"furnace tap out overflow, manual operator. So it is a human mistake. "

The accidental release of molten metal unfortunately is a common incident that the Aluminium Plant Safety Blog has repeatedly covered. Here is a recent incident highlighting the hazard associated with an accidental molten metal release.

A fire broke out on Sunday morning inside a company in Southern Europe during the 2^nd week of August 2021. Shortly after 10 a.m., a high column of black smoke rose into the sky. On the spot, the firefighters of the city immediately intervened, with four vehicles.

According to reports from the fire brigade operations centre, liquid metal - possibly aluminium - and glowing metal leaked, causing the fire. Fortunately, the workers present in the company came out unharmed from the accident, which took place in the basement of the structure.

Firefighters worked for about three hours to secure the shed.

Thankfully, no worker nor fire fighter was injured in this incident. A contact informed us that the incident occurred “due to furnace tap out overflow, manual operator. So it is a human mistake. Nobody hurt but big damages.”

The manual removal and insertion of tap out hole is common throughout the industry. Some of the largest molten metal releases was due to incorrect insertion of the tap out. One notable error was when a worker drove the tap hole into the furnace allowing the molten metal to escape. Nearly the entire furnace emptied causing a huge mess.

When molten metal escapes its holding spot it will flow to the lowest point. Companies need to be aware of where that lowest point is. From underneath furnaces, to electrical conduit trenches, to basements (floors below), molten metal will continue to flow until prevented.

We do believe whole heartedly that every incident can be a learning tool. This incident in particular can be used by a company that handles molten metal. By simply asking, where is the molten metal in our workplace? If that molten metal escaped. Where would it flow? Then inspect that localized area(s) for what the molten metal will come into contact. Hopefully, the molten metal will not come into contact with combustibles. Because molten metal will easily ignite any combustible that it comes into contact with.

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