Safex Newsletter No.83 November 2025

As per usual we start the Newsletter with a safety message from an industry leader, this time it is from Mauro Neves, the CEO of Dyno Nobel, John Rathbun, our chairman, hosted a successful meeting with the CEOs from our industry on 28 October, aiming to foster substantial support for SAFEX from industry leaders. This gathering underscore our commitment to strengthening strategic alliances and advancing our core mission under challenging circumstances. The primary objective is to secure widespread backing and collaboration to ensure the successful promotion and development of SAFEX initiatives, reflecting our dedication to industry growth and innovation.

Under the leadership of Juan Andres Errazuriz, ENAEX sponsored our ninth webinar focused on "Lessons Learned During Burning Ground Activities." This topic is highly relevant to safety practices across our industry. Participants are encouraged to review the Argyle incident detailed on our website, which highlights the hazards associated with burning ground operations. The incident underscores the importance of implementing effective mitigation strategies to prevent similar occurrences. Emphasizing safety protocols and hazard awareness is essential to ensure the well-being of personnel and the integrity of operations during such activities.

Andy Begg and Paul Siqueira have published an authoritative awareness document on Safety Management Systems. This comprehensive resource is now available on our website, designed to serve as a valuable reference for all stakeholders. It encourages active engagement and input from users, fostering a collaborative approach to safety management practices within the organization.

SAFEX received two articles on dust extraction very much complimenting each other:

Energetic Dust control: Lessons from Recent Incidents by Joao Roorda and Nadia Engler

Dust Generation and Control in the Explosives Industry by Paulo Siqueira.

Bob Woolley emphasizes the importance of establishing a solid foundation in our hazardous industry. Proper understanding and implementation of fundamental safety protocols are crucial, as neglecting these principles can lead to severe consequences, including threats to human life and infrastructure integrity. Ensuring that safety measures are correctly applied not only mitigates risks but also promotes a culture of safety and responsibility within the industry.

At Dyno Nobel, safety leadership is not just a role—it’s a responsibility woven into the fabric of how the Company Operates. There behavioural safety journey has evolved from foundational programs like SafeTEAMS and concepts of SafeGROUND to the launch of SafeLEADERS, a comprehensive leadership development initiative designed to embed safety into every decision, conversation, and action.The article on this was presented by Diana Gianne from Dyno Nobel.

Following numerous years of dedicated service, several esteemed Expert Panel Members elected to dedicate their retirement to personal pursuits. This transition posed a significant challenge to SAFEX, as it resulted in the loss of valuable industry experience accumulated over the years. In response, Andy Begg initiated a strategic recruitment campaign to attract new talent. We are pleased to introduce the new members who have joined our Expert Panel. Comprehensive details about these individuals are also available on our official website, reflecting our ongoing commitment to maintaining a highly qualified and experienced panel to support industry excellence.

It is with profound sadness that we acknowledge the passing of Mervyn Traut, a highly respected member of our industry community. Mervyn was renowned for his mentorship, unwavering support, and dedicated assistance to SAFEX and its members over many years. His contributions have left a lasting impact, and he will be sincerely missed. Below is a tribute written by Dr. Boet Coezee, honoring his exceptional life and legacy.

Finally, I am pleased to share a flyer to inform members about the upcoming Third International Explosives Conference scheduled to take place in Cardiff, Wales, in June 2026. For comprehensive details and registration information, please visit the official conference website.

Energetic Dust control: Lessons from Recent Incidents

By Joao Roorda, Austin Powder Global SHES Director & Nadia Engler, Austin Powder Global Sustainability Manager

It is not new to our industry that energetic dust control plays a critical role in maintaining safety and is an important concept of Basis of Safety (BOS) and Good Explosives Practices (GEP). The risk of having energetic materials accumulating in unexpected places requires relentless effort in designing, operating, maintaining and inspecting systems, buildings and operations. Dust extractions systems are an important control to minimize this risk but also poses hazard when not properly designed or maintained. This article revisits three significant events involving energetic materials and extraction or air conditioning systems, drawing key lessons to strengthen our collective safety culture.

