How to Choose Compliant Explosion-Proof Cranes for Refineries & Chemical Plants?
Introduction
In refineries and chemical plants, the risk of explosions due to flammable gases, vapors, or combustible dust is a constant threat. Standard cranes can ignite these hazardous substances through electrical sparks, static discharge, or overheating, leading to catastrophic accidents.
This is why explosion-proof cranes are mandatory in such environments. But how do you choose the right one? What certifications should you look for? And how can Dongqi Crane, a leading explosion-proof crane manufacturer, provide a safe, reliable, and cost-effective solution?
This guide covers:
✔ Key explosion risks in refineries & chemical plants
✔ International explosion-proof standards (ATEX, IECEx, NEC, GB 3836)
✔ How to select the right explosion-proof crane
✔ Dongqi Crane’s specialized solutions for hazardous environments
1. Why Do Refineries & Chemical Plants Need Explosion-Proof Cranes?
1.1 Common Explosion Risks in Refineries
Refineries handle highly flammable substances, including:
- Hydrogen (H₂) – Used in hydrocracking and desulfurization
- Hydrogen Sulfide (H₂S) – Common in crude oil processing
- Methane (CH₄) – Present in natural gas refining
- Volatile Organic Compounds (VOCs) – Released during chemical reactions
A single spark from an ordinary crane’s motor, wiring, or brakes can trigger a fire or explosion, leading to:
- Worker injuries or fatalities
- Multi-million-dollar equipment damage
- Regulatory fines and shutdowns
1.2 Chemical Plant Hazards
Chemical plants deal with:
- Flammable solvents (e.g., acetone, ethanol)
- Corrosive substances (acids, alkalis)
- Combustible dust (e.g., powdered chemicals, polymers)
An unprotected crane in such environments can:
✔ Generate static electricity (from friction in hoists or trolleys)
✔ Overheat (due to high ambient temperatures)
✔ Corrode quickly (reducing lifespan and safety)
→ Solution: Only ATEX/IECEx-certified explosion-proof cranes can operate safely in these zones.
2. Key Explosion-Proof Standards for Cranes
2.1 ATEX Directive (EU) – Explosive Atmospheres
- Applies to: EU and many international projects
- Classification:
- Zone 0/20 (Continuous explosive atmosphere)
- Zone 1/21 (Likely to occur during normal operation)
- Zone 2/22 (Unlikely but possible in abnormal conditions)
- Required Protection Types:
- Ex d (Flameproof Enclosure) – Contains explosions inside the motor
- Ex e (Increased Safety) – Prevents sparks in electrical components
2.2 IECEx (International) – Global Compliance
- Recognized in: Middle East, Asia, Australia
- Similar to ATEX but with global acceptance
- Key for refineries exporting products
2.3 NEC/CEC (North America) – Class I, Div 1/Div 2
- Class I: Flammable gases/vapors
- Division 1: Hazard present under normal operation
- Division 2: Hazard only under abnormal conditions
2.4 GB 3836 (China Standard)
- Widely used in Chinese refineries & chemical plants
- Equivalent to ATEX but with local certification requirements
→ Dongqi Crane’s Advantage: Our cranes are multi-certified (ATEX, IECEx, GB 3836, NEC) for global compliance.
3. How to Choose the Right Explosion-Proof Crane?
3.1 Determine the Hazardous Zone Classification
| Zone | Risk Level | Required Protection |
|---|---|---|
| Zone 0/20 | Continuous hazard | Ex ia (Intrinsic Safety) |
| Zone 1/21 | Frequent hazard | Ex d, Ex e, Ex p |
| Zone 2/22 | Occasional hazard | Ex n, Ex ec |
Example:
- Refinery hydrocracking unit (Zone 1) → Ex d crane required
- Chemical storage (Zone 2) → Ex e or Ex n crane sufficient
3.2 Material & Corrosion Resistance
- Stainless steel (316L) – Best for corrosive environments (e.g., sulfuric acid exposure)
- Special coatings (epoxy, zinc-aluminum) – Extends lifespan in humid/salty conditions
3.3 Motor & Electrical Safety Features
✔ Explosion-proof motors (Ex d/Ex e rated)
✔ Anti-static brakes & wheels
✔ Sealed wiring (IP66 rating for dust/water resistance)
3.4 Smart Monitoring Systems (Optional)
- Temperature sensors – Prevent overheating
- Gas detectors – Alert if flammable gas levels rise
- Remote diagnostics – Predictive maintenance to avoid failures
4. Dongqi Crane’s Explosion-Proof Solutions for Refineries & Chemical Plants
At Dongqi Crane, we specialize in manufacturing high-safety, high-performance explosion-proof cranes designed specifically for refineries, petrochemical plants, and chemical processing facilities. Our cranes are engineered to operate reliably in Zone 1, Zone 2, and Division 1/Division 2 hazardous areas, ensuring compliance with ATEX, IECEx, NEC, and GB 3836 standards.
Below, we detail our product range, key safety features, customization options, and real-world applications in hazardous environments.
4.1 Our Explosion-Proof Crane Product Range
Dongqi Crane offers three main types of explosion-proof cranes, each optimized for different lifting needs in hazardous areas:
✅ 1. Explosion-Proof Overhead Cranes (Ex d, Ex e, Ex n)
- Best for: Indoor/outdoor lifting in refineries, chemical plants, and storage areas
- Capacity: 1 ton to 100+ tons
- Key Features:
- Ex d (Flameproof) motors & electrical components – Contain sparks inside explosion-proof enclosures
- Stainless steel or coated construction – Resistant to corrosive chemicals, saltwater, and high humidity
- Anti-static trolley & hoist system – Prevents static buildup when handling flammable liquids/gases
- IP65/IP66 protection – Sealed against dust and water ingress
✅ 2. Explosion-Proof Gantry Cranes (Ex de IIC T4)
- Best for: Outdoor tank farms, loading/unloading areas
- Capacity: 5 tons to 50 tons
- Key Features:
- Galvanized or stainless steel structure – Long-term durability in harsh weather
- Explosion-proof limit switches & control panel – Safe operation in gas-rich environments
- Custom span & height – Adaptable to different refinery layouts
✅ 3. Explosion-Proof Jib Cranes (Ex nA, Ex ec)
- Best for: Localized lifting in confined spaces (e.g., reactor maintenance, pipeline installation)
- Capacity: 0.5 ton to 10 tons
- Key Features:
- Compact, maneuverable design – Ideal for tight workspaces
- Non-sparking aluminum or bronze components – Eliminates ignition risks
- 360° rotation – Flexible material handling
4.2 Key Safety & Performance Features
Dongqi’s explosion-proof cranes are built with multiple layers of protection to ensure maximum safety and uptime:
✔ 1. Explosion-Proof Electrical System
- Motors, brakes, and wiring are Ex d/Ex e certified to prevent sparks
- Sealed cable glands prevent gas/dust penetration
✔ 2. Corrosion-Resistant Materials
- 316L stainless steel (for highly corrosive zones)
- Epoxy-coated carbon steel (cost-effective for moderate environments)
✔ 3. Advanced Safety Controls
- Overload protection – Prevents crane failure due to excess weight
- Emergency stop (E-stop) button – Instant shutdown in case of danger
- Gas detection integration (optional) – Alerts operators if flammable gas levels rise
✔ 4. Smart Monitoring & Predictive Maintenance
- Real-time temperature sensors – Prevent overheating in motors
- Remote diagnostics – Reduces unplanned downtime
- Automated lubrication system (optional) – Extends component lifespan
4.3 Customization for Refinery & Chemical Plant Needs
Every facility has unique requirements. Dongqi Crane provides tailored solutions based on:
🔹 Hazardous Zone Classification (Zone 1, Zone 2, Division 1, etc.)
🔹 Chemical Exposure (acid-resistant, anti-corrosion coatings)
🔹 Lifting Capacity & Span (custom-designed for heavy-duty refinery equipment)
🔹 Automation Level (remote control, IoT integration)
Example Customization:
- A Middle Eastern refinery needed Ex d cranes with stainless steel hoists for hydrogen sulfide (H₂S) resistance.
- We provided 10-ton overhead cranes with Ex d motors, IP66 protection, and anti-static trolleys – zero incidents in 5+ years.
4.4 Case Studies: Dongqi Cranes in Action
📌 Case 1: Explosion-Proof Cranes for a Chinese Petrochemical Plant
- Challenge: Handling ethylene gas (Zone 1) required ATEX & GB 3836 compliance
- Solution: Supplied 5-ton Ex d overhead cranes with gas detection alarms
- Result: 100% safety compliance, reduced maintenance costs by 25%
📌 Case 2: Offshore Oil Platform Crane Upgrade
- Challenge: Saltwater corrosion + methane explosion risk
- Solution: Stainless steel explosion-proof gantry crane with Ex e controls
- Result: No corrosion issues after 3 years, passed DNV-GL certification
5. Conclusion: Why Choose Dongqi Crane?
Selecting the right explosion-proof crane is not just about compliance—it’s about safety, efficiency, and long-term cost savings.
Dongqi Crane offers:
✔ Globally certified explosion-proof cranes
✔ Custom solutions for extreme environments
✔ Proven reliability in refineries & chemical plants
📩 Need a compliant explosion-proof crane?
➡ Get a customized quote in 24 hours
➡ Schedule a safety consultation with our engineers
