On October 15, 2024, experts from different industries came together for Dustiness Day 2024, a seminar that dove deep into the often-overlooked world of dust—how it forms, the health risks it poses, and the dangers of dust explosions. Dust might not seem like a huge issue at first glance, but in the industrial world, it’s a serious concern. It can harm workers, pollute the environment, and, in the worst-case scenario, trigger devastating explosions. The event featured key speakers, each with valuable insights on how to handle and mitigate dust risks. The speakers included Gabrie Meesters, Brecht Bruneel, Martijn Lampe, Michel Vandeweyer, Shannon Groen, Albert Kaptein, and last but certainly not least Mark Kosters.
Dust Formation and Particle Strength: Gabrie Meesters
The seminar kicked off with Gabrie Meesters from TUDelft, who broke down exactly what dust is and why it’s such a big deal. Dust, as he explained, is made up of tiny, dry particles—usually less than 100 microns in size.
These particles are created through all kinds of industrial processes, like handling powdered materials, crush-ing solids, or moving products through a system.
What makes dust so tricky is its ability to become airborne, or what Meesters referred to as dustiness. The dustiness of a material depends on factors like particle size, shape, and bulk density. The smaller the particles—especially those under 10 microns—the bigger the problem, since they can be inhaled and cause respiratory issues. Meesters also pointed out that certain activities, like sonication, can cause more dust to become airborne, which increases health risks.
He also covered how to measure dust in industrial environments. Using standard methods like the rotating drum and continuous drop systems (outlined in EN 15051), companies can measure how much dust is being generated, which helps break down particles into different sizes to figure out how much of the dust is inhalable or respirable. As industries focus more on reducing exposure to harmful particles, especially PM2.5, Meesters made it clear that regular dust measurement and control is essential.
Dust Exposure and Safety in Feed Production: Brecht Bruneel
Brecht Bruneel, Innovation Manager at Orffa N.V. was up second, he tackled the unique dust-related challenges in the animal feed industry. As a part of Marubeni’s extensive network, Orffa handles a wide range of feed additives, such as amino acids, vitamins, minerals, and probiotics. Bruneel explained that the production of these additives isn’t just about mixing and distributing materials; it involves navigating tight safety regulations and managing dust risks along the entire supply chain.
In his presentation, he highlighted how dust isn’t just a nuisance; it’s a real safety concern, particularly for workers exposed to it during produc-tion. Bruneel pointed to guidelines from the European Food Safety Authority (EFSA), specifically Section 3, which outlines requirements for studies on additive safety. These regulations cover not only the safety of the final product but also the risks posed to workers’ respiratory systems, eyes, and skin.
Brecht emphasized the delicate balancing act between maintaining worker safety and staying econom- ically viable. Complying with legis-lation inevitably raises production costs, but it’s essential to secure a “license to operate” in such a tightly regulated industry.
His message was clear: safety isn’t an option—it’s a must.
Dust Filtration in Practice: Martijn Lampe
Martijn Lampe from Lampe Technical Textiles took a more hands-on approach, focusing on dust filtration systems—practical solutions that can keep dust under control. He talked about the importance of filtering fine dust to keep workers safe and prevent dust from polluting the environment.
Lampe compared dust filtration to HVAC systems. While HVAC systems handle general air quality, dust filtration systems are specifically designed to deal with dust particles. He explained how to choose the right filters, using ISO 16890 standards, which rank filters based on how well they handle PM10 and PM2.5 particles. One of the key things he highlighted was the “dust cake”—a layer of dust that collects on the filter medium and actually helps improve the system’s efficiency.
Lampe warned that you shouldn’t clean filters too soon; if you let the dust cake build up a bit, the filtration system works better. His talk offered practical advice for companies looking to improve their dust control measures and reduce worker expo-sure.
The Dust Explosion Phenomenon: Michel Vandeweyer
Next up was Michel Vandeweyer from ISMA N.V., who addressed one of the dramatic things that can happen in an industrial setting: a dust explosion, which was brought home with his case on the Heino Plant Dust Explosion, focussing on electrostatic discharges.
Vandeweyer explained that for a dust explosion to happen, you need three things: a cloud of dust particles suspended in the air, oxygen (which is usually a given), and a spark or some other ignition source. Combine those, and you’ve got a potentially explosive situation.
Smaller particles, especially those under 100 microns, are a major problem because they can hang in the air for a long time, making it easier for them to reach explosive levels. Vandeweyer walked through the dangers of overpressure during an explosion—something as small as 50 mbar of overpressure can shatter windows, and at 140 mbar, buildings can start to collapse. It’s easy to see how these explosions can turn deadly fast.