Incident Summaries

1. Detonation in Lead Azide Drying Bay
A detonation occurred at the air blower at the Lead Azide drying area. The root cause was traced to the replacement of the bay’s extractor with a model not designed for explosive dust environments. This change has bypassed the MOC process. Over time, Lead Azide residues accumulated in the motor, leading to ignition. The extractor had never been included in the preventive maintenance schedule, and its location at the rear of the building meant it was excluded from operational checklists. The original extractor, designed for alcohol fumes, featured a sealed motor and inlet filter—features absent in the replacement.

2. Deflagration in Scrubber Blower – Booster Building
A deflagration occurred inside a scrubber blower, when accumulated PETN was initiated by a failed fan blade that broke off during operation. Although the system was under preventive maintenance, deep cleaning of the blower had been neglected. Design changes to the extraction system —originally intended to collect TNT fumes only — resulted in unintended PETN collection. These modifications were not adequately covered by the Management of Change (MOC) process.

3. Air Conditioning System Dispersing Explosive Dust
During a facility review following an energetic event, it was found that the air conditioning system was unintentionally dispersing explosive dust into areas not designed to handle such materials. The system had not been assessed for its potential to accumulate or transport energetic powders. This oversight posed a serious risk of secondary ignition and contamination. As a corrective action, the location and design of the air inlet system were reviewed to prevent future dispersion of hazardous materials.

Key Learnings

These incidents revealed critical insights that must be embedded into operational practices:
• Extraction systems will collect energetic materials - even if not designed for it.
• Modifications must go through the MOC process, especially in critical equipment.
• Cleaning must be comprehensive, covering all parts of the system.
• Maintenance findings must be escalated, particularly when abnormal buildup is observed.
• Training must include BOS principles, ensuring personnel understand risks and controls.

These learnings were formally captured and disseminated through a Safety Alert, which mandated action across all manufacturing sites.

Basis of Safety (BOS): A Critical Framework

As a direct response to these incidents, Austin Powder developed a dedicated Basis of Safety (BOS) document for dust and fumes extraction systems in energetic material environments. This BOS outlines the minimum safety requirements and operational controls necessary to prevent ignition and accumulation.

Key characteristics of this BOS include:

Design Controls

  • Smooth internal surfaces in pipework to reduce friction.
  • Short and direct ducting to minimize accumulation.
  • Adequate airspeed and suction power, reviewed after any process change.
  • Avoidance of “dead legs” and internal steps where dust can settle.

Ignition Source Mitigation

  • Proper grounding to prevent static discharge.
  • Use of non-sparking tools and materials.
  • Elimination of friction points and foreign object ingress.
  • Temperature control to avoid decomposition of aged explosives.

Maintenance and Inspection

  • Full-system preventive maintenance from suction point to exhaust.
  • Deep cleaning protocols with formal documentation and supervision.
  • Escalation procedures for abnormal accumulation or equipment damage.

Administrative Safeguards

  • MOC for any modification, regardless of perceived risk.
  • Hazard studies (PHA/HAZOP) that include worst-case scenarios, including auxiliary systems and interfaces not originally designed to handle energetic materials.
  • Training programs for operators and maintenance teams on BOS principles.

This BOS is now a foundational reference for all sites handling energetic materials and is subject to periodic review and improvement.

Building a Culture of Learning and Sharing

These incidents serve as stark reminders that safety is not static. Organizations must foster a culture where:

  • Lessons are shared openly.
  • Incidents are investigated thoroughly, with findings disseminated across sites.
  • Operators are empowered to escalate concerns, and maintenance teams are trained to recognize abnormal conditions.
  • MOC is treated as a living process—not a checkbox.

Conclusion

Dust and fumes extraction systems in explosives environments are inherently risky. When energetic materials accumulate, even minor mechanical failures can lead to catastrophic outcomes. The Basis of Safety must be rigorously applied, and every modification, maintenance task, and operational change must be scrutinized. By learning from incidents and sharing knowledge, we can build a safer future for all.

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