Hazards and Control Measures in Iron and Steel Industry in India

Hazards and Control Measures in Steel Industry  

The steel industry is vital to the modern world, with strong linkages to material flows and income generation, contributing about 2% of India's GDP and employing approximately 25 lakh people .

India has grown from a 1 million tonne capacity at independence to become the 2nd largest crude steel producer and the largest sponge iron producer globally .

The Indian steel industry is classified into Integrated Steel Producers (ISP), accounting for around 55% of finished steel production, and Mini Steel Plant/ Processing Units, making up about 45% .

Four main legislations cover Occupational Safety & Working Conditions Management: The Factories Act, 1948, The Mines Act, 1952, The Dock Workers Act, 1986, and The Building & Other Construction Workers Act, 1996 .

Other related legislations address specific substances, machinery, and environmental issues, applicable across all sectors . 

Here’s a stepwise flow diagram for the Iron and Steel Manufacturing Process:

1. Raw Material Processing

Iron Ore, Coal, and Limestone are mined and transported to the steel plant.

Coke Making: Coal is heated in the absence of air to produce coke.

Machines Involved:

Excavators & Loaders – Used in mining iron ore, coal, and limestone.

Crushers & Grinders – Crush raw materials into smaller pieces.

Conveyor Belts – Transport raw materials within the plant.

2. Iron Making (Blast Furnace)

Iron ore, coke, and limestone are fed into a blast furnace.

Hot air is blasted to create a chemical reaction, producing molten iron (also called hot metal or pig iron).

Machines Involved:

Blast Furnace – A large furnace where iron ore is converted into molten iron.

Hot Air Blowers – Supply heated air to the blast furnace.

Slag Granulation System – Separates slag from molten iron. 

3. Steel Making (Basic Oxygen Furnace or Electric Arc Furnace)

BOF Method: Oxygen is blown into the molten iron, removing impurities and converting it into steel.

EAF Method: Scrap steel and direct reduced iron (DRI) are melted using electric arcs.

Machines Involved:

Basic Oxygen Furnace (BOF) – Converts molten iron into steel by blowing oxygen.

Electric Arc Furnace (EAF) – Uses electric arcs to melt scrap steel.

Ladle Refining Furnace (LRF) – Helps in secondary refining of steel.

4. Continuous Casting

The liquid steel is cast into semi-finished shapes like slabs, billets, or blooms.

Machines Involved:

Continuous Casting Machine (CCM) – Converts liquid steel into semi-finished shapes like slabs, billets, and blooms.

Cooling Systems – Rapidly cools and solidifies the cast steel.

5. Rolling and Finishing

The semi-finished steel is heated and passed through rolling mills to produce sheets, rods, bars, or coils.

Surface treatment (galvanizing, coating, etc.) is done as per requirement.

Machines Involved:

Hot Rolling Mill – Shapes and reduces steel thickness at high temperatures.

Cold Rolling Mill – Produces thinner and stronger steel sheets.

Galvanizing & Coating Machines – Adds protective coatings to steel.

6. Quality Control & Dispatch

Steel products undergo testing and quality checks before being sent for use in construction, automotive, and other industries.

Machines Involved:

Ultrasonic Testing Machines – Detect defects in steel products.

Spectrometers & Chemical Analyzers – Ensure chemical composition is correct.

Automated Packing Systems – Prepare finished steel for shipment. 

The key hazards identified in the steel industry include:

1. Toxic Gases: Presence of gases rich in carbon monoxide and other harmful substances throughout the plant.
2. Explosive Gases: Accumulation of gases rich in hydrogen and methane poses risks of explosions.
3. Liquid Metal and Slag: Risks of burns and explosions associated with handling liquid metal in processes like blast furnace and continuous casting.
4. Extreme Temperatures: Operations involving high temperatures, from -180°C to 1700°C, in various plant areas such as coke ovens and rolling mills.
5. Fire Hazards: Flammable materials and processes can lead to fires across the plant.
6. Electrical Hazards: Risks of electric shock, electrocution, and flashover can occur throughout the industry.
7. Transportation Hazards: Movement of vehicles and equipment can cause accidents in plant and project sites.
8. Hazards from Moving/Rotating Machinery: Workers may face risks of being caught, pressed, or hit by machinery.
9. Working at Heights: Activities performed above ground level can lead to falls and serious injuries.
10. Physical Hazards: Exposure to noise, vibration, heat, and dust can impact worker health and safety.
11. Confined Spaces: Entry into areas like tanks and pits requires special precautions to prevent suffocation or gas poisoning.
12. High-Pressure Systems: Hazards associated with high-pressure steam, water, and industrial gases are prevalