Allgemeine Industrie
From pharmaceuticals to mining and steel, across general industry there are a plethora of risks from hazardous gases that pose a danger to life, and property. As experts in gas detection for many years, there isn’t an industry we haven’t worked with to enhance safety and mitigate risk from gas and fire hazards. Whether you’re manufacturing chemicals or working in sinter plants, we can help keep you and your people safe.
Gas hazards around general industry
Whether it is the risk of oxygen displacement from methane or nitrogen leaks, or mitigating fire and explosion hazards around combustible chemicals, there are a vast array of gas and flame hazards to be mindful of across general industry. Thankfully, with careful monitoring and safety protocols in place, these workplaces can be made safe and the risk of harm minimised. Here, we look at four industries in more detail to outline the specific risks, and how they can be managed.
Mining is a notoriously hazardous industry, with risk of exposure to carbon monoxide (CO) and methane (CH4) gases and oxygen deficiency costing countless lives over the centuries.
Methane that has been trapped within coal seams is released directly during the process of coal extraction, and this is then distributed into the air supply of the mine. Colourless and odourless, methane is highly flammable, so without warning of its presence, workers are exposed to risk of fire and explosion, as well as asphyxiation.
Similarly, carbon monoxide is a common risk during the oxidation process of coal and wood pits. Equally undetectable to human senses, carbon monoxide causes poisoning in those exposed, resulting in dizziness, weakness, upset stomach, vomiting, headaches, chest pain, and confusion. At high concentrations, CO can cause individuals to lose consciousness or worse, cause fatalities.
These risks have meant that crude methods of gas testing have been in place for centuries, with use of singing canaries and methane wick wall testing to alert for dangerous gases. Thankfully, today we have far more effective methods for testing, with fixed and portable gas detectors for monitoring air quality, keeping your workers – and canaries – safe from harm.
APPLICATIONS
Gold mining operations often involve the use of toxic chemicals like cyanide, as well as processes that release dangerous gases, such as sulphur dioxide (SO2) during the roasting or smelting of ore. Monitoring for these toxic vapours and gases during ore processing is crucial, as well as for the presence of flammable gases like methane (CH4) to prevent explosions.
This involves excavating large ‘rooms’ of ore while leaving behind pillars for structural support; a method commonly used for coal, but can also apply to other materials like gypsum or salt. The confined spaces this naturally entails makes oxygen monitoring vital, as well as detecting methane levels which pose a flammability risk. Carbon monoxide (CO), and hydrogen sulphide (H2S) are also often byproducts of the mining process and can cause asphyxiation, making monitoring and proper ventilation of the utmost importance.
In both these applications, gas emissions in backfilled areas and where large sections of (often coal) seams are cut, optimising ventilation and preventing toxic gas buildup (such as carbon monoxide) in confined spaces is essential. However early fire detection is also important, as mining equipment generates heat and in combination with methane or coal dust, can create a significant combustion hazard.
The release of toxic gases from blasting and caving such as methane, nitrogen dioxide (NO2) and hydrogen sulphide pose significant risks, making detection of these gases and monitoring of air quality important. Ensuring these detectors are also dust resistant is crucial, as many detectors can be impaired by high-dust environments.
As large volumes of ore collapse, gas trapped in fractures or pockets may be released. Gas detection systems monitor for methane, CO2, and other harmful gases that might escape as ore is extracted. Similar to sub-level caving, block caving releases a significant amount of dust and particulate matter, which can obscure visibility and affect air quality. Ensure your gas detectors can function well even in dust-laden environments.
The gases found within the chemical industry are wide ranging, due to the prevalence of organic and inorganic hazardous materials with low flashpoints, low LELs (the lowest concentration of a gas or vapour in the air that will burn with an ignition source) and a wide explosive range. Although the products and byproducts from the industry are vital to countless industries globally, they can be some of the most dangerous to work directly with, making effective and reliable gas detection systems non-negotiable.
The chemical industry presents several gas hazards, including the release of toxic, flammable, and reactive gases during production, storage, and transport. Common risks involve exposure to gases like ammonia, chlorine, and hydrogen sulphide, which can be harmful or deadly in high concentrations. Leaks and accidental releases pose explosion risks, particularly with flammable gases, however the maintenance of chemical sites pose additional risk, with hot work and confined spaces adding another layer to the risks.
Maintenance and repair of spaces and facilities in the chemical industry can require use of soldering equipment in areas at high risk of combustion, while confined spaces with poor ventilation like silos, columns and tanks require regular cleaning. Hot work permits, pre entry checks, effective gas detection, monitoring, and safety protocols are critical to protecting workers from these dangers and ensuring a safe operating environment.
APPLICATIONS
Chemicals like chlorine (Cl2), ammonia (NH3), sulphur dioxide (SO2), and hydrogen sulphide (H2S) are common in production processes, while flammable gases like methane (CH4), hydrogen (H2), acetylene (C2H2), and volatile organic compounds (VOCs) can leak during production. Leaks can also occur in chemical reactors and pipelines, making gas detection throughout the production process of the utmost importance, to safeguard against gaseous and fire related hazards.
Gases or volatile chemicals stored in containers, tanks, or silos can pose significant risks if not properly monitored. Gas detection in chemical storage facilities is essential to identify any potential leaks, monitor oxygen levels, and keep an eye on any possible chemical reactions occurring.
