dc.description.abstract |
DEVELOPMENT OF A MODEL TO MINIMIZE DUST EXPLOSION
IMPACTS
IN PHARMACEUTICAL INDUSTRY
Dust explosion is a major industrial disaster which result catastrophic outcomes if not
controlled with necessary enforcements. Various industries which handled powdered materials
are associated with dust explosion risk. Food, Tobacco, Plastics, Wood, Paper and pulp,
Rubber, Pesticides, and Pharmaceutical are some of the industries associated with dust
explosion risk. All the powder types does not responsible for dust explosions though particle
size, dimension of particles, moisture content, upper and lower ignition limits, powder
resistivity and charge relaxation time of combustible powders has a direct correlation with dust
explosions. Dust explosions, initiated with the formation of dust explosion pentagon, which
comprises with Combustible dust, Oxidant, Ignition source, Dust cloud and Confinement of
dust.
However, the comprehensive literature review reveals that there is lack of studies on dust
explosion scenarios, it’s impacts, in-depth investigations in to causes and strategies to
minimize the impacts of dust explosions in pharmaceutical industry. Therefore, the aim of this
research is to develop a model to minimize the dust explosions and its subsequent impacts in
pharmaceutical industry. The research objectives were achieved through mixed research
approach by using semi structured interviews with experts in pharmaceutical industry and
through the direct observations made during the site visit of pharmaceutical plant visits. The
data collected during the structured interviews and site visits were collated in to tabulated and
graphical mode to create a comparative analysis of three pharmaceutical manufacturing plants
belongs to same mother company in three different countries. The findings of the research
revealed the risk profiles of three pharmaceutical plants were differentiated with the
combustible nature of the powdered raw materials used for each products in plant, quantity of
those materials stored at plant and the risk associated with each activity or unit operation.
Combustible nature depends on the minimum ignition energy of the material, and quantity of
materials stored at plant depends on the batch size, chemical quantity of that particular
chemical used for a batch. Finally the risk related to activity depends on the frequency of
operation, no of peoples involve for the activity and the nature of the activity and the powder
type.
Causes of dust explosions were analysed using the investigations done for dust explosion
incidents happened at three pharmaceutical manufacturing plants. Causes identified were
categorized in to three causes types immediate, underline and root causes. The root causes
which need to be eliminated to prevent the dust explosions were identified as inadequate risk
assessments, inadequate housekeeping inadequate training and deficiencies in change
management. Failure to eliminate these root causes will effect health and safety, environmental
and business impacts which could directly affect to the continuation of business. Impacts of
dust explosions in pharmaceutical industries can be controlled through disaster cycle approach
which includes prevention, preparedness, response and recovery strategies. A single model
which discuss the causes and impacts of dust explosions and the strategies to minimize the
impacts of dust explosion using disaster cycle was developed to be used in pharmaceutical
industries. |
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