2024 U.S. Dust Explosions Report

According to the 2024 Agricultural Dust Explosions Report by Purdue University, there were nine grain dust explosions reported in the U.S. this year, which is consistent with the previous year and aligns with the ten-year national average of 8.6 explosions. Fortunately, no fatalities occurred, but the explosions resulted in two injuries. These incidents took place in a variety of facilities, including feed mills, grain elevators, ethanol plants, and a corn processing plant.

Key Findings

  • Ignition Sources: The probable ignition sources for these explosions were:
    • Two cases: smoldering grain
    • Two cases: equipment malfunction
    • One case: welding work
    • One case: cutting work
    • Three cases: unknown
  • Fuel Sources: The fuel sources for the explosions were primarily:
    • Grain dust: 6 incidents
    • Smoldering grain: 2 incidents
    • Smoldering feed: 1 incident
  • Geographic Distribution: The nine explosions occurred in varying states. They occurred in Illinois, Iowa, Kansas, Michigan, Minnesota, Nebraska, North Carolina, Tennessee, and Wisconsin.

While these numbers show no increase in fatalities or a significant rise in injuries, Kingsly Ambrose, Purdue University professor of agricultural and biological engineering, notes that the damage caused by these explosions—including downtime, repair costs, and potential litigation—can be substantial. It’s important to note that even low-magnitude explosions can still cause significant disruption to operations.

Prevention: Proactive Measures for Grain Storage Safety

The key to preventing grain dust explosions lies in maintenance, housekeeping, and proper handling of grain throughout the season. Here are a few critical tips from Ambrose to prevent such accidents:

  1. Pre-Harvest Equipment Maintenance
    Preventive maintenance is essential before the harvest or handling season begins. Inspect equipment for any potential issues, such as belt misalignment in bucket elevators, which can cause friction and heat generation—an increased risk for dust explosions. Check out our courses on preventative equipment maintenance:
    Bucket Elevator: Components & Operation
    Bucket Elevator: Maintenance
    Dust Collector: Maintenance
    Belt Conveyors: Maintenance
    Screw and Chain Conveyors: Maintenance
    Grain Dryers: Maintenance
    Grain Dust Explosions: Prevention
  2. Aeration and Storage Conditions
    Once grain is harvested, maintaining the proper aeration in storage bins is critical to reduce the risk of smoldering grain. Improper aeration can lead to fungal growth, which in turn can cause the grain to smolder, increasing the chances of a dust ignition. To better understand how grain can be explosive under the right conditions, check out our course Grain Dust Explosions: The Chain Reaction.
  3. Housekeeping is Key
    Proper housekeeping is one of the most effective ways to prevent explosions and safeguard employee health. Ensure there is no visible settled dust in the facility and that suspended dust in the air is minimized. Dust accumulation, whether it’s in storage bins or on machinery, significantly raises the risk of an explosion. For more information, check out our course Housekeeping and Combustible Dust.
  4. Regular Inspections
    Conduct regular inspections and clean the facility often. Equipment should be checked for wear and tear, and any signs of malfunction should be addressed immediately. Take the time to ensure that dust collection and monitoring systems are functioning properly and that grain handling equipment is in good working condition. We offer a course on Hazard Monitoring Equipment.

Proactive Steps Save Lives

While 2024’s report shows a stable number of incidents, it’s a reminder that vigilance and proper preventive measures are crucial in avoiding grain dust explosions. Preventive maintenance, safe grain storage practices, housekeeping and regular inspections/maintenance can make a significant difference in protecting workers, facilities, and the surrounding community from the devastating effects of dust explosions.

For more in-depth training on maintaining a safe work environment, Safety Made Simple offers courses that can help you implement the right practices to keep your team safe and compliant. Explore our training catalog!