In the chemical and pharmaceutical industries, risk management is an integral part of the production process—a responsibility shared by all stakeholders. Due to the complexity of process industries, every component installed in a plant must meet strict safety requirements, especially when operating in the presence of potentially explosive gases, vapors, or dust. This is what is meant by an ATEX zone: an operational context strictly regulated by European directives that define the essential preventive measures to avoid any possibility of ignition.
In such sensitive environments, choosing the right technology and configuring the pump according to actual production needs directly impacts the safety of both facilities and workers. Magnetic drive centrifugal pumps manufactured by CDR Pompe stand out for their ability to ensure complete circuit sealing, with no leakage points or direct contact between fluid and atmosphere.
CDR designs and manufactures pumps certified for ATEX zones, supporting companies from the initial technical analysis phase, configuring—already during the kick-off meeting—the most suitable solution for the type of fluid, temperature, and area classification, through to commissioning and periodic maintenance. This expertise stems from hands-on experience in the most complex industrial plants and translates into real, documented safety, fully compliant with current European regulations.
Safety and Classification in ATEX Zones
The term ATEX stands for ATmosphères EXplosibles and refers to all areas where the interaction between flammable substances and oxygen can create an explosive atmosphere, posing a risk of explosion or ignition. These conditions occur when mixtures of gases, vapors, mists, or combustible dust accumulate at concentrations that can explode upon contact with an ignition source. In industrial settings, this risk is present in tanks, reactors, pumping systems, loading and unloading lines, synthesis laboratories, or mixing departments. For a real-life example, typical gas stations are classified as ATEX environments.
To manage this risk, the European Union introduced two key directives: 2014/34/EU, which governs the design and certification of equipment intended for explosive atmospheres, and 1999/92/EC, which defines minimum safety requirements for workers.
ATEX zones are classified based on the frequency and duration of explosive atmosphere presence:
- Zone 0 / Zone 20: Explosive atmosphere is present continuously or for long periods. The most restrictive category, requiring equipment with the highest protection level.
- Zone 1 / Zone 21: Explosive atmosphere occurs occasionally, e.g., during certain process phases or maintenance.
- Zone 2 / Zone 22: Explosive atmosphere formation is unlikely and, if it occurs, lasts briefly.
In each ATEX zone, pump selection must match the risk level. CDR Pompe offers certified models for Zone 1 and Zone 2, designed to operate reliably even with highly flammable or corrosive fluids, minimizing ignition risk.
Advantages of Magnetic Drive Pumps in ATEX Zones
In an ATEX-classified environment, even a minor leak, localized overheating, or a small spark can become a major hazard for both the plant and personnel. Magnetic drive centrifugal pumps provide an advanced technological solution for ATEX zones: thanks to their seal-less design, they prevent any fluid leakage and keep the circuit completely sealed.
The operating principle is simple yet effective: the motor’s motion is transmitted to the impeller via magnetic coupling, with no direct contact between parts. The absence of dynamic seals and mechanical seals eliminates the most vulnerable point of traditional pumps, drastically reducing the likelihood of leaks or friction that could generate sparks.
Key benefits of magnetic drive pumps in ATEX zones include:
- Leak-free operation: Complete pump body sealing prevents hazardous or flammable substance leaks, protecting both environment and operators.
- Intrinsic safety: Without mechanical seals, there are no friction points that could trigger sparks, making the pump suitable for classified areas.
- Long-term reliability: Reduced internal component wear minimizes maintenance needs, ensuring service continuity and fewer plant shutdowns.
- Regulatory compliance: CDR Pompe models are certified for ATEX Zone 1 and Zone 2, fully compliant with EU directives 2014/34/EU and 1999/92/EC.
Stable, quiet, durable, and compliant with the strictest Italian and European regulations, a CDR magnetic drive pump is the safest choice for efficient, uninterrupted operation in environments with high explosion risk.
Construction Materials and Configurations for Hazardous Areas
The reliability of a pump intended for any ATEX zone largely depends on the quality of materials used and its design configuration. CDR Pompe uses only top-quality components, resistant to corrosion and high temperatures, and selected based on the nature of the fluid handled. Main materials include PVDF, ETFE, PFA, and AISI 316, each with specific chemical and mechanical resistance properties.
PVDF and ETFE, for example, offer excellent stability against strong acids and concentrated bases, while AISI 316 stainless steel is ideal for high-temperature solvents. Material selection results from an in-depth analysis of process conditions during the initial negotiation phase, considering operating temperature, fluid pH, and application plant compatibility with reference standards.
CDR-certified ATEX pumps are used for transferring complex fluids such as flammable solvents, concentrated acids and bases, aggressive chemical mixtures, and high-temperature thermal oils. Each application requires a customized configuration, where hydraulic geometry, materials, and magnetic couplings are calibrated according to specific risk. This engineering and consulting approach, developed over decades of experience in industrial fluid management, ensures consistent performance and safety even in the most sensitive processes, where an anomaly could compromise the entire production cycle.
Guidelines for Selecting and Installing Pumps in ATEX Zones
Adopting centrifugal pumps for ATEX zones always requires a thorough technical assessment of the entire environment and operational process. It is not enough for a pump to meet required certifications: it must also be installed and used correctly, in line with area classification and fluid type.
Before installation, follow these essential guidelines:
- Correctly classify the installation area: Identify whether it is Zone 0, 1, or 2 (gas) or Zone 20, 21, or 22 (dust), assessing the likelihood and duration of explosive atmosphere presence.
- Verify equipment category: Pumps for ATEX zones are divided into categories (1G, 2G, 3G for gas; 1D, 2D, 3D for dust), each with specific protection levels.
- Check material compatibility: Choose materials resistant to the fluid to avoid unwanted chemical reactions, corrosion, or electrostatic phenomena that could cause ignition.
- Ensure proper grounding and ventilation: Preventing electrostatic charge buildup is crucial in ATEX zones, as is keeping pump temperature within safe limits.
- Avoid dry running: Lack of fluid can cause rapid overheating of the magnetic assembly; CDR Pompe provides control solutions to prevent this condition.
- Schedule controlled periodic maintenance: Regular inspections, certification checks, and operational parameter monitoring ensure long-term ATEX compliance and plant safety.
Every ATEX installation requires complete documentation, from declaration of conformity to instruction and maintenance manuals. CDR Pompe supports customers at every stage, providing technical consulting and operator training.
CDR Pompe: Experience and Reliability for ATEX Zone Plants
Choosing a magnetic drive centrifugal pump certified for ATEX zones means adopting an engineering solution that combines safety, efficiency, and regulatory compliance. CDR Pompe assists companies in risk assessment and plant design for potentially explosive atmospheres, offering consulting, customized configuration, and after-sales support.
Each pump results from rigorous design, laboratory testing, and witnessed acceptance tests certifying full compliance with European standards. The outcome is a stable, reliable, and durable product, capable of meeting the needs of sectors where precision and safety are essential for operation.