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During manufacturing and production processes of pyrotechnic compositions, semi-finished devices and regular pyrotechnic articles an inadvertent reaction or even explosion cannot be fully excluded. The optimization of the design of the involved single work processes can only reduce the risk of such a scenario. For doing so, one must consider the respective properties regarding thermal, mechanical, chemical and electrostatic sensitivities of the compositions being processed. One major key parameter in reducing the risks of such an event is to minimize the consequences, if the likelihood of this event cannot be further reduced.
Minimizing the consequences in cases of unintended explosions during production processes comprises of construction measures regarding buildings (different walls, orientation etc.), increasing safety distances to other buildings, and lowering the maximum net explosive masses and the number of people per room or production process.
Important criteria for defining and setting protection measures are the so-called ‘hazard groups’ (in German ‘Gefahrgruppen’), net explosive masses and the main impacts or hazards (such as blast pressure, heat/radiation and debris).
This paper aims at presenting some approaches used in Germany to minimize the impacts of possible reactions or inadvertent explosions during production processes of pyrotechnic compositions and articles in work spaces. This includes also the determination of safety distances and discussions on reducing thermal impacts.