Over 6,100 pallets can be stored in the 51 rack rows of the Chemion Logistik hazardous goods warehouse. Every day, 200 pallets each are handled in incoming and outgoing goods. In the 25 high-bay aisles, an explosion-protected MX-X narrow-aisle forklift from Still transports drums and cans with liquid hazardous goods as well as big bags and bagged goods with chemical solids to the storage locations. Hubert Kubitza, responsible for general cargo logistics at Chemion Logistik in Chempark Leverkusen: "In accordance with the BimSchV, our general cargo warehouse is certified for substances with a particularly high hazard potential. Leaking solvents from the filled base chemicals can evaporate and combine with the oxygen in the air to form an explosive mixture. The areas in which such atmospheres can occur must therefore be specially marked as potentially explosive zones. The hazardous materials storage facility must also be equipped with drip pans to prevent possible leaks and be open at the front and rear without external walls to allow the explosive vapors to evaporate."

Explosive atmosphere divided into zones
Legal regulations govern both the manufacture and operation of industrial trucks with explosion protection. The criteria here are the type of potentially explosive atmosphere. Users are guided by the Atex Directive 2014/34/EU. For example, the danger zones for explosive gas mixtures are divided into three classes. No effective ignition sources may be present in these areas. This also includes electric vehicles that are not specially encapsulated. Furthermore, electric forklift trucks may only be operated in an explosive atmosphere if their maximum surface temperatures remain below the ignition temperature of the surrounding explosive mixture. Six temperature classes have been defined for easy assessment.

The manager of Chemion Logistik responsible for the use and rental of the industrial trucks, Adrian Ksoll, adds: "Explosive gas concentrations rarely occur in our hazardous materials warehouse and only for short periods of time. Consequently, the MX-X from Still requires explosion protection conversions 3G and temperature class 4 for hazard zone 2 in the equipment category. The maximum radiation temperature of the MX-X from Still must therefore not exceed 135 degrees Celsius. Almost 2,200 industrial trucks are available in our rental pool - 500 of which are explosion-proof. The manufacture and operation of explosion-proof forklift trucks is very complex. That's why there are only a few rental companies in Europe offering such equipment."

Explosion protection solutions: Preventing sparks or discharges
Almost all electrically powered forklift trucks are therefore also offered by Still in an explosion-proof version. Industrial trucks that need to meet explosion protection requirements are developed by Still and Miretti, the specialist for such conversions. The entire conversion is geared to the previously determined application profile. All vehicle parts that could trigger explosions due to sparks, voltage or electrostatic charges are then encapsulated or encased in appropriate materials.

All connections are specially protected to prevent any sparks or discharges. The stainless steel coatings on the forks prevent the formation of sparks in the event of impact and friction contact. The horn also functions pneumatically and no longer electrically. In order to prevent explosive deflagrations, any oxyhydrogen gas produced is discharged separately in the battery. The explosion-proof special version also includes the personal protection system for the simultaneous presence of pedestrians and MX-X, the flashing light, the battery adapter and the battery plug as well as the two work lights and the cab heater.

To comply with explosion protection regulations, the brakes and hydraulics are encased. The avoidance of electrostatic charge plays a role both in the choice of upholstery materials for the driver's seat and in the design of the interior cladding. The running wheels, drive wheel and guide rollers are also antistatic. Charges from the mechanical forced guidance are also dissipated. The cockpit display shows warning messages about the surface temperature of the MX-X.

Driving comfort and safety
The thermostat-controlled heating and ventilation system in the driver's cab of the MX-X ensures a pleasant working environment. The sliding door on the left-hand side makes it easy to get in and out. The large panoramic windows at the front and sides provide a clear view of the forks and the storage areas in the hazardous materials warehouse. The switchable LED headlights on the left and right of the overhead guard are used to illuminate the racking compartments. The height and angle of the control panel can be adjusted for standing or seated operation. The integrated two-hand control system ensures fatigue-free operation thanks to the contactless sensor. The Optispeed driver assistance system combines the advantages of optimized vehicle movements for increased turnover as well as comfort and safety thanks to the payload diagram. The permissible load weight is shown dynamically on the LCD display depending on the fork height. The safety equipment also has an emergency exit via the roof window with the abseiling system. "We also have a reserve forklift in case the MX-X should ever break down,"
adds Hubert Kubitza from Chemion Logistik.

In areas with potentially explosive atmospheres, non-explosion-proof industrial trucks can become a source of ignition due to high surface temperatures, impact or friction sparks and electrostatic charges. Almost all electric forklift trucks are therefore also available from Still in an explosion-proof version. Nevertheless, only careful and prudent action on the part of everyone involved will help when handling hazardous goods.

About Chemion Logistik
Chemion Logistik has been an independent site logistics provider since 2001 and specializes in handling a large number of hazardous goods and storage classes for the chemical industry. With an annual throughput of almost 700,000 pallets at the Chempark sites in Leverkusen, Dormagen, Krefeld-Uerdingen and the two external warehouses in Duisburg, Chemion Logistik is equipped for the general cargo orders of the chemical industry with around 70,000 pallet spaces in block racking, narrow-aisle racking and open-air warehouses - for both solids and liquids.