A specialist fertiliser powder manufacturer needed to replace a legacy handling system that was unsuitable for an exceptionally ignition-sensitive powder. The material has a Minimum Ignition Energy of only 6–10 mJ, meaning even a small electrostatic spark could present a serious dust-explosion hazard.

The internal conveyor environment required ATEX Zone 21 classification because turbulent dust clouds are present during normal operation, while the area around the bulk-bag station was classified Zone 22 because occasional dust release could occur during bag connection.

After assessing the powder characteristics, zoning, throughput and existing process constraints, Entecon engineered a complete ATEX-compliant system comprising an FIBC Discharge Station and Aero Mechanical Conveyor. The project covered hazard analysis, equipment selection, grounding strategy, integration, commissioning support and compliance documentation.

The FIBC Discharge Station uses a dust-tight docking arrangement and grounding interlocks so a conductive Type C bulk bag is correctly bonded to earth before discharge.

The Aero Mechanical Conveyor was engineered for Category 2D, Zone 21 internal operation. Metal housings, flanges and structural frames are earth bonded, while an ATEX motor, rope-sprocket speed monitoring and temperature sensing provide additional protection against mechanical or friction-related ignition risks.

The completed installation achieved the required Zone 21 internal and Zone 22 external compliance, eliminated unmanaged static-discharge risks and provided sealed, high-throughput transfer of the 6–10 mJ powder. It enabled the plant to return to reliable production with a system designed specifically around the material's unusually demanding ignition characteristics.