of the factory:
This Chemical factory producing Starch, Glucose and
Gluten (animal food) from Corn.
Date and Time of the incident: 10-11-2003 at
Two workers were burnt in the gluten section due
to falling of burning material in the work room
(gluten department). Workers were sent for treatment,
died during treatment on the same day and other
was relieved after treatment.
After separating seeds and fiber during wet
milling process, Starch and Gluten remain
in the stream
Starch and Gluten are separated in the centrifuge
Gluten is made thick in the thickener machine
Cakes are made in the plate filter machine
Filtrate is recycled in the process
Gluten Cakes are sent to dryer machine for
Dried gluten is conveyed numerically to sieve,
in the shifter room, in the nearby room which is
separated by a wall of 20 thick, dust collectors
are also provided in this room (packing room)
Dryer machine is from Bunter Company
and it is a flash dryer.
It consists, peddler mixture (to breaks lumps of
gluten), feed screw, sling fan, I. D. fan, cyclones,
rotary air lock and settler.
Hot air to dry the gluten is received from furnace
using bio-gas from E. T. P. Plant
Process in the dryer:
Gluten cakes from filter, contents 55% moisture,
fed to peddler mixture by belt conveyer, and then
it is fed to the center of sling fan by screw conveyer
fitted below peddler mixture. Sling fan is fitted
on the hot air ducting.
Hot air is received from furnace by burning
bio-methane gas; temperature of hot air is maintained
310 to 320 c.temperatures is controlled automatically.
Negative pressure of 70 to 80 column of water
is maintained with the help of I. D. Fan in the
dryer, so the moist gluten is conveyed pneumatically
up ward and loose its wetness due to contact of
hot air in the dryer and gluten having 10-11 % moisture
Temperature of air going from settler is
80 to 85O c in the dryer or settler.
Dried material is collected from rotary air
lock below the cyclone.
Rupture disk is fitted on top of the cyclone
with hinge, it opens if negative pressure is reduced
in the cyclone, and negative pressure is maintained
by I. D. fan.
Start up procedure
I. D. fan is started before gluten dryer
is started and sling fan is also started after it.
Semi-moist material is fed in the sling fan
and material flow is ensured by taking material
in the feeder again and then after only bio-gas
in the furnace is made on and fired.
Slowly fresh moist material is fed and dryer
is made working.
Shut down procedure
First of all gas firing is stopped and bio-gas
in let valve is closed
Chemist of bio-gas plant is informed to stop
supply of bio-gas and chemist of bio-gas plant will
flare the gas
After gas supply is stopped, operator of
dryer will try to cool down the dryer and he will
continue the working of both the fan i.e. I.D. Fan
and sling fan
Operator will take fresh moist gluten and
recycle it till the dryer is cooled
Sling fan is stopped now and I.D. Fan is
kept on and continued till the temperature of the
dryer is come down to atmospheric temperature
I. D. fan can be stopped now.
Cause of the incident:
On the day of incident operator have told to stop
the supply of bio-gas and must have stopped the
I. D. fan before reaching the temperature of dryer
at atmospheric temperature and negative pressure
of the dryer must have reached some higher side
and due to positive pressure the rupture disc, which
is working as safety ventilation system must have
opened and burning material from this opening came
out and fall on the operator and other workman passing
from there and both were seriously injured. Because
of serious burnt injury operator died on 10-11-2003
and worker was relived after treatment.
As per provision of 5(e) of Rule 68(G) of Gujarat
Factories Rule 1963 under F.A. Act 1948, safety
ventilation of every dryer shall be such that-
Exhaust ducts of safety ventilation systems
should be so designed and placed that their ducts
discharge (the mixture of air and flammable substance)
away from the workrooms and not near windows or
doors or other opening from where the mixture could
re-enter the workrooms;
Rupture disk of the cyclone, which is working as
safety ventilation for dryer was not designed to
discharge material away from the workroom, and material
fell in the workroom.
So prosecution is launched against the manager for
contravention of the above provision i.e. 5(e) of
Rule 68(G) of Gujarat Factories Rule 1963.