Archer Daniels Midland Sued by Man Severely Injured in Explosion

A worker suffered third-degree burns and lifelong injuries after an explosion at Archer Daniels Midland’s Decatur facility.

An Illinois man injured in a 2023 explosion at Archer Daniels Midland’s facility in Decatur, Illinois filed a lawsuit against the company, alleging that ADM’s conduct leading up to the explosion demonstrated a serious disregard for employee safety.

According to the complaint, ADM had an explosion suppression system in place, but federal safety inspectors later determined that the system had not been inspected or tested since late 2016 and was in a state of disrepair. The lawsuit also alleged that combustible corn germ dust had accumulated to unsafe levels near the bucket elevator where the explosion occurred.

Quick Answer:
Workplace explosions involving combustible dust can cause catastrophic burn injuries in seconds. When an employer allegedly fails to maintain required safety systems, control hazardous materials, or warn workers about dangerous conditions, those facts may become important in a personal injury investigation.

What Happened at ADM’s Decatur Facility?

The plaintiff, who was in his 40s, arrived for work at ADM’s facility on April 20, 2023. According to the lawsuit, the previous shift did not warn him about a buildup of combustible corn germ dust in a bucket elevator, a machine used to move material vertically.

Later in the shift, the plaintiff’s supervisor reportedly noticed smoke coming from the elevator. The complaint alleged that the smoke indicated an explosion was imminent. The plaintiff was directed to stand at a specific location while the elevator was opened. According to the lawsuit, exposing the burning material to oxygen then triggered the explosion.

Combustible Dust Had Accumulated

The lawsuit alleged that corn germ dust had accumulated to unsafe levels in the bucket elevator area. Grain and agricultural dust can create serious fire and explosion hazards when combustible particles accumulate and encounter an ignition source.

Smoke Was Reportedly Detected

During the plaintiff’s shift, his supervisor reportedly saw smoke coming from the elevator. The lawsuit alleged that the condition meant an explosion was imminent.

The Elevator Was Opened

According to the complaint, the plaintiff was directed to stand at a particular location while the elevator was opened. The lawsuit alleged that once the burning material was exposed to oxygen, the explosion occurred.

A Catastrophic Explosion Occurred

The explosion severely injured the plaintiff and caused extensive damage at the ADM facility. Federal investigators later found that the explosion suppression system on the bucket elevator was non-functional and in a state of disrepair.

The Plaintiff Suffered Severe Burn Injuries

The plaintiff suffered third-degree burns to his face, head, and body. According to the lawsuit, the burns left him disfigured and caused lifelong injuries.

After the explosion, doctors placed him in a medically induced coma for approximately three weeks to assist with his recovery. His attorney said that he continued to require medical care and was unable to work because of his injuries.

Lifelong Consequences

Third-degree burns can require extensive medical treatment, surgeries, rehabilitation, and long-term care. They may also result in permanent disfigurement, disability, emotional trauma, and loss of earning capacity.

What the Lawsuit Alleges About ADM’s Safety Practices

The complaint alleged that ADM was “fully aware of the unsafe conditions” in the elevator. It further alleged that, at the direction of an ADM employee or agent, the plaintiff was positioned directly in the path of the explosion.

The lawsuit also alleged that the company failed to warn the plaintiff about the dangerous dust buildup before the explosion. Those allegations are significant because an employer’s knowledge of a dangerous condition and the steps it takes—or fails to take—to protect employees may become important evidence in a workplace injury lawsuit.

OSHA Findings:
Following the April 2023 explosion, OSHA determined that ADM had not conducted inspections and testing of the explosion suppression systems since late 2016. OSHA cited ADM for two willful, one serious, and one other-than-serious safety violations and proposed $324,796 in penalties.

A History of Safety Incidents at ADM’s Decatur Facility

The 2023 explosion was not the only serious safety incident reported at ADM’s Decatur facility. The lawsuit and subsequent investigations referenced a series of prior explosions, fires, and other incidents involving employees and first responders.

November 2018

A dust explosion occurred at the facility. Following the incident, OSHA cited ADM and reached a formal settlement requiring the company to conduct and document preventative maintenance on safety equipment.

January 2019

Another explosion and deflagration event caused equipment and structural damage. OSHA sent ADM a hazard alert addressing concerns about explosion suppression equipment and maintenance practices.

April 2023

Days before the bucket elevator explosion, a locomotive collision at the facility killed an employee. OSHA later cited ADM in connection with the incident.

April 2023

The bucket elevator explosion injured three workers, including the plaintiff whose lawsuit is discussed in this article. OSHA later proposed more than $324,000 in penalties over safety violations tied to the explosion.

September 2023

Another explosion at ADM’s Decatur facility injured eight employees, according to OSHA and reporting about the plant’s safety history.

OSHA stated that the April 2023 explosion occurred because the explosion suppression system on the indoor bucket elevator was non-functional and in a state of disrepair. Federal investigators also found that ADM had not inspected or tested the explosion suppression systems since late 2016.

Investigate Midwest later reported that the April 2023 explosion was one of several incidents at the Decatur facility involving employees and first responders.

What Is a Combustible Dust Explosion?

Certain materials used in agricultural and industrial facilities can create dangerous combustible dust. When fine dust particles accumulate and are dispersed into the air, an ignition source can trigger rapid combustion and an explosion.

OSHA has specifically warned about the dangers associated with agricultural dust. In its investigation of the ADM explosion, the agency noted that agricultural dust can explode in seconds when an ignition source is available.

Dust Accumulates

Combustible material can accumulate in equipment and work areas when housekeeping and dust-control systems are inadequate.

An Ignition Source Appears

Heat, sparks, smoldering material, or another ignition source can cause combustible dust to ignite.

A Rapid Explosion Can Follow

The resulting combustion can spread rapidly and produce an explosion capable of causing catastrophic injuries.

Who May Be Responsible for a Workplace Explosion?

A workplace explosion injury case may involve difficult questions about employer safety practices, equipment maintenance, hazardous conditions, employee instructions, and regulatory compliance. Investigators may need to determine what the employer knew about the danger and what safety measures were reasonably available.

In this case, the plaintiff’s lawsuit focused on alleged failures involving the explosion suppression system, combustible dust accumulation, warnings to employees, and the decision to place the plaintiff near the equipment before the explosion.

Federal safety findings can provide important information when investigating a workplace injury. They do not automatically establish civil liability, but inspection reports, citations, photographs, maintenance records, safety policies, and witness statements may help an attorney understand what happened.

The Plaintiff Is Seeking More Than $50,000

According to the lawsuit, the plaintiff is seeking more than $50,000 in damages. His injuries include severe burns, disfigurement, continuing medical needs, and an inability to work.

The amount of compensation available in a personal injury case depends on many factors, including the nature and permanence of the injuries, medical expenses, lost income, future treatment needs, pain and suffering, disability, and the evidence establishing responsibility for the accident.

Preserve the Evidence:
Serious industrial accidents can involve technical evidence that may be difficult to reconstruct later. Photographs, medical records, OSHA documents, safety records, equipment maintenance records, witness information, and other evidence should be preserved as early as possible.

Talk to a Decatur, Illinois Burn Injury Lawyer Today

Patel Law, PC represents the interests of plaintiffs in personal injury lawsuits filed against negligent defendants. If you or a loved one has suffered serious burn injuries in a workplace explosion, call our Decatur personal injury lawyers today to schedule a consultation so we can begin investigating your claims right away.