Worst case scenario
of any aluminium plant is if a furnace leaks. In the past furnace leaks range
from minor leaks to catastrophic. Some of our largest explosions have occurred
when an unexpected release from a furnace occurred. Here is a recent story that
thankfully did not result in an explosion. Nevertheless, workers were injured.
During one night during the week of October 28, 2019 around 500 kilograms of
liquid aluminum from a smelting furnace leaked from an aluminium company’s workshop in Europe. Six
employees blotted the material with powder and were treated with suspected
smoke poisoning. Two of them came to the hospital for examination, but were
allowed to leave the clinic after one hour, said an authorized representative
of the company.
Two of the six employees suspected of smoke poisoning were taken
to the hospital. Such an incident that a melting pot burst, was nothing
unusual. The cracked graphite crucible would be replaced, then the production
could be continued. The Criminal Investigation Department, the Environmental
Protection Agency and the Office for Occupational Safety and Health determined later
the day that the hall was then cleared again.
A local fireman explained that the fire brigade had been alerted
in the night at 23.44 clock. In the factory, the employees had already very
prudently tried to contain the danger. The difficulty was that the liquid, very
hot aluminum (it melts at around 660 degrees Celsius) had spread on the floor
and the hall was heavily smoked with non-hazardous vapors. Four respirator
squads advanced into the hall and pushed in air through large fans to squeeze
the smoke out. In use were around 50 firefighters from six neighboring
fire departments.
We pray that the injured workers recover fully from their injuries.
The crucible leaked 500 kilograms of molten metal that immediately
came into contact with a combustible or the metal reacted with the “powder”
that was used. We wonder what the powder was. We will reach out to the company
and inquire and update this post as needed.
On our plant tours we ask greenfield plants if they have planned for
a molten metal release. This question usually is dumbfounds them. Why ? They
reply. We respond that even that you have brand new equipment accidental molten
metal releases can occur. We know of a plant whose workers placed a reject
rolling ingot into a furnace thinking it was ok. They were shocked that a “tidal
wave” of molten aluminium came out and made a mess of everything. If not
immediately contained the molten metal will flow to the lowest area. Commonly
that area is maintenance pits under furnaces, maintenance channels (covered
with steel plates) through the factory etc. A number of years ago the Aluminium
Insight publication had an article about this topic. It can be found here.
Please comment.
No comments:
Post a Comment