We decided to draft this document to address the growing need for transparency and information in the industrial sector. The use of flammable solvents requires highly safe equipment, compliant with rigorous international standards such as the ATEX Directive. However, regulations and safety requirements can be complex and difficult to interpret for many companies, who must evaluate both legal compliance and worker and environmental protection.<\/p>\n\n\n\n
The document aims to guide customers in understanding the essential certifications and safety measures, clarifying the risks associated with using non-certified machinery and the value of third-party certifications, which are essential for accident prevention and regulatory compliance. The document also provides criteria for the safe purchase and use of distillers, promoting greater awareness of safety in production and the importance of compliance to protect the integrity of the business and the well-being of employees.<\/p>\n\n\n\n
Use of solvents in industrial applications<\/strong><\/p>\n\n\n\n Solvents are chemicals used in numerous industrial sectors in the production of inks and paints, in cleaning, degreasing, and in chemical production. Due to their properties, which vary depending on their chemical composition, the storage, use, and handling of solvents can present varying levels of risk, such as:<\/p>\n\n\n\n Essential information about solvents<\/u><\/strong><\/p>\n\n\n\n When dealing with solvents, it is important to know some essential physical data that influence their safe use, particularly in terms of flammability and explosion risk.<\/p>\n\n\n\n Flash Point (FP)<\/strong><\/p>\n\n\n\n It is the lowest temperature at which a liquid releases sufficient vapors to form a flammable mixture with air following an ignition. Solvents with a low PF are more dangerous because they can form flammable vapors even at room temperatures.<\/p>\n\n\n\n The PF value is reported in section 9 of the solvent’s SDS. For safety, a margin of at least 15\u00b0C below the PF is used to assess flammability; it can be reduced to 5\u00b0C for single-component solvents under controlled conditions.<\/p>\n\n\n\n Self-Ignition Point<\/strong><\/p>\n\n\n\n It is the minimum temperature at which a mixture of combustible vapor and air can ignite without an ignition source. The autoignition point is related to the chemical structure of the solvent and not to the boiling point or flash point, and is usually higher than the latter.<\/p>\n\n\n\n The solvent’s autoignition point is listed in section 9 of the SDS. It can be lowered in the presence of high pressure or catalysts (such as metals found in industrial equipment). It provides an indication of the maximum temperature to which flammable mixtures can be exposed without autoignition, but requires a large safety margin.<\/p>\n\n\n\n Lower Explosive Limit (LEL)<\/strong><\/p>\n\n\n\n Indicates the minimum concentration of solvent vapors in the air, expressed as a percentage, below which ignition cannot occur (the mixture is too “lean” in combustible).<\/p>\n\n\n\n It is essential for defining the safety conditions of environments and for designing adequate ventilation systems. Below the LEL, the mixture is considered non-flammable.<\/p>\n\n\n\n Upper Explosive Limit (UEL)<\/strong><\/p>\n\n\n\n It represents the maximum concentration of solvent vapors in air, above which the mixture cannot burn (the mixture is too “rich” in fuel).<\/p>\n\n\n\n It helps establish safe operating conditions. Above the UEL, the vapor mixture is considered non-flammable, but further dilution with air can bring it back into the flammable range.<\/p>\n\n\n\n Boiling Point (BP)<\/strong><\/p>\n\n\n\n The temperature at which, at atmospheric pressure, the solvent changes from a liquid to a gaseous state. It is important for distillation operations and for evaluating the evaporation of the solvent at room temperature.<\/p>\n\n\n\n Vapor density<\/strong><\/p>\n\n\n\n Indicates whether solvent vapors are heavier or lighter than air. Heavier vapors tend to accumulate at ground level, increasing the risk of fire.<\/p>\n\n\n\n Vapor pressure<\/strong><\/p>\n\n\n\n Indicates a solvent’s tendency to evaporate. Solvents with high vapor pressures can form flammable mists more easily.<\/p>\n\n\n\n Risks in solvent distillation<\/u><\/strong><\/p>\n\n\n\n Distillation is a physical separation technique used to purify solvents by heating, separating volatile components from less volatile ones. This process allows contaminated solvents to be recovered and reused in production cycles, reducing operating costs and environmental impact.