Modernization of ATEX Explosion Protection Systems in our client’s sugar factory required innovative yet practical solutions. This led to the creation of a coherent explosion protection system that not only complies with legal regulations but also significantly improves plant safety.

The Challenge

• ATEX explosion protection in the client’s sugar factory was fragmented.
• The greatest risk came from potential secondary explosions.
• The Explosion Protection Document (EPD) contained as many as 60 recommendations, including 22 related to explosion protection. 

Solution

• We optimized project costs by proposing an unconventional solution that eliminated the formation of an explosion hazard zone.
• We ensured compliance with regulations by implementing the EPD recommendations.
• The work was completed in just one day, minimizing downtime at the plant.

Is a bridge with missing spans a safe crossing? At first glance, the structure may seem stable — but in reality, it’s better not to step on it! The same applies to ATEX explosion protection systems in sugar factories. Only when all components are properly selected and securely installed can we speak of a “system” rather than a collection of elements. And only such a system provides real safety in a production facility, especially one as prone to dust explosions as a sugar factory.

Scale of destruction after the 2008 explosion at the Imperial Sugar refinery in the USA. Source: CBS.com

The Challenge: Fragmented protection is no protection

Our client, one of the largest sugar producers in Poland, had been using various explosion protection systems over the years. However, an independent audit conducted in 2020 identified 60 recommendations, 22 of which specifically addressed explosion protection.

The core issue was that the existing explosion protection systems in the factory were fragmented. For example, the drying, sorting, and packaging lines had only partial or sometimes improperly selected protections. The dedusting installations connected to the silos—critical points for explosion safety—were also not adequately protected.

In the event of an explosion, the shockwave generated in the filter could travel back into the silo, dedusting system, and big-bag filling system. The owners of the American Imperial Sugar refinery learned just how dangerous such secondary explosions can be.

Source: Associated Press

The infamous 2008 explosion claimed the lives of fourteen people. Eight died instantly, and six succumbed to burn injuries later. The silos and surrounding towers were damaged, the southern packaging building and the palletizing facility were destroyed, and the refinery area suffered severe damage.

The Solution: Eliminate explosion risk without excessive cost

GRUPA WOLFF was selected to carry out critical safety work. Our task included selecting, delivering, installing, and commissioning the equipment. We started with the silo’s ventilation filter, which was previously only secured with a decompression panel.

We took an unconventional approach: instead of replacing the large fan behind the filter with one suitable for Ex zones, we proposed a Sintrol dust sensor on the duct before the filter. Its purpose is to automatically shut down the system upon detecting even minimal dust concentrations. This eliminated the potential formation of an explosion hazard zone—without the high cost of replacing the fan with an ATEX-compliant model.

Dust sensor on the dedusting installation. Photo: GRUPA WOLFF

To prevent explosion propagation to adjacent devices, we installed the explosion isolation flap valves at the filter inlet and a rotary valve at the outlet.

Explosion isolation on the dedusting installation. Photo: GRUPA WOLFF

In the first stage of the implementation (2023), we delivered ATEX-compliant protection systems for two filters: silo dedusting and air-conditioning. Additionally, we verified the correct selection of the filter’s decompression panels and provided grounding for mobile sugar conveyors beneath the silo.
One year later, in the second stage, we secured three more dedusting filters for the drying, sorting, and packaging lines. Here too, we used rotary valves, backdraft dampers, and dust sensors.

Protecting a sugar factory against explosions is a strategic process, not a one-off project

Thanks to our flexible approach and expert knowledge, we implemented the audit’s recommendations while optimizing costs and execution time. Each line had to be shut down for just one day, minimizing production losses. A post-implementation audit confirmed the effectiveness of the solutions, and the client expressed satisfaction with both the outcome and the cooperation process.

The sugar factory continues its modernization efforts. In the next stages, the plant plans to install HRD explosion suppression and isolation systems on five bucket elevators, along with a tank and filter system supporting pneumatic sugar transport.

Our client’s case shows that a strategic approach to ATEX explosion protection in a sugar factory is not a one-time project but a long-term commitment to protecting people and processes.

Do you need a reliable partner to help implement EPD recommendations? Or maybe help securing funding for ATEX protections in your sugar factory? Get in touch—our experts will help you prioritize and schedule the work to fit your capabilities. You can also read our client’s story to learn how to implement EPD recommendations without breaking the bank.