Static Electricity and Chemicals in Electrical Engineering: How to Prevent Dangerous Discharges During Handling and Storage
Static electricity can cause fires, explosions, or damage to sensitive components when working with chemicals in the electrical engineering industry. How to minimize risks during handling, storage, and processing?
Photo: Антон Дмитриев / Unsplash
In the electrical engineering industry, where solvents, powdered materials, adhesives, or coating systems are handled, static electricity often represents an underestimated risk. Even a small electrostatic discharge can, in environments with flammable vapors, dust, or sensitive electronic components, cause a fire, explosion, or irreversible damage to products. The problem is not limited to the handling of substances but also concerns their storage, mixing, or application. How can work procedures, equipment, and environments be properly designed to minimize the risk of discharges? The key lies in a combination of technical measures, appropriate materials, and adherence to antistatic protection principles according to applicable safety regulations.
How static electricity is generated and why it is dangerous in the chemical industry
Static electricity is generated by friction, separation, or contact between two materials with different electrical properties. In the electrical engineering industry and when handling chemical substances, this phenomenon is particularly hazardous, as it can trigger unexpected spark discharges. These discharges not only endanger worker safety but can also damage sensitive electronic components or initiate the ignition of flammable vapours, dusts, or liquids. In environments containing organic solvents, powdered materials, or surfactants, the risk is even higher because these substances often exhibit low electrical conductivity and become easily charged.
The danger of static electricity lies primarily in its ability to accumulate on insulated surfaces, such as plastic containers, hoses, or packaging. If the accumulated charge suddenly discharges, it can cause equipment damage, data loss, or even fire or explosion. According to REACH and CLP regulations, all chemical substances and mixtures must be properly labelled with regard to their flammability and electrostatic properties, which is crucial for the correct risk assessment during handling and storage.
Critical Factors Influencing the Generation of Static Electricity When Working with Chemicals
The generation of static electricity when handling chemical substances depends on several key factors. The first is relative air humidity – at low humidity (below 30%), electrostatic charge accumulates more easily because the air loses its ability to dissipate excess electrons. Another factor is the material of packaging and handling equipment: plastics, glass, or ceramics have high insulation resistance, whereas metals or antistatically treated materials dissipate charge more effectively. The speed of handling also plays a role – the faster substances are poured, transferred, or mixed, the greater the risk of charge generation.
An important parameter is also the electrical conductivity of the chemical substances themselves. Liquids with low conductivity (e.g. certain organic solvents or polyols) charge easily, while conductive solutions (e.g. those containing ions) dissipate charge more quickly. When working with powdered materials, such as additives for plastics or construction chemicals, the risk is even higher due to friction between particles and against container walls. To minimise risks, it is essential to consider these factors when designing work procedures and selecting suitable materials.
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Technical and organisational measures for minimising the risks of static electricity
Effective prevention of hazardous static electricity discharges requires a combination of technical and organizational measures. The foundation is the use of antistatic-treated materials – for example, containers, hoses, or flooring with low surface resistance. In high-risk areas such as storage halls or production lines, the installation of grounding systems, which dissipate accumulated charge to the ground, has proven effective. For liquids, it is crucial to adhere to recommended filling and emptying speeds to minimize friction and thus the generation of charge.
Organizational measures include regular employee training on the risks of static electricity and proper handling procedures. Workers should be familiar with the importance of grounding, the use of protective equipment (e.g., antistatic gloves or footwear), and procedures for safely pouring or transferring chemicals. It is also important to follow proper storage principles – for example, separating flammable substances from ignition sources and ensuring adequate ventilation. Regular inspections and maintenance of equipment, including measuring the surface resistance of materials, help keep risks to a minimum.
Practical Tips for Safe Handling and Storage of Chemicals
When handling chemicals, it is important to follow several basic rules to reduce the risk of static electricity generation. When pouring liquids, use metal or antistatic-treated containers and always ground them before starting work. The pouring speed should be as low as possible – ideally below 1 m/s for flammable liquids. For powdered materials, it is advisable to use closed systems with antistatic filters and minimize free pouring. If possible, work with substances in a humid environment (relative humidity above 50%), which reduces the risk of charge accumulation.