<\/p>\n\n\n\n In addition to heating, the spent solvent must be transferred from storage tanks to the boiler and from the condensation system to storage tanks, through which it will then be reintroduced into the manufacturing process. The most common risks during these phases are:<\/p>\n\n\n\n Fire<\/strong><\/p>\n\n\n\n Flammable solvents have low flash points, meaning they can release vapors that form flammable mixtures with air at relatively low temperatures. An ignition source, such as an electric spark, flame, or a hot surface, can start a fire.<\/p>\n\n\n\n This can happen if flammable vapors come into contact with equipment parts that reach high temperatures.<\/p>\n\n\n\n Explosion<\/strong><\/p>\n\n\n\n The presence of flammable vapors at concentrations between the lower explosive limit (LEL) and upper explosive limit (UEL) can create an explosive atmosphere. In closed rooms or confined spaces, the dispersion of vapors can be limited, increasing the likelihood that a spark or electrostatic discharge will cause an explosion.<\/p>\n\n\n\n Overheating and chemical decomposition<\/strong><\/p>\n\n\n\n Distillation requires heating the solvent. If the temperature exceeds the solvent’s autoignition point, the vapors can ignite spontaneously. Some solvents can decompose at high temperatures, releasing hazardous substances or increasing pressure within the system, which can cause explosions or equipment failure.<\/p>\n\n\n\n Accumulation of electrostatic charges<\/strong><\/p>\n\n\n\n Solvents with low electrical conductivity can accumulate electrostatic charges during pumping or handling. These charges can start fires if not properly discharged to ground.<\/p>\n\n\n\n Mechanical risk and equipment breakage<\/strong><\/p>\n\n\n\n Distillation equipment can be subject to wear, leaks, or breakage due to pressure or overheating. This can cause liquids and vapors to escape, increasing the risk of fire or explosion.<\/p>\n\n\n\n For these reasons, it’s essential to invest in a safe and certified distiller to recover and reuse solvents safely, saving on operating costs, and complying with environmental standards.<\/p>\n\n\n\n Installation and use of distillation units<\/u><\/strong><\/p>\n\n\n\n To safely manage risks, distillation units must be built, installed and operated following specific criteria:<\/p>\n\n\n\n What is ATEX?<\/u><\/strong><\/p>\n\n\n\n ATEX (ATmosph\u00e8res EXplosibles) is the European Directive 2014\/34\/EU that ensures the safe use of equipment in explosive atmospheres. This includes areas where flammable gases, vapors, or mists may be present.<\/p>\n\n\n\n Why does a distiller need to be ATEX certified?<\/u><\/strong><\/p>\n\n\n\n ATEX certification guarantees that the distiller has been designed and built to operate in environments where there is a significant likelihood of an explosive atmosphere forming. Certified equipment must meet stringent safety requirements to prevent the ignition of explosive atmospheres.<\/p>\n\n\n\n What are the advantages of installing a certified distiller?<\/u><\/strong><\/p>\n\n\n\n A certified distiller is:<\/p>\n\n\n\n The guarantees of ATEX certification<\/u><\/strong><\/p>\n\n\n\n Safety in explosive environments<\/strong><\/p>\n\n\n\n Certified equipment does not generate sparks or sources of excessive heat that could ignite explosive atmospheres.<\/p>\n\n\n\n Compliance with European regulations<\/strong><\/p>\n\n\n\n It demonstrates that the equipment has been designed and tested to the required standards.<\/p>\n\n\n\n Reducing the risk of explosions and accidents<\/strong><\/p>\n\n\n\n Design, construction and maintenance follow rigorous criteria to minimize risks.<\/p>\n\n\n\n Need for a third party<\/strong><\/p>\n\n\n\n Certification must be carried out by a body independent of the machinery manufacturer, ensuring that the checks are accurate and impartial.<\/p>\n\n\n\n Support in legal liability<\/strong><\/p>\n\n\n\n In the event of an accident or regulatory inspection, ATEX certification helps demonstrate that the company has complied with all applicable safety regulations, thus reducing the risk of legal sanctions and civil or criminal liability.<\/p>\n\n\n\n The costs of ATEX certification<\/u><\/strong><\/p>\n\n\n\n The cost of a non-certified still is 20-50% lower than one certified by a third-party organization. Third-party certification involves additional costs for design, compliance testing, and required documentation. These costs can represent a significant portion of the final price of the still. Other factors that influence the cost difference include:<\/p>\n\n\n\n Materials and Components Used<\/strong><\/p>\n\n\n\n ATEX-certified distillers must use specific components (such as explosion-proof motors, protected wiring, and spark-proof ventilation systems) that are more expensive than standard components.<\/p>\n\n\n\n Manufacturing Process and Testing<\/strong><\/p>\n\n\n\n Producing a certified distiller requires more rigorous manufacturing processes, including quality controls and additional inspections, which increase production costs.