Tanzanian sugar factory explosion reminder of steam pipe danger

An explosion at a Tanzanian sugar factory caused by a leaking steam pipe has killed 11 workers
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An explosion caused by a steam pipe bursting during production at a sugar factory in Tanzania recently killed 11 workers.

The blast at Mtibwa Sugar in the Mvomero district occurred as production restarted following a period of maintenance.

Speaking after the explosion, commander of fire and rescue services in the city of Morogoro, Shabani Marugujo said: “There are reports that a steam pipe had leakage which caused the explosion. The factory control room and some other machines were damaged by the accident.”

All the fatalities were amongst electrical and machine staff working in the control room at the time. Amongst the deceased were workers from multiple countries including Tanzania, Kenya, India, China and Brazil.

Sugar factory environments present high risk of explosion for multiple reasons. Sugar ground down from crystals into powder provides a larger surface area for combustion. When mixed with air, this can ignite with devastating results.

Pipes which are not properly maintained can also pose a real danger. The piping system in a sugar mill is crucial to the transportation of liquids, steam and gases required for various stages of production.

Due to the high-pressure and high-temperature conditions pipe systems operate at in sugar factories, any failure or malfunction can lead to catastrophic results. As appears to be the case in the explosion at the Mtibwa Sugar factory.

What can cause a pipe explosion at a sugar factory?

There are several key factors which can potentially contribute to pipe explosions in sugar mills.

  • Pressure and temperature: Sugar mills operate under high-pressure conditions to generate steam for processing sugar. Over time, pipes can corrode or weaken when exposed to extreme temperatures or pressure fluctuations. These pipes may fail if not regularly inspected and maintained, leading to an explosion.
  • Corrosion and material degradation: The environment in a sugar mill is often humid, which accelerates the corrosion of metal pipes. Corroded pipes are more likely to develop cracks or weaknesses that can rupture under pressure. Furthermore, the sugar production process involves acids, hot water and steam; all of which can further degrade pipe materials.
  • Faulty or inadequate maintenance: Many explosions occur as a result of poor maintenance practices. Failure to inspect pipes for signs of wear and tear, not replacing damaged sections or neglecting to clean pipes regularly can lead to dangerous failures. Outdated systems which have not been upgraded with modern safety features are also more susceptible to breaking down.
  • Blockages and clogs: A blockage in the pipes can lead to dangerous pressure build up. Sediment, sugar syrup and even pipe scaling can accumulate in sugar factory lines, creating blockages. When this happens, pressure increases in the system. If the pipes cannot withstand the added force, an explosion may occur.

How can pipe explosions at sugar mills be prevented?

Whilst the risk of pipe explosions in sugar mills cannot be completely eliminated, there are several measures that can reduce the likelihood of an incident like the one at Mtibwa Sugar occurring.

  • Regular maintenance and inspections: One of the most important ways to prevent explosions is to conduct regular maintenance and inspections of the piping system. Pressure gauges, temperature monitors and corrosion sensors should be checked frequently to ensure they are functioning properly. Pipes should be examined for any signs of wear, rust, or damage. Any holes or cracks should be immediately sealed by making a sugar mill pipe repair.
  • Upgrading equipment: Older piping systems may not be able to withstand the demands of modern sugar mill operations. Replacing outdated pipes with more durable materials such as stainless steel or specialised alloys can reduce the likelihood of an explosion. Installing pressure relief valves and automated shutdown systems can also help prevent accidents.
  • Employee training: Workers should be trained in the proper handling and maintenance of piping systems. They need to recognise the signs of potential pipe failure such as unusual pressure readings or leaks and be prepared to take corrective actions. Training also ensures that workers follow industry standard safety protocols when working with high-pressure systems.
  • Controlling corrosion: Implementing corrosion control measures such as coating pipes or using corrosion inhibitors can help extend the life of the piping system. Additionally, the water chemistry within the system should be monitored to ensure it does not accelerate corrosion or scaling.
  • Implementing safety protocols: Establishing comprehensive safety protocols such as emergency response plans is crucial in the event of an explosion. Mills should have fire suppression systems in place and workers should be trained to evacuate quickly if a dangerous situation arises.
  • Monitoring for blockages: Regularly cleaning and inspecting pipes to remove any blockages caused by sugar syrup or sediment can prevent dangerous pressure build up. Specialised filtration and flushing systems can help keep pipes clear and running smoothly.

Lessons from the Tanzanian sugar factory explosion

The explosion at the sugar factory in Tanzania serves as a reminder of what a dangerous industry sugar milling can be.

It remains unclear currently how the steam pipe at Mtibwa Sugar came to be leaking after the factory had been shutdown for maintenance. Local police are continuing to investigate the incident.

For other sugar factories, lessons which can be learned from the Tanzanian incident include the importance of proper maintenance, employee training and preventive measures.

Focusing on safety and upgrading outdated systems can help sugar mills protect their workers, equipment and bottom line whilst ensuring smooth and efficient production processes.

Proactive management of potential hazards will help prevent explosions and ensure the long-term sustainability of the mill.

Following the explosion, Mtibwa Sugar have suspended all production at the factory for the foreseeable future.


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