Why do conventional electronic devices fail in hazardous areas.docx

It would be risky to use an ordinary smartphone in a grain elevator or oil refinery. Conventional electronic devices cannot withstand explosive environments. Small electrical sparks can cause disasters in chemical production areas, as well as in mines and fuel storage sites, where these places hide invisible hazards.

1. Why do conventional electronic devices fail in hazardous areas-2025
It would be risky to use an ordinary smartphone in a grain elevator or oil refinery. Conventional
electronic devices cannot withstand explosive environments. Small electrical sparks can cause
disasters in chemical production areas, as well as in mines and fuel storage sites, where these
places hide invisible hazards.
The presence of flammable substances comes in three main forms:
gases, vapors, and dust clouds, which the human eye cannot always detect. A typical work
environment contains three types of gases: decomposing materials produce methane, oil
operations release hydrogen sulfide, and industrial facilities generate aluminum dust. The
combination of oxygen, the right concentrations, and an ignition source can cause a total
catastrophe.
What are the reasons why conventional technological devices fail in high-risk hazardous areas?
What technical methods do hazardous area-certified electronic devices use to protect sensitive
systems from complete failure? This article simplifies this information with clear and accessible
explanations, avoiding complex terms, to inform readers of the risks and associated solutions.
Why do traditional electronic devices fail in hazardous areas?
1. They generate sparks and heat
Standard electronic devices produce small electrical sparks and thermal effects during
operation. Electrical sparking occurs during routine operations. Electronic devices generate
sparks when switches or relays operate and break.
When switching motor brushes.
During static discharges on plastic surfaces.
When connecting or disconnecting batteries.

2. Explosive conditions containing flammable gases, vapors, and dust can ignite and cause an
explosion from small sparks. Heat generated by battery-operated equipment in a mining tunnel
can ignite the methane. Thousands of lives have been lost in methane explosions in mines,
primarily due to improper electrical equipment used at mine sites.
2. They lack proper sealing
Environments that remain hazardous contain acidic vapors as well as dust particles or liquid
moisture.
Common contaminants include:
Acid fumes in chemical plants.
Metal dust in machine shops.
Salt spray in marine environments.
Humid air in food processing plants.
Unprotected openings and vents in normal electronic devices allow outside elements to enter,
resulting in several negative effects:
Short circuits.

3. Corrosion.
The malfunctions.
Conventional industrial sensors become inoperable when flour mill dust accumulates inside
them. The 2008 Imperial Sugar refinery explosion demonstrated that explosive reactions can
occur when combustible dust accumulates on electrical equipment, resulting in the loss of 14
lives and the destruction of factory facilities.
3. They are not energy limited
Intrinsically safe (IS) electronics operate at minimal power levels because this design limits the
possibility of ignition.
Key differences in IS design:
Current is limited to milliampere levels.
The tension is capped below the inflammation thresholds.
Energy storage is minimized in capacitors.
Thermal management to prevent hot spots.
Most conventional devices require so much power that they pose dangerous explosion hazards.
A typical flashlight battery has enough stored energy to ignite gasoline vapors. Engine repair
technicians at various stations have caused fuel leaks using ordinary flashlights, according to
documented reports.

4. 4. They use uncertified materials.
Plastics and metals chosen in standard electronic devices pose the following problems:
Create static electricity (risk of sparks).
Lose their structural integrity under extreme temperatures.
React with industrial chemicals.
Materials used in electronic devices certified for hazardous areas do not generate static
electricity or sparks because they use materials with built-in anti-static properties.
Special considerations regarding materials:
Conductive plastics to dissipate static electricity.
Non-ferrous metals are used to prevent sparks.
Chemical resistant coatings.
High temperature alloys.
5. They do not comply with safety standards.
Hazardous areas require safety certifications, which include either ATEX, IECEx, or UL HazLoc.
These certifications guarantee:

5. Design suitable for explosive atmospheres.
Rigorous testing in worst-case scenarios.
Manufacturing quality control.
Traceability of safety components.
Ordinary electronic components lack the necessary tests, making their application illegal and
dangerous in high-risk areas.
The special features of our hazardous area electronics surpass standard products
1. Intrinsically Safe (IS) Design
The devices limit electrical power and heat output below the ignition threshold.
Implementation includes:
Current limiting resistors.
Voltage limiting diodes.
Energy restriction barriers.
Thermal mass calculations.
Short circuits cannot cause explosions because the devices do not have sufficient power.
2. Explosion-proof enclosures
Robust, sealed enclosures are used to contain sparks and explosions occurring inside the device.
Design Features:
Cast metal structure.
Precision flame paths.
Pressure resistant seals.
Corrosion resistant finishes.
The case contains stainless steel and reinforced polymers for its robust construction.
3. Certified for hazardous areas
The company conducts extensive testing to obtain ATEX certification, IECEx certification and UL
approval for its products.
Tests include:

6. Spark ignition tests.
Temperature rise assessments.
Impact resistance tests.
Environmental stress resistance tests.
This equipment is officially approved for operation in Zone 0/1 gas hazardous areas as well as
Zone 20/21 potentially explosive dust environments.
4. Corrosion and dust resistance
The IP66/IP67 rated seal provides a barrier against moisture, as well as dust and chemicals.
Protection methods:
Multi-layered joints.
Airtight seals.
Conformal coatings.
Pressurized purge.
The system does not contain any exposed wiring components that may fail in extreme weather.
5. No risk of static discharge or sparks
Anti-static coatings work with non-sparking metals to prevent electrical shock.
Applications in materials science:
Intrinsically conductive polymers.
Spark resistant alloys.
Triboelectric tests.
Surface resistance checks.
Gases, liquids, and powders are considered safe when using this system.
Real example of failure
Failure: Smartphone ignites gas leak (2018)
A refinery worker used an uncertified mobile device in a hazardous area.
The consequences:

7. $2.3 million in property damage.
6 weeks of lost production.
OSHA fines exceeding $150,000.
Implementation of permanent changes in security policy
An explosion occurred after the phone's battery generated a spark that ignited methane gas
escaping into the atmosphere.
How could this have been avoided?
The intrinsically safe (IS) circuits built into our ATEX-certified smartphones are specifically
designed to prevent this type of ignition, preventing incidents like gas explosions before they
occur.
Conclusion:
Hazardous areas pose the same danger to traditional electronics as an open flame does to
ordinary materials. The risks of explosions, equipment failure, and regulatory fines far outweigh
the cost of certified solutions.