Storing chemical substances requires careful planning. Flammable and explosive substances should be stored in separate, well-ventilated areas with antistatic flooring and grounded shelving. Chemical containers should be placed on metal or conductive pallets and must not be stacked in high layers to prevent them from falling and subsequent friction. Regularly inspect the condition of containers and handling equipment for signs of damage or wear. By following these measures, you will significantly reduce the risk of dangerous discharges and ensure a safe working environment for all employees.
Photo: Troy Bridges / Unsplash
Impact of Physical Properties of Chemicals on Static Electricity Accumulation
Static electricity is generated by friction or separation of materials with different electrical conductivities. In the chemical industry, the physical properties of substances play a key role, particularly their resistivity and dielectric strength. Substances with high resistivity (e.g., organic solvents, certain polymers, or powdered materials) easily accumulate electrical charge because they prevent its dissipation. In contrast, conductive liquids or metals quickly disperse the charge, thereby minimizing the risk of discharge. Dielectric strength determines the voltage a material can insulate—when exceeded, breakdown and subsequent discharge occur, which can initiate the ignition of flammable vapors or dust.
For practical risk assessment, it is important to know the specific conductivity of a given substance. Liquids with conductivity below 50 pS/m (picosiemens per meter) are considered non-conductive and require increased caution. These include, for example, hydrocarbons, esters, or certain alcohols. When handling such substances, it is essential to ensure the grounding of all metal parts of the equipment and to use antistatic tools. For powdered materials, particle size also plays a role—fine dusts (below 100 micrometers) have a greater tendency to become charged and form explosive clouds.
Specifics of Storing Flammable and Explosive Chemicals in Terms of Static Electricity
Storing flammable and explosive substances requires special attention due to the risk of static discharges. A key factor is the selection of suitable packaging materials—plastic containers or non-conductive polymer containers can accumulate charge, whereas metal containers with grounding are safer. When filling or emptying containers, low flow rates (typically below 1 m/s) must be maintained to minimize friction and the generation of static electricity. For liquids with low conductivity, the use of inert gases (e.g., nitrogen) is recommended to displace air and reduce the concentration of flammable vapors.
In warehouse areas, it is necessary to ensure antistatic treatment of floors and work surfaces. Floor coverings should have a surface resistivity in the range of 10^6 to 10^9 ohms to allow gradual charge dissipation without generating dangerous sparks. It is also important to separate storage zones according to hazard classes (in accordance with CLP/GHS) and ensure adequate ventilation. When handling powdered substances, it is essential to prevent dust swirling, which increases the risk of explosion. For these purposes, enclosed systems with local extraction units are used.
Monitoring and Control of Static Electricity in Industrial Operations
Regular monitoring of static electricity levels is essential for preventing hazardous situations. Industrial operations use specialized measuring instruments, such as electrostatic voltmeters or teraohmmeters, to check the resistivity of materials and surfaces. Measurements should be conducted at critical points, such as filling stations, mixing vessels, or conveyor systems. For continuous monitoring, stationary sensors are installed to detect charge accumulation in real time and can automatically activate safety measures, such as grounding or process shutdown.
In addition to technical controls, it is important to implement a system of regular inspections and employee training. Staff should be trained to recognize hazardous situations and correctly use protective equipment, such as antistatic clothing, footwear, or gloves. This equipment must meet low-resistivity requirements while being compatible with the chemicals handled. In high-risk operations, it is recommended to introduce a work permit system to ensure that every handling of hazardous substances is supervised and conducted under all safety conditions.
Safety starts with the right information
Every chemical raw material requires an individual approach to preventing risks associated with static electricity. GCG Group provides detailed Safety Data Sheets (SDS) and technical support for all supplied products to help you choose the optimal measures for your specific conditions and applications. Contact us – or browse our catalog of over 1,300 products right away.
