Plant got a warning on dust danger

SAVANNAH, Ga. --- A consultant hired by Imperial Sugar issued a report warning the company about dust hazards at its Georgia refinery two days before a deadly explosion fueled by sugar dust erupted at the plant near Savannah.

The Savannah Morning News reported in Tuesday editions that consultant McAljon Engineering warned the company that the refinery's dust collection systems were impaired in a report dated Feb. 5, 2008.

Two days later, a massive explosion tore through the plant, killing 14 workers and injuring dozens more.

Imperial Sugar said in a statement Tuesday it did not receive the consultant's report until after the blast occurred.

Federal investigators later blamed the explosion on sugar dust that ignited like gunpowder.

The Occupational Safety and Health Administration said in July that Imperial Sugar executives knew about dust hazards at the plant. The agency said its investigation of the Georgia explosion found company audits, insurance records and other documents showing the company had been warned about combustible dust hazards at its plants several times since 2002.

OSHA has proposed fines totaling $8.7 million against Imperial Sugar for safety violations at the Georgia refinery and another plant in Gramercy, La. The Sugar Land, Texas-based company is contesting the fines.

The newspaper reported it obtained three reports -- from 2006, 2007 and last year -- from consultants hired by Imperial Sugar that cited problems with the refinery's dust collection systems. The newspaper did not say how it got the reports.

An August 2006 report said the safety system was outdated. The report dated two days before the deadly blast said parts of a machine used to suck dust from the air inside the plant were operating at about half the air flow they were designed to produce. A few dust collection pathways were blocked altogether.

Imperial Sugar's statement said the company did not ignore safety concerns raised by its consultants.

"Imperial did take action in terms of repairs and maintenance to its dust collection systems prior to the February 7, 2008 explosion, along with many other efforts towards improving safety at the facility," the company said.