<\/p>\n\n\n\n Documentation and Inspection Costs<\/strong><\/p>\n\n\n\n In addition to initial testing, ATEX-certified products must be documented and subjected to periodic inspections, which incur additional costs.<\/p>\n\n\n\n Consequences of failure to comply with ATEX regulations<\/u><\/strong><\/p>\n\n\n\n Non-compliance with ATEX regulations can have serious consequences. Here are some key reasons why this choice can be counterproductive and dangerous.<\/p>\n\n\n\n Lack of Legal Compliance<\/strong><\/p>\n\n\n\n Using non-certified equipment can result in legal penalties, fines, and the requirement to suspend operations until the problem is resolved. Furthermore, in the event of an accident, the employer may face civil and criminal liability.<\/p>\n\n\n\n High Risk of Accidents<\/strong><\/p>\n\n\n\n Damage caused by accidents involving non-certified equipment can be extremely serious, putting workers’ lives, company infrastructure, and the environment at risk.<\/p>\n\n\n\n Insurance Issues<\/strong><\/p>\n\n\n\n Using non-compliant equipment can also lead to higher insurance premiums, as the company is perceived as being at greater risk.<\/p>\n\n\n\n Lower Quality, Durability, and Reliability<\/strong><\/p>\n\n\n\n Any initial savings are quickly lost due to the additional costs of repairs, downtime, and replacement parts for non-certified machinery that is not built with the same quality components or safety standards, leading to frequent malfunctions and breakdowns and costly maintenance.<\/p>\n\n\n\n Impact on the Company’s Reputation<\/strong><\/p>\n\n\n\n Accidents caused by uncertified equipment can cause significant reputational damage, with negative consequences for the business. Customers and business partners may perceive the company as unreliable or negligent when it comes to safety and sustainability.<\/p>\n\n\n\n Problems During Inspections and Audits<\/strong><\/p>\n\n\n\n Companies are subject to periodic inspections to verify compliance with safety regulations. Using an uncertified still can lead to non-compliance during inspections, requiring equipment replacement or costly modifications.<\/p>\n\n\n\n Is it sufficient to install ATEX certified components for the distiller to be certified in turn?<\/u><\/strong><\/p>\n\n\n\n No, simply installing ATEX-certified components for Zone 1 is not enough to automatically consider a distiller ATEX-certified. Certifying the entire distiller as ATEX equipment requires much more than simply having certified components. Various aspects must be considered to ensure the entire machine meets the safety requirements of the regulations:<\/p>\n\n\n\n Interaction between components<\/strong><\/p>\n\n\n\n Even if individual components are certified, the way they interact with each other within the distiller could create unforeseen risks.<\/p>\n\n\n\n Specific operating conditions<\/strong><\/p>\n\n\n\n Each application has unique operating conditions that must be assessed to ensure the safety of the entire system.<\/p>\n\n\n\n Lack of comprehensive assembly testing<\/strong><\/p>\n\n\n\n Certifying individual components does not guarantee that the assembled system meets ATEX requirements without proper testing.<\/p>\n\n\n\n Is it sufficient to deposit the machinery’s technical file with a notified third-party body to obtain ATEX certification?<\/u><\/strong><\/p>\n\n\n\n No, filing the technical file is not sufficient to ensure compliance with ATEX regulations. Although the technical file documents the machinery’s design and safety measures, it must be accompanied by a valid ATEX certification, issued by a notified body, certifying that the equipment complies with the essential safety requirements for use in potentially explosive environments.<\/p>\n\n\n\n ATEX compliance in hazardous areas<\/u><\/strong><\/p>\n\n\n\n ATEX compliance is required by European Directive 2014\/34\/EU, which regulates the use of equipment in areas with explosive atmospheres. ATEX zones are classified based on the likelihood and duration of the presence of explosive atmospheres, and are primarily divided into Zone 0, Zone 1, and Zone 2.<\/p>\n\n\n\n Zone 0<\/strong>: An area in which an explosive atmosphere consisting of a mixture of air and flammable substances is present continuously, for long periods, or frequently.<\/p>\n\n\n\n Example: The interior of solvent storage tanks where vapors are always present.<\/p>\n\n\n\n Zone 1<\/strong>: An area in which an explosive atmosphere is likely to occur during normal operation. It is present for a sufficiently long period of time to require special preventive measures.<\/p>\n\n\n\n Example: Near the loading openings of solvent storage tanks, where vapors may escape during filling or emptying operations.<\/p>\n\n\n\n Zone 2<\/strong>: An area in which an explosive atmosphere is not likely to occur during normal operation and, if it does occur, is short-lived (generally less than 10 hours per year).