To drive his point home, Vandeweyer even staged a live dust explosion demo outside. The speed and inten- sity of the explosion made it clear that dust control isn’t something to take lightly. His message was to the point: industries need to stay on top of dust monitoring and enforce strict safety measures wherever dust is being generated.
Dustiness Potential Measurement: Shannon Groen
Shannon Groen, from Delft Solids Solutions, shared valuable insights on assessing the dustiness potential of solid materials. While she touched on the basics of dust classification, her main focus was on the importance of standardized testing methods. Groen covered techniques like the Continuous Drop and Rotating Drum tests, which are critical for measuring the dustiness of fine powders in line with EN 15051 standards.
Groen’s presentation served as a reminder of the need for consistency and reliability in dust assessments.
She reinforced what Gabrie Meesters had emphasized earlier: that predicting dustiness isn’t just about knowing a material’s physical properties. Instead, reliable tests are essential for understanding how dust behaves during actual handling.
Her take on aligning testing practices with the latest nano-particle dust guidelines under-scored the need for industries to stay up-to-date with regulations to keep workers safe.
Advanced Powder Processing for Risk Reduction: Albert Kaptein
Albert Kaptein, a Senior Process Technologist from Hosokawa Micron B.V., presented how advanced powder processing can minimize the risks associated with dust.
Kaptein emphasized that the best way to tackle these risks is to address them at the source. He talked about granulation—a process that increases the size of particles, making them less likely to become airborne or explode. According to Kaptein, granules larger than 500 microns are much safer because they don’t suspend in the air as easily or form explosive mixtures.
Beyond just safety, he pointed out that granulation and coating pro- cesses can also improve the quality of the product itself. These processes can help powders flow more smoothly and dissolve better, all while reducing dust. Although these extra steps might increase production costs, Kaptein argued that the improve- ments in safety and product quality make them worth it.
Practical Dust Measurement Techniques: Mark Kosters
Mark Kosters, from Buro Blauw Luchtkwaliteit, brought a hands-on perspective to the seminar by focusing on practical dust measurement techniques. His talk centered around three key areas: stack emissions, outdoor air quality, and workplace dust levels. Each case study he presented gave a real-world look at how precise monitoring can guide dust management decisions.
Kosters first described how his team tackled stack emissions at a modified wheat starch facility. They knew that startup and shutdown phases often release significant amounts of dust, so they used a manual gravimetric method to measure it. By gathering this data, they were able to recommend the right dust control measures to the facility.
He then shifted to air quality monitoring near a proposed biomass power plant, where residents were understandably concerned about increased dust levels. For over a month, Kosters and his team measured concentrations of PM10 and PM2.5 to get a clear picture of the air quality impact. Finally, he discussed a workplace scenario near a repacking machine for polyacrylic acid, highlighting the importance of personal dust exposure measure- ments and protective gear when safe limits are exceeded. Kosters’ talk brought home the need for precise and consistent dust monitoring in real-world industrial scenarios. It’s not just about com- pliance—it’s about taking care of people and the environment.
Interactive Case Studies and Networking Event
One of the standout features of Dustiness Day 2024 was the interactive case study session. Each attendee received a color-coded badge, which grouped them with others wearing the same color. This clever setup fostered collaboration between professionals from various industries, giving them a chance to dive into specific case studies related to dust formation, explosion risks, or control measures. By working together in small groups, participants could directly apply the insights from the presentations to real-world challenges, making the learning experience more engaging and practical.
After wrapping up the case studies, everyone gathered for a traditional network borrel. This Dutch-style networking event was a laid-back opportunity for attendees to unwind, enjoy some drinks, and chat with their peers and the speakers. It created a relaxed atmosphere where people could exchange ideas, discuss what they’d learned, and make new connections within their field. It was the perfect way to end a productive day of learning and collaboration.
Conclusion: Lessons from Dustiness Day 2024
Dustiness Day 2024 made it crystal clear that dust is more than just a housekeeping issue—it’s a real threat that can harm workers, damage the environment, and even cause deadly explosions if left unchecked. Each speaker brought a different pers- pective to the table, whether it was Gabrie Meesters breaking down the science of dust formation, Michel Vandeweyer’s eye-opening demon- stration of a dust explosion, or Albert Kaptein’s advice on using advanced processing techniques to minimize risks.
Martijn Lampe’s practical tips on improving dust filtration gave attendees actionable steps they can take to better control dust in their operations.
Shannon Groen’s talk helped re- inforce the need for consistent dust measurement and monitoring to ensure safe work-places.
For industries working with fine powders, the lessons from Dustiness Day are vital. Companies need to stay proactive, regularly check their dust levels, install effective filtration systems, and make sure their processing techniques keep dust risks to a minimum. The insights shared at this seminar will no doubt help companies improve safety, reduce their environmental footprint, and prevent the potentially devastating consequences of dust explosions.
