Hoeganaes Corporation, a subsidiary of GKN (UK), is an international producer of iron powder and atomized steel with facilities in U.S, Germany, Romania, and China. On 31st January 2011, a fire arising from the motor that drive bucket elevators resulted in two fatalities. On 29th March 2011, a flash fire injured an engineer replacing igniters on a band furnace. On 27th May 2011, there were three fatalities and two injuries resulting from the explosion of a leaking hydrogen pipe.
Analyses of these cases revealed that significant quantities of iron dust escaped from conveyance equipment. The bag-house filters were often out of service hence the smallest and most dangerous dust particles escaped. Consequently, iron dust became airborne and accumulated on elevated surfaces in the processing areas. The trench housing the hydrogen and nitrogen pipes also acted as the drain for the cooling water used in band furnaces leading to corrosion of the pipes. However, according to CSB investigators, Hoeganaes Corporation did not regularly inspect the pipes.
Written protocols to mitigate gas leaks were non-existent in the company. Maintenance crews began investigating a suspected leak before testing the atmosphere for explosive gas. Observations by the CSB investigators shortly after the first incident revealed that combustible dust was leaking from the equipment, and that housekeeping was ineffective. The victims of the flash fires of 2011 were wearing Flame Resistant Clothing (FRC), but the FRC worn by the Hoeganaes 2011 victims did not provide any significant protection.
Conclusion
Opportunities to increase awareness and address metal dust issues through were available through literature, audits, inspections, and regulatory oversight. Hoeganaes Corporation did not effectively utilize these resources. Gaps in codes and regulations, inadequate inspections and poor hazard recognition all contributed to the three 2011 incidents at the Gallatin facility.
