Explosion-proof drives: Solutions for underground mining, chemical, pharmaceutical, and food production
Four industries, one common goal: safety. Underground mining, chemicals, pharmaceuticals, and food production—at first glance, these are completely different industries. And yet they have one thing in common: in all four areas, combustible gases, vapors, or dust create potentially explosive atmospheres.
A spark, overheating, or technical defect can have serious consequences:
- Explosion hazard
- Risk to life and limb
- Production downtime with high costs
- Compliance violations with legal consequences
Maximum safety and absolute reliability are therefore particularly important in drive technology. An explosion-proof drive is not only a technical requirement here, but also a decisive competitive factor.
ATEX zones at a glance – brief overview
Strict regulations apply in potentially explosive atmospheres. The EU-wide Explosion Protection Directive (ATEX 2014/34/EU) regulates which devices may be used in such areas.
| Zone | Description | Examples |
|---|---|---|
| Zone 0 | Explosive atmosphere is permanently present | Evaporators, reaction vessels, dust filters, mine gas in underground mining |
| Zone 1 | Explosive atmosphere is frequently or permanently present | Chemical reactors, solvent plants, conveyor tunnels |
| Zone 2 | Explosive atmosphere occurs occasionally | Food packaging, pharmaceutical cleaning |
Industry-specific challenges
Whether underground mining, chemicals, pharmaceuticals, or food production—every industry has its own specific requirements for explosion protection in its drive systems. Different material properties, production processes, and environmental conditions lead to specific risks that must be carefully considered when selecting an explosion-proof drive.
Conditions in mining are particularly critical: methane (mine gas) and coal dust can combine with the air to form highly dangerous, explosive mixtures. Even a small spark or overheating can trigger a devastating explosion. Underground mining is therefore subject to the strictest safety regulations, and the drive technology used must meet the highest requirements.
Challenges:
- Methane leaks and dust accumulation lead to Zone 0, Zone 1, and Zone 2 conditions within the tunnels.
- Constant exposure to moisture, dust, and high temperatures.
- Maintenance and repairs are extremely costly because the equipment is difficult to access.
- Absolute reliability is required to avoid production downtime and personal injury.
Chemical processes regularly produce flammable substances – from solvents to gas mixtures. Zone 1 is widespread here, which places particularly high demands on drive technology.
Challenges:
- Permanent explosion hazard due to gases and vapors
- Heavy continuous operation with high performance requirements
- Need to remain reliable and safe even during 24/7 operation
Pharmaceutical production has two requirements:
- Explosion protection for sensitive substances and solvents
- Cleanroom compatibility to prevent contamination
Conventional electric motors quickly reach their limits here:
- Lubricants or abrasion can contaminate products
- Additional protective housings make cleaning more difficult
Dust particles such as flour, sugar, or milk powder pose an often underestimated risk. Even small sparks or overheating can lead to a dust explosion.
Typical sources of danger:
- Silos and mills (Zone 1)
- Filling and packaging plants (Zone 2)
The solution
An explosion-proof turbine drive combines numerous advantages that make it an ideal solution for demanding production environments:
- Maximum safety: Spark-free operation and no hazardous heat sources minimize the risk of explosions.
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High operational reliability: Low probability of failure and consistent performance even under extreme conditions.
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Low maintenance and long service life: Fewer wear parts mean minimal downtime and predictable maintenance intervals.
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Hygienic: Lubricant-free operation and easy cleaning. The stainless steel exterior parts are resistant to cleaning agents, and the turbines are sealed to meet the highest hygiene requirements.
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Increased efficiency: Reduced downtime and reliable continuous operation sustainably increase productivity.
Conclusion: A turbine drive combines maximum safety with efficiency and reliability, making it the perfect solution for many industries.
Advantages of the turbine solution – designed with specific industries in mind
Instead of talking generally about the advantages of turbine drives, let's take a look at the direct benefits for the industries.
Read also: Turbine vs. electric motor – a comparison for hazardous areas
| Advantage | Underground mining | Chemicals | Pharmaceuticals | Food |
|---|---|---|---|---|
| Spark-free operation | ✔ | ✔ | ✔ | ✔ |
| No overheating | ✔ | ✔ | ✔ | ✔ |
| Low maintenance | ✔ | ✔ | ✔ | ✔ |
| Oil-free operation | ✔ | ✔ | ✔ | ✔ |
| High power density | ✔ | ✔ | ✔ | ✔ |
| Easy cleaning | ⚪ | ⚪ | ✔ | ✔ |
Integration without long downtimes
With the right planning, switching to explosion-proof drives can be a smooth process. Every hour of production downtime counts, especially in sensitive industries, which is why a structured approach is crucial.
DEPRAG turbines are equipped with different planetary gearboxes and are available in standardized speeds for electric motors:
- 2-pole: 2880 rpm
- 4-pole: 1335 rpm
- 6-pole: 1000 rpm
- 8-pole: 750 rpm
- 12-pole: 525 rpm
All DEPRAG turbine drives are supplied with a standardized IEC flange connection and can therefore be connected to a wide variety of machines in a standardized manner. It is only important that the recommended hose lengths and diameters are observed and that an operating pressure of 6 bar is applied to the turbine. Done.
Checklist: The right explosion-proof drive
Before purchasing a new drive, decision-makers should consider the following points:
- Suitability of the temperature class for the ambient conditions
- Compliance with the explosion protection directive
- Appropriate power and size
- Ease of maintenance and cleaning
- Energy efficiency and operating costs
- Compatibility with existing systems
- Reliability
Would you like advice?
Our team will help you find the optimal drive for your requirements. Contact us.
Conclusion: Increase safety, avoid downtime
Explosion protection is essential in underground mining, chemical, pharmaceutical, and food processing plants. Modern explosion-proof turbine drives not only reduce safety risks, but also increase productivity and efficiency.
If you would like to learn more about the basics and technical background of ATEX-certified drives, read our feature article on ATEX turbine technology.
Act now: Check your production lines for risk areas and ensure sustainable, reliable operation.
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