Hayes Lemmerz Aluminum Dust
Explosion
Group 7
Jennifer Costello
Jenna Jeffryes
Wendy Salabay
Chelsea Winkelmann
Background
 Dust Explosions in the US
 At least 281 dust fires and explosions since 1980
 Hayes Lemmerz International, Inc.
 Produces steel and aluminum wheels
 20 facilities in 12 countries
The Incident
 October 29th, 2003
 Huntington, Indiana
 Aluminum dust explosion
 Killed 1, Injured 6
Case Study
 Process Description
 Incident Timeline
 Results
 Root Causes
 Lessons Learned
Process Flow Diagram- Scrap Metal System
Process Flow- Dust Collection System
Timeline
Chip Feed System was shut down due
to smoldering fire however workers
did not turn off dust collector fan.
Fire was determined out, fume duct was
opened and residue was cleared out
Two hours later the dry chip feed was
restarted
Within ten minutes maintenance noticed
chips were falling out of the spark box into
the dust collector duct
A fireball erupted from beneath the
furnace fume hood
http://www.youtube.com/watch?feature=player_d
etailpage&v=3d37Ca3E4fA#t=167s
Aftermath
• Worker’s clothing was engulfed in flames along with two other
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nearby workers
Fire reached the roof where a contract worker was knocked off his
feet but able to notify authorities
An emergency was reported over intercom, employees evacuated
Fire department on site within minutes
Fire was extinguished two hours later
Large amount of structural damage
Root Causes
 Accumulation of dust
 Improper housekeeping
 Lack of knowledge of danger
 Improper communication between
management and operators
 Failure to investigate near misses
Lessons Learned
 Dust explosions are a major problem
 Minimal amounts of energy are required to explode
 Airborne dust can provide fuel for secondary explosions
 Dust lying around can easily become airborne during an explosion
 Learn from near misses and minor accidents
 With proper documentation
 Easier to connect the dots
Prevention
 Good housekeeping
 Inert the facility if possible
 Make sure all employees are aware of danger and wear
necessary PPE
 Vent explosions/ use blast walls
 Regulations and legislations
 Currently no mandates
 H.R. 522: Worker Protection Against Combustible Dust
Explosions and Fires Act of 2011- still pending
Summary
 Incident & Results
 Aluminum dust explosion resulting in 1 death
 Fire started in furnace, led to a secondary explosion
 Major cause: Dust build-up
 Lessons learned: The importance of proper housekeeping and
good communication
Questions?
Works Cited
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1. Blair, Angela S. "Dust Explosion Incidents and Regulations in the United States." Journal of Loss
Prevention in the Process Industries 20.4-6 (2007): 523-29. SciVerse. Web. 25 Feb. 2012.
<http://www.sciencedirect.com/science/article/pii/S0950423007000071>.
Crowl, Daniel A., and Joseph F. Louvar. "Concepts to Prevent Fires and Explosions." Chemical
Process Safety: Fundamentals with Applications. Upper Saddle River, NJ: Prentice Hall, 2011. 317-74.
Print.
Crowl, Daniel A., and Joseph F. Louvar. "Fires and Explosions." Chemical Process Safety: Fundamentals
with Applications. Upper Saddle River, NJ: Prentice Hall, 2011. 245-304. Print.
"CSB Determines Fatal 2003 Incident at Hayes Lemmerz Plant in Indiana Most Likely Caused by
Explosion in Dust Collection System; Company Did Not Identify or Control Hazards of Aluminum
Dust." U.S. Chemical Safety and Hazard Investigation Board. Web. 25 Feb. 2012.
<http://www.csb.gov/newsroom/detail.aspx?nid=264>.
3. CSB. "Investigation Report:Aluminum Dust Explosion." U.S. Chemical Safety and Hazard
Investigation Board. Web. 21 Feb. 2012. <www.csb.gov/assets/document/Hayes_Report.pdf>.
2. "Cutting Edge Technology and Products from Hayes Lemmerz." Cutting Edge Technology and
Products from Hayes Lemmerz. Web. 25 Feb. 2012. <http://www.hayes-lemmerz.com/>.
4. "Emulsion." Merriam-Webster. Merriam-Webster. Web. 21 Feb. 2012. <http://www.merriamwebster.com/dictionary/emulsion>.