control and safety is necessary. Regular Dust Hazard Analyses should be conducted to identify potential hazards and areas for improvement. Engaging with industry experts like ioKinetic on how to adhere to relevant safety standards and guidelines can provide valuable insights and best practices for preventing dust explosions.

Conclusions

Ultimately, the dust explosion at this facility could have been avoided through the implementation of proper dust control measures, effective process safety training, and regular hazard analyses. Similar incidents can be prevented, protecting the lives of personnel and the integrity of their facility, by prioritizing safety and taking proactive measures to mitigate dust hazards.

We Can Help

ioKinetic has reduced process safety risk, maintained compliance and substantially increased peace of mind for our clients worldwide. To learn more about how we can help you manage risk, contact us today or call us at 1-844-ioKinetic.