Heat, fire, explosions, ear-shattering noise, heavy materials, falling objects, toxic gas – these could be ingredients in an action movie, but they actually present an overview of very real safety and health hazards for many steel industry workers.
Although worker health and safety has come a long way in the steel industry, which is committed to a zero-harm goal, there is no denying that modern steel manufacturing is still one of the more dangerous occupations. Each year sees several fatalities and thousands of injuries – and that is only the tip of the iceberg.
In a 2023 report on health and safety, the World Steel Association said, “It has been indicated that typically around 20% of incidents have the potential to become serious injuries or fatalities.” Furthermore, the report noted almost 200,000 “near misses” in 2022.
Electric heating improves steel production safety
Dilip Chandrasekaran, Kanthal, Business Development ManagerAn electric furnace in the steel-making process can be powerful in improving the work environment. While it will have a low impact on some of the most common incidents, such as falls, moving machinery and falling objects, it can reduce many risks associated with gas heating.
Gassing and asphyxiation are at the top of the WSA table, “Ratio Lost Time Injury vs Fatality 2004–2022.” They are not among the most frequent incidents, but the outcome is usually severe.
“The work environment will be noticeably cleaner as the production premises are free of exhaust gases,” says Dilip Chandrasekaran, Kanthal Business Development Manager. “Our customers have testified that headaches or mild nausea among their operators caused by gas burners have been eliminated thanks to the transition to electric heating elements.”
Cleaner air and quieter workplaces reduce health problems
You can easily reduce the noise level in the production environment from 100 decibels to 85 decibels, which is an enormous difference in sound level.
Reducing noise is another area where electrification excels. “Electric elements are completely silent,” says Chandrasekaran. “You can easily reduce the noise level in the production environment from 100 decibels to 85 decibels, which is an enormous difference in sound level.”
Electrification may lower workers’ exposure to excruciating heat, and phasing out gas will significantly reduce the risks of fires and explosions. Electric systems are generally more stable and provide superior control, minimizing risks from improper operation.
The future of health and safety in the steel industry
In summary, electric heating can contribute to a cleaner, safer and quieter working environment, making for a much healthier workplace for steel industry employees. This aligns with the WSA Board of Members, which strongly endorses the commitment: “Nothing is more important than the safety and health of the people who work in the steel industry.”
Three reasons why electric heating enables a safer work environment
- No toxic or harmful emissions. Unlike gas heating, electric furnaces and ladle heaters don’t introduce NOx, SOx or carbon monoxide into the workspace.
- Improved working environment. Electric heating elements are virtually silent in operation, therefore vastly improving the work environment. Additionally, due to higher efficiencies, electric furnaces also introduce five times less heat into the work environment.
- Reduced risk of explosions and fires. Removing gas, fuel and oxygen lines reduces the risk of explosion and fire. All fossil fuel heaters produce water vapor as part of the combustion process. This can condense in cold ladles and molds, increasing the risk of explosion. Uniform drying and heating reduce the risk of water vapor explosions.