During the transportation and distribution of chemicals, leaks and spills can occur, especially when transferring gases or volatile liquids between containers. Gas detection plays a vital role in ensuring the safe handling of chemicals during distribution, particularly at hazardous moments such as loading and unloading where leaks of toxic or flammable gases at connection points and valves is most likely.
Chemical processes often produce gaseous byproducts that may be hazardous, toxic, or flammable. Gas detection tracks hazardous byproducts such as sulphur oxides (SOx) and VOCs, ensuring safe capture, treatment, and compliance with environmental regulations.
The varied range of applications and processes within the steel sector create a variety of potentially dangerous levels of gases, including sulphur dioxide, carbon monoxide, carbon dioxide, hydrogen, nitrogen and oxygen depletion.
With the release and presence of so many hazardous gases, alongside the dust and hot working conditions the steel sector is rife with gas related hazards, specifically in furnace areas, pits, and underground walkways.
Gas detection equipment should be implemented to keep teams safe and aware of the dangers as they arise and fluctuate. Accurate monitoring can also help avoid detector contamination, false alarms, and reduce downtime, while ensuring compliance with the required occupational exposure limits.
The grinding of metals and non-ferrous metals in steel production produces grainy ferrous dust, which can cause issues for certain gas detectors, preventing gases reaching the detector and skewing readings. Removable filters that are able to be cleaned and replaced will ensure that the gas has a clear path to the sensor.
APPLICATIONS
Sinter plants process fine iron ores by heating them to create larger particles or “sinter,” which can be used in blast furnaces. Gas detection is vital in these operations due to the gases generated during the sintering process, such as carbon monoxide (CO), sulphur dioxide (SO2), and nitrogen oxides (NOx).
Blast furnaces are used to convert iron ore into molten iron using high temperatures and reducing gases. These operations involve hazardous gases, making gas detection critica to prevent poisoning and explosions, and ensures safe reuse of blast furnace gases.
Coke plants produce coke from coal by heating it in the absence of air, a process known as pyrolysis, and this is essential for the blast furnace process. The toxic and flammable gases generated, such as methane, hydrogen, benzene, and sulphur compounds (e.g., H2S), require careful monitoring to prevent toxic exposure and fires.
Casting involves pouring molten metal into moulds to form steel products, and during this process harmful fumes such as carbon monoxide and carbon dioxide can be released, alongside other hazardous particles. Therefore the careful monitoring of air quality is vital for safeguarding workers’ health.
Iron production involves the extraction and processing of iron ore into molten iron, which is then used to produce steel. Gas detection is crucial to managing the risks associated with the release of dangerous gases, such as the detection of CO, SO2, NOx, and hydrogen sulphide (H2S) during iron ore processing to protect workers and meet environmental regulations.
From health supplements to breakthrough treatments for chronic and acute illnesses, the pharmaceutical industry develops and manufactures a wide range of products, and calls upon an extensive network of suppliers and distribution companies to do so, and each stage of the industry comes with its own hazards.
Pharmaceutical manufacturing involves multiple hazardous unit operations, from synthesis of active pharmaceutical ingredients (APIs) to processing operations such as milling, blending, granulation and drying. Solvents and APIs used in pharmaceutical production are generally highly toxic, and prolonged exposure to some APIs may cause chronic health effects, or even death. They also pose a risk of fire and explosion, as exposure to flammable chemicals and solvents is one of the commonest hazards in pharmaceutical manufacture, and the storage of combustible solids and flammable liquids also generates fire hazards.
Nitrogen is also often used on pharmaceutical sites, and when liquid nitrogen leaks, it will quickly expand and displace oxygen in the surrounding area, which in a confined space can be fatal. Because nitrogen is an inert gas, detection of oxygen deficiency is a better indication of risk than the detection of nitrogen alone.
APPLICATIONS
Gas detection systems are crucial in the pharmaceutical industry to ensure safe handling, storage, research, and production of chemicals. Key applications include:
Many pharmaceutical chemicals are stored in gas or liquid form in pressurised containers. Gas detection systems monitor for leaks of toxic or flammable gases, such as ammonia (NH3), chlorine (Cl2), and solvents like acetone or ethanol, which can pose fire and health risks. Gas detection also plays a vital role in keeping track of the release of VOCs, and compliance with environmental regulations.
In pharmaceutical research and development, laboratories handle a wide variety of chemicals in controlled environments. Cleanrooms must maintain strict air quality standards to prevent contamination, making gas detection essential. Equally, research often involves experimenting with potentially hazardous gases or volatile chemicals, making the proper ventilation and maintenance of air quality vital for workers’ wellbeing.
Cleaning is a critical part of pharmaceutical manufacturing and research to maintain sterile conditions and prevent contamination. Many of the cleaning agents release gases that require careful monitoring, such as peracetic acid (PAA) and hydrogen peroxide, which are commonly used in the pharmaceutical industry for cleaning equipment and surfaces. Tracking air quality is especially important in confined or enclosed spaces where cleaning products need to be used.
Casting involves pouring molten metal into moulds to form steel products, and during this process harmful fumes such as carbon monoxide and carbon dioxide can be released, alongside other hazardous particles. Therefore the careful monitoring of air quality is vital for safeguarding workers’ health.
In large-scale pharmaceutical manufacturing, processes often involve the handling of chemicals, solvents, and gases that can pose risks if not properly controlled. Gas detection systems are essential for monitoring solvent vapours, CO2 build up, ammonia, and VOCs to prevent toxic exposure, fire risks, and ensure environmental compliance.
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