<\/p>\n\n\n\n Example: The vicinity of a storage area where vapors could only emerge in the event of an accidental release.<\/p>\n\n\n\n Who evaluates the classification of hazardous areas in the company?<\/u><\/strong><\/p>\n\n\n\n Employer or company manager<\/strong>: legally responsible for ensuring workplace safety and ensuring that potentially explosive areas are properly classified and marked.<\/p>\n\n\n\n Health, Safety, and Environment (HSE) manager<\/strong>: coordinates risk assessments and implements necessary safety measures. They may also conduct periodic inspections to ensure that zone classifications remain appropriate.<\/p>\n\n\n\n Under what circumstances can a manufacturer self-certify a machine?<\/u><\/strong><\/p>\n\n\n\n In ATEX environments, self-certification may be applicable only in limited circumstances, particularly for equipment intended for use in Zone 2, where protection requirements are less stringent than those for Zones 0 and 1, for which self-certification is not applicable.<\/p>\n\n\n\n Self-certification for Zone 2 implies that the manufacturer is fully responsible for the safety of the equipment. This involves preparing a Declaration of Conformity and a technical file describing the safety requirements and tests performed.<\/p>\n\n\n\n In the event of an accident, the manufacturer is legally and civilly liable. Self-certification for Zone 2 may not be sufficient for insurance purposes and, in some jurisdictions, may result in penalties.<\/p>\n\n\n\n Although it is legal for equipment intended for use in Zone 2, self-certification is not guaranteed to be accepted by authorities or business partners, especially in areas with stringent safety standards.<\/p>\n\n\n\n In many industries, customers and internal regulations require certification by a notified body even for Zone 2 equipment to provide additional assurance of compliance and safety.<\/p>\n\n\n\n ATEX protection types<\/u><\/strong><\/p>\n\n\n\n Ex ia (Intrinsic Protection)<\/strong>: Limits the energy available within the equipment, preventing ignition even in the event of a fault. Suitable for Zone 0.<\/p>\n\n\n\n Ex d (Explosion-Proof Enclosure)<\/strong>: Contains a potential explosion within the device, preventing the spread of flames. Suitable for Zones 1 and 2.<\/p>\n\n\n\n Ex p (Pressurization)<\/strong>: Maintains the internal pressure of the equipment higher than the ambient pressure, preventing the entry of explosive gases. Suitable for use in Zones 1 and 2.<\/p>\n\n\n\n What is the relationship between the temperature class of a distiller and the autoignition temperature of the solvent to be recovered?<\/u><\/strong><\/p>\n\n\n\n The temperature class of a certified distiller is the maximum temperature the system can reach even in the event of a fault. ATEX temperature classes range from T1 to T6, where the maximum surface temperature is:<\/p>\n\n\n\n T1<\/strong> \u2264 450\u00b0C T2<\/strong> \u2264 300\u00b0C T3<\/strong> \u2264 200\u00b0C T4<\/strong> \u2264 135\u00b0C T5<\/strong> \u2264 100\u00b0C T6 <\/strong>\u2264 85\u00b0C<\/p>\n\n\n\n The distiller’s temperature class must be chosen such that the maximum surface temperature allowed by the equipment is below the autoignition temperature of the solvent. In general, the surface temperature of the equipment must be at least 5-10\u00b0C below the autoignition temperature of the solvent to ensure a safety margin.<\/p>\n\n\n\n Practical example: if a solvent has an autoignition temperature of 210\u00b0C, the distiller must have a temperature class of T3 or higher (T4, T5, T6), with a maximum surface temperature not exceeding 200\u00b0C.<\/p>\n\n\n\n This ensures that the equipment operates safely without risking vapor ignition.<\/p>\n","protected":false},"excerpt":{"rendered":" We decided to draft this document to address the growing need for transparency and information in the industrial sector. The use of flammable solvents requires highly safe equipment, compliant with rigorous international standards such as the ATEX Directive. However, regulations and safety requirements can be complex and difficult to interpret for many companies, who must […]<\/p>\n","protected":false},"author":2,"featured_media":1481,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_gspb_post_css":"","footnotes":""},"categories":[30],"tags":[],"class_list":["post-1480","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-further-information"],"blocksy_meta":[],"yoast_head":"\n\n
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Thinking of saving money by purchasing a non-certified distiller involves numerous risks and disadvantages that far outweigh the immediate economic benefits.<\/h3>\n\n\n\n
The correct evaluation and classification of ATEX zones is essential to ensure safety at work and prevent the risk of explosions.<\/h4>\n\n\n\n