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Author: Veress Árpád · Explosion-protection expertDAILY Ex - 2 NOVEMBER 2026
TODAY'S FOCUS: New technology does not remove the need for engineering judgement. An industrial fire in South Korea, an equipment explosion in India, the commercial arrival of explosion-protected inspection robots, and new research into battery-recycling hazards lead today's edition. We also examine a major US refinery investigation and the responsibilities that remain when Ex equipment becomes autonomous. For Heads of Operations: Automation can improve inspection coverage, but protection must remain effective throughout the entire operating system.
⚡ DAILY Ex | 2 NOVEMBER 2026
Explosion Protection | Operational Ex | Global Watch
TODAY'S FOCUS: New technology does not remove the need for engineering judgement.
An industrial fire in South Korea, an equipment explosion in India, the commercial arrival of explosion-protected inspection robots, and new research into battery-recycling hazards lead today's edition.
We also examine a major US refinery investigation and the responsibilities that remain when Ex equipment becomes autonomous.
For Heads of Operations: Automation can improve inspection coverage, but protection must remain effective throughout the entire operating system.
🔴 1. SOUTH KOREA | Fire at major zinc smelter
CURRENT INCIDENT - 2 November 2026
A fire broke out at the Onsan No. 2 plant operated by Korea Zinc in Ulsan.
According to YTN, the fire started at approximately 10:40 local time and involved fibre-reinforced plastic piping.
Thick smoke spread across the industrial complex, prompting emergency warnings to nearby residents.
Firefighters brought the main fire under control in approximately 40 minutes. No injuries had been confirmed in the initial report.
The cause remains under investigation. No explosion has been confirmed.
Why it matters operationally: Non-metallic process piping introduces fire, smoke and containment hazards that must be considered alongside corrosion resistance and process performance.
Management action: Review FRP piping inspection, fire exposure, material compatibility and emergency isolation arrangements.
https://www.ytn.co.kr/_cs/_ln_0115_202611021223137760_005.html
🔴 2. INDIA | Explosion involving steam-processing equipment
CURRENT INCIDENT - 31 October; reported 1 November 2026
An explosion-like event occurred at a cellulose-processing facility in Kalmeshwar, near Nagpur.
Initial reporting described a steam-processing machine located beside a boiler.
The event sent debris and glass fragments across the premises. Several workers sustained minor injuries while escaping.
Police reported that pressure or temperature fluctuations were being considered, but the precise cause and material involved had not been established.
Why it matters operationally: Not every industrial explosion is an explosive-atmosphere event.
Steam pressure, thermal energy, process reactions and combustible powders require different assessments.
Management action: Verify pressure protection, operating limits, abnormal-condition alarms and safe shutdown procedures.
⚙️ 3. SWITZERLAND | Explosion-protected walking robots enter commercial service
NEW MANUFACTURER DEVELOPMENT - 27 October 2026
https://www.anybotics.com/ announced customer deliveries of its ANYmal X autonomous inspection robot.
The manufacturer says the system has been developed for ATEX/IECEx hazardous-area applications and is being delivered to industrial operators.
The robot combines thermal imaging, acoustic monitoring, visual inspection and gas sensing.
Its explosion-protection approach addresses batteries, actuators, electronic systems, electrostatic charging and mechanical ignition sources.
The manufacturer reports that early-access testing included hundreds of industrial missions.
Why it matters operationally: Autonomous inspection could reduce personnel exposure while improving equipment-condition monitoring.
However, operators must verify the complete robot's certification, permitted operating conditions and inspection limitations.
Misconception check: An Ex-certified motor does not make an entire robot Ex-certified.
https://www.anybotics.com/news/anymal-x-launch/
⚖️ 4. ATEX / IECEx | Mobile equipment requires lifecycle control
REGULATORY PRACTICE
Directive 1999/92/EC requires employers to maintain an up-to-date explosion-protection document and review it when significant changes occur.
IEC 60079-14:2024 covers electrical installations involving fixed, portable, transportable and temporary Ex equipment.
The IECEx online certification system provides the controlled master version of IECEx equipment certificates.
Why it matters operationally: Introducing autonomous equipment may affect access arrangements, charging locations, maintenance procedures and emergency response.
Engineering lesson: Equipment certification and workplace risk assessment are complementary obligations.
https://eur-lex.europa.eu/eli/dir/1999/92/oj/eng · https://www.iecex.com/certified-equipment-scheme/faqs-certified-equipment-scheme/
🔬 5. USA | Battery black mass creates additional fire and exposure hazards
RESEARCH SPOTLIGHT - September 2026
Researchers at Michigan Technological University investigated particulate emissions from burning lithium-ion battery black mass produced by cryogenic processing.
The study found that higher battery states of charge increased particulate emissions during the investigated ignition scenarios.
Metallic contamination further intensified the observed effects.
The emitted particles included metal oxides and fluorinated compounds.
These findings concern the tested materials and conditions; they do not establish general explosion-severity characteristics for all black mass.
Why it matters operationally: Battery recycling combines fire, chemical exposure, potentially combustible materials and process-equipment hazards.
Engineering lesson: A process that avoids ignition during shredding does not necessarily eliminate hazards during subsequent material handling.
https://digitalcommons.mtu.edu/michigantech-p2/2809/
📘 6. USA | Furnace explosion exposes weaknesses in control-system design
DOCUMENTED INCIDENT LEARNING - 2025 incident; September 2026 final report
The U.S. Chemical Safety and Hazard Investigation Board investigated an explosion at the https://www.shell.us/about-us/who-we-are/shell-usa-at-a-glance/projects-and-locations/shell-polymers.html in Pennsylvania.
During the return to service of an ethane-cracking furnace, two motor-operated isolation valves were inadvertently opened.
Flammable cracked gas flowed backwards into the furnace and ignited.
The incident caused approximately $95 million in damage.
Investigators identified weaknesses in the human-machine interface, personnel experience and reliance on administrative controls instead of available engineered safeguards. https://www.csb.gov/us-chemical-safety-board-releases-final-investigation-report-on-2025-explosion-and-fire-at-shell-polymers-monaca-facility-in-pennsylvania/?SID=1&pg=1
Why it matters operationally: A technically capable control system can still permit dangerous operating sequences.
Historical lesson: Critical isolation arrangements must remain effective during startup, shutdown and maintenance—not only normal production.
📅 7. UAE | ADIPEC 2026 opens today
CURRENT INDUSTRY EVENT - 2–5 November 2026
ADIPEC 2026 opens today in Abu Dhabi.
The program includes autonomous inspection, asset-performance management, digitalization and industrial energy technology.
Why it matters operationally: New technology should be assessed against measurable reliability improvements, inspection quality and reduced personnel exposure.
https://www.adipec.com/?hss_channel=fbp-149798988425458
📅 8. GLOBAL | International Process Safety Day registration opens
UPCOMING EVENT - 2 December 2026
FABIG has opened registration for International Process Safety Day 2026.
The free virtual event is organised with international process-safety organizations and will include technical presentations, case studies and discussions. https://fabig.com/events/international-process-safety-day-ipsd-2026
Why it matters operationally: Competence development should include learning from actual failures and verification of protective barriers.
https://fabig.com/events/international-process-safety-day-ipsd-2026
▶️ OPERATIONAL Ex USE CASE
The inspection robot is certified. Is its operating route safe?
PRACTICAL | Illustrative scenario
A refinery introduces an autonomous inspection robot for routine rounds through a Zone 1 process area.
The robot's Ex certification has been verified.
Its route includes pumps, compressors, valves and elevated platforms.
During maintenance, temporary scaffolding is installed. A process connection is modified, and the robot's original route is no longer available.
Operations proposes an alternative route.
Can the robot simply continue operating?
Not without reviewing the change.
The alternative route may introduce different hazardous-area conditions, mechanical impact risks, obstacles, access restrictions or emergency-response requirements.
The charging and docking arrangements also require verification against the equipment's approved conditions.
Required decision: Engineering and Operations must confirm that the revised mission remains within the certified equipment's limitations and the site's assessed operating conditions.
Owner: Head of Operations, supported by the Ex Responsible Person, Maintenance and Automation Engineering.
Required evidence: Verified certificate and instructions, approved route assessment, operating restrictions, emergency arrangements and change authorization.
Measure: 100% of autonomous inspection routes assessed before initial operation and following relevant modifications.
▶️ TODAY'S Ex QUESTION
“When we introduce new technology into hazardous areas, who verifies the complete operating arrangement—not just the equipment certificate?”
Consider mobile equipment, temporary installations, charging systems, software-controlled functions and changing operating routes.
⚡ DAILY Ex | CLOSING THOUGHT
Today's developments show two sides of industrial progress.
New technologies can reduce exposure, detect abnormal conditions and improve maintenance planning.
But industrial incidents continue to demonstrate the consequences of unexpected equipment behaviour, inadequate protective functions and incomplete understanding of process hazards.
Automation can improve operational safety, but it cannot replace engineering responsibility.
For Heads of Operations, the objective is to connect certification, operating conditions, maintenance, change management and emergency preparedness.
The equipment may be intelligent. The responsibility for keeping the installation safe remains human.
That is Operational Ex.