Dust explosion hazards in animal feed production in Brazil: A process safety review

Abstract Animal feed production facilities present a significant risk for dust explosions due to the handling and processing of dry, seed‐based ingredients. These explosions can cause catastrophic consequences, including injuries, fatalities, and extensive property damage. This review examines the inherent hazards associated with dust explosions in animal feed mills, highlighting their potential impact on the Brazilian industry. The paper explores the generation of combustible dust during feed production, its ability to form explosive mixtures within confined spaces, and the role of ignition sources. Statistical data is presented, demonstrating the prevalence of dust explosions in industrial settings, particularly those involving grain storage and handling. Additionally, the review pinpoints the vulnerability of the Brazilian feed sector due to its heavy reliance on soybean and corn processing, both materials known to contribute significantly to dust explosion risks. This review highlights the critical need for a two‐pronged approach in Brazilian feed mills: firstly, robust dust control and mitigation strategies must be implemented to minimize the explosion hazard; secondly, fostering awareness and strict adherence to established safety protocols are essential to prevent catastrophic dust explosions and ensure the safe and sustainable production of animal feed in Brazil.