Fire and Explosion Safety: Going Beyond Traditional Protection

A sophisticated approach to fire and explosion safety requires one that expands conventional protection strategies to comprehensively consider storage, containment and tool compatibility

Industrial fires and explosions are a serious risk to chemical processing facilities worldwide, threatening significant harm to personnel, assets and the environment. Despite advancements in safety practices, root causes continue to pose persistent challenges. Managing these hazards means addressing volatile chemicals, ignition sources and the safety demands of modern processes.

This article examines risks, explores essential safety measures and provides actionable insights for improving fire and explosion safety, with special focus on storage considerations for flammable, combustible or otherwise hazardous materials (Figure 1).

 

Keeping facilities up to date

Complexity in the chemical processing industries (CPI) is increasing due to process intensification, automation and the introduction of novel chemical pathways. Modern facilities must evaluate and upgrade their safety infrastructure regularly, including advanced containment systems, intentional storage solutions, advanced tools and integrated safety operations.

Facility updates occur within a comprehensive regulatory framework that includes the Process Safety Management (PSM) standard put forth by the U.S. Occupational Safety and Health Administration (OSHA; www.osha.gov), the Risk Management Program (RMP) requirements developed by the U.S. Environmental Protection Agency (EPA; www.epa.gov), and international standards such as the European Union’s ATEX directives.

In Canada, the Process Safety Management standard generally aligns closely with the PSM standard from OSHA. Globally, the International Labor Organization’s (ILO; www.ilo.org) Chemicals Convention has been ratified by many countries to establish guidelines for the safe use of chemicals. Ensuring compliance with these regulations demands an integrated approach, beginning with proper material classification and extending through storage, handling and emergency-response protocols.

 

Classifying material hazards

Effective fire and explosion safety starts with understanding the specific hazards in a facility. Safety datasheets (SDS/CAS) provide critical information on a substance’s flammability, reactivity and toxicity, along with handling, storage and disposal guidelines. They also specify personal protective equipment (PPE) requirements, safety precautions and emergency response measures. Chemical processing facilities rely on SDS details to inform storage infrastructure and emergency-response plans, ensuring proper hazard management.

The distinction between flammable and combustible materials lies in their ignition temperatures, a key part of safe handling and storage. Flammable materials — those with flash points below 100°F (37.8°C) — demand the most stringent storage and handling protocols. Examples include solvents and petroleum-based liquids commonly used in chemical processing facilities. Combustible materials —with flash points between 100°F and 200°F — require different, but equally specific, safety measures. Examples of combustible materials often include hydraulic fluids and lubricating oils. Bio-based hydraulic fluids offer an added safety advantage because they generally have a higher flash point than petroleum-based alternatives. The classification of materials as flammable or combustible determines storage requirements and influences facility layout, emergency response planning and operational procedures.

When determining storage requirements for hazardous materials, facilities should consider factors such as physical state, potential incompatibilities, ventilation needs and temperature sensitivity. Vapor pressure characteristics, chemical stability and potential reactivity are also important. These properties inform decisions about engineering controls, including ventilation systems, temperature regulation and material compatibility. Modern facilities that handle multiple hazard classes simultaneously will require advanced approaches to segregation and storage. A thorough assessment from a skilled supplier is useful to support a facility with risk-mitigation strategies.

 

Effective storage solutions

Effective fire and explosion safety relies on storage solutions that integrate multiple safety features. Fire-resistant storage cabinets (Figure 2) are a prime example, incorporating insulating layers, automatic door closures and technical ventilation systems. These features achieve three critical objectives proposed by EN 14470-1, the European standard designed to regulate the storage of flammable liquids in fire-safe cabinets — minimizing vapor emissions, containing potential leaks and protecting materials during fires. For highly flammable liquids and vapors (often designated as H224 substances), regulations mandate 90-minute fire-protection ratings to prevent them from becoming ignition sources or contributing to a fire’s spread. Fire cabinets control vapor buildup, contain leaks and protect stored materials during fires. Their advanced design ensures compliance with strict regulatory standards and provides reliable safety. Integrated ventilation systems prevent dangerous vapor buildup to maintain a safe environment. The cabinets serve as containment solutions and act as vital components of facility-wide fire protection.

One of the primary advantages of fire-safe cabinets is their two-way protection. These cabinets protect the facility from fires that may originate within the cabinet itself while also safeguarding the cabinet contents from external fires. In case of a fire inside the cabinet, the insulation layers and automatic door closures can hold the blaze for up to 90 minutes, providing crucial time for evacuation and emergency response. This dual protection significantly reduces the likelihood of a minor incident escalating into a devastating event.

Fire-safe cabinets can incorporate several features that distinguish them from standard steel cabinets. These features include the following:

• 90-minute fire-protection ratings in accordance with EN 14470-1 and NFPA standards, providing maximum safety for highly flammable liquids
• Automatic door closures that engage when temperatures rise, sealing off the contents
• Technical ventilation systems that prevent dangerous vapor accumulation and ensure constant airflow
• Integrated spill-containment trays to manage leaks and prevent the spread of hazardous materials
• Insulating layers that offer high fire resistance and slow the heat transfer into or out of the cabinet, preserving stored materials and keeping facilities safe

 

Cabinet selection

Despite the clear benefits, common mistakes when selecting fire-safe cabinets sometimes undermine safety efforts. One frequent error is choosing cabinets based solely on cost rather than protection needs. Cabinets with lower fire-resistance ratings, such as the 30-minute models, may seem appealing due to their lower price, but they are not suitable for storing highly flammable substances (H224) and may not meet the regulations of the local authority having jurisdiction (LAHJ). Companies that opt for cheaper, non-fire-rated steel cabinets often do so because they believe their operations involve only small quantities of flammable materials under exempt amounts.

Another mistake is failing to recognize that fire-resistant cabinets are not just about internal fires. Their primary purpose is to delay external fires from reaching the hazardous contents inside, giving workers more time to evacuate and first responders more time to contain the blaze. Some facilities mistakenly believe their overall fire-protection measures are sufficient without cabinet-level protection, not realizing that improper storage can lead to rapid fire escalation and potentially catastrophic damage.

Misunderstanding certification standards also leads to non-compliant purchases. Fire-safe cabinets tested to EN 14470-1 or NFPA 30 standards provide reliable protection, while uncertified steel cabinets do not offer the same protection. Facilities that buy uncertified cabinets may find themselves unable to meet legal installation requirements or obtain insurance coverage. Finally, overlooking installation conditions is a recurrent issue. Cabinets without fire protection face strict placement restrictions, often requiring structural fire-protection measures and designated explosion-proof zones. In contrast, 90-minute fire-rated cabinets offer greater flexibility and allow for placement directly in workspaces. They also reduce transport times and improve operational efficiency.

Understanding the full scope of fire-safe cabinet functions, features, and potential pitfalls helps chemical processing facilities make informed choices to prioritize safety, ensure compliance and safeguard both people and property.

 

Fire-rated buildings

Fire-rated buildings, containers and lockers manage large-scale hazardous-substance storage (Figure 3). Designed to meet stringent safety standards and to be used indoors or outdoors, fire-rated buildings offer robust fire protection, secondary spill containment and controlled environments for hazardous materials. They come in two primary types: non-occupancy buildings and walk-in storage facilities.

Non-occupancy buildings are designed to minimize personnel exposure during storage and retrieval. They feature full-face opening doors to allow forklift access and simplify movement of large containers, such as drums or intermediate bulk containers (IBCs). These buildings can be strategically placed indoors or outdoors and often include climate-control options for temperature-sensitive materials. Non-occupancy designs prioritize efficiency and safety by reducing the need for workers to enter the storage area.

Walk-in storage facilities are designed for situations requiring direct handling of materials.

To protect all personnel, these buildings feature enhanced safety measures like advanced fire protection, special spill-containment trays and dedicated dispensing areas. Because workers must enter the storage space, walk-in facilities meet higher safety standards than non-occupancy buildings. While non-occupancy buildings focus on protecting materials and the surrounding environment, walk-in designs prioritize worker safety due to the higher risk of exposure.

When selecting a fire-rated building, there are some key things to consider. Fire ratings give information on a structure’s ability to provide protection. Many buildings are designed to provide two-hour fire protection or more, depending on setback distances. Segregating incompatible materials increases safety and involves the use of physical barriers or separate compartments that prevent hazardous reactions. Spill containment systems can provide added back up protection. They must accommodate 10% of the total stored volume or 100% of the largest container, whichever is greater, to manage leaks and prevent the spread of hazardous substances.

Ventilation systems are fundamental to managing hazardous vapors and supporting a safe atmosphere. For temperature-sensitive chemicals, climate-controlled options ensure that materials remain stable, reducing the likelihood of spontaneous ignition or decomposition. Fire-rated buildings are designed to address many regulations, such as OSHA, EPA and NFPA standards, to ensure compliance and operational safety. These buildings are a helpful part of site plans designed to securely contain hazardous substances to reduce risk.

 

Lithium battery safety

Lithium batteries pose a risk of fire and pressure release if not handled or stored correctly. When mishandled, these batteries can overheat, catch fire or release pressure, leading to costly damage and potential harm to workers. Understanding the hazards, using proper storage solutions and having the right tools can all contribute to fire prevention.

A primary danger associated with lithium batteries is thermal runaway. Thermal runaway occurs when cells overheat from thermal stress, damage or defects. Such occurrences can produce intense heat, flammable gases and oxygen, which can lead to fires. In some cases, electrolyte fluid vaporizes, creating more combustible gases that can ignite and make the fire worse. Deep discharge is another risk. If batteries discharge completely and are then recharged, the electrolyte fluid can break down, generating flammable gases and increasing the likelihood of a fire. Mechanical damage, such as drops, collisions or deformations, can also cause internal short circuits and fires.

To mitigate these risks, facilities should use fire-rated storage buildings or cabinets specifically designed for lithium batteries. These provide fire resistance from both inside and outside, which allows more time to contain a fire and evacuate the area. They are equipped with liquid-tight spill sumps to contain leaks from defective batteries and smoke extraction ventilation systems to manage to reduce heat and gas buildup. Fire-rated storage buildings offer expanded capacity and enhanced features, such as pressure-relief and climate-controlled options.

There are effective emergency-response tools for dealing with battery fires. Since these fires generate their own oxygen, traditional fire extinguishers aren’t effective. Instead, facilities should stock specialized suppression powders or granules designed to combat Class D fires involving burning metals. These granules work by displacing oxygen, absorbing heat and forming a barrier to prevent further combustion. In addition, damaged or defective batteries should be stored in quarantine containers until they can be professionally disposed of. Combined with proper handling, these solutions help reduce fire and explosion risks from batteries.

 

Facility-wide integration

Storage solutions must align with facility-wide systems for grounding and ventilation. Electrostatic discharge is a major risk during material transfers, so modern facilities use grounding systems with continuous monitoring. Active grounding systems with LED indicators allow quick connection verification. For highly flammable materials or combustible dust, this provides better protection than passive methods, especially during transfers.

The effectiveness of storage systems also depends on how well they work with emergency-response capabilities. Strategic placement ensures emergency access while supporting safe separation distances. Some materials, including volatile dusts, require specialized extinguishing agents, so fire suppression systems should match the specific hazards present. For example, Class D fire extinguishers may be necessary for combustible metal dusts like aluminum or magnesium. Carbon dioxide systems are often used for extinguishing fires involving flammable solvents or chemicals where water could cause a hazardous reaction. Foam suppression systems are needed for handling fires involving large quantities of flammable liquids, such as toluene or acetone, because they help smother the flames and prevent any re-ignition. Emergency showers and eyewash stations should be readily accessible with clear access paths from storage areas.

Ventilation systems play a vital role as they manage both routine emissions and potential emergency scenarios. Technical ventilation requirements vary based on stored materials but typically include both high-level and low-level extraction points to manage vapors of varying densities. Modern systems often add monitoring capabilities that allow users to verify proper airflow and provide early warning of system failures.

 

Specialized tools to reduce risks

In chemical processing facilities, flammable gases, vapors and dust make the risk of ignition ever-present. Preventing sparks during routine maintenance or emergency repairs is necessary for fire and explosion safety. Non-sparking tools are designed for hazardous environments like these (Figure 4).

Non-sparking tools are made from non-ferrous metals, such as aluminum bronze, phosphor bronze, beryllium copper and brass. These materials do not produce sparks when struck or rubbed against other surfaces, which reduces the chance of ignition in environments where a single spark could cause an explosion. These tools are indispensable for working around flammable substances like solvents, gases and combustible dust.

Beyond spark prevention, non-sparking tools are often corrosion-resistant, making them suitable for environments where chemicals, moisture or extreme conditions could degrade standard tools. Their durability ensures effectiveness in harsh chemical or humid conditions. Non-sparking tools are available in a variety of forms to support different maintenance needs, including wrenches, hammers, screwdrivers, pliers and scrapers. These tools are designed for safe use in situations where traditional steel tools pose a risk. Non-sparking tools help chemical processing facilities reduce the risk of fires and explosions, making them a part of a comprehensive prevention strategy.

 

Continuous improvement

As hazards evolve and new safety technologies emerge, facilities must upgrade monitoring systems, enhance containment measures, and integrate solutions that boost safety and efficiency. This involves maintaining documentation, frequent inspections and responsible equipment management. Comprehensive training programs covering routine operations and emergency response are essential to this effort. By building and maintaining a robust safety system, facilities can stay compliant, reduce risks and protect employees, assets and the environment. Continuous improvement is the foundation of effective fire and explosion hazard management. ■

Edited by Mary Page Bailey

 

Acknowledgement

All images provided by author

 

Author

Steve Eyer is an engineered systems sales manager at the DENIOS U.S. (1152 Industrial Blvd., Louisville KY 40219; Phone: 1-800-216-7776; Email: [email protected].) Eyer has over 25 years of experience within the safety industry with a focus on design and engineering of flammable combustible products. He has worked for many leading manufacturers and is a three-time patent recipient. Throughout his career, Eyer has contributed to industry regulations and given influence for engineered judgments to third party insurers. He holds a mechanical engineering degree from Vincennes University and is currently pursuing his M.S. in technology from Eastern Illinois University.

 

Further reading

1. Design for Safety: Tips for Proactive Risk Reduction, Chem. Eng., Feb. 2023, pp. 30–33.

2. Steps to Improve Safety Challenges in Hazardous Environments, Chem. Eng., Aug. 2022, pp. 42–46.

3. Process Changes: Understanding and Mitigating Fire- and Life-Safety Risk Factors, Chem. Eng., Sept. 2020, pp. 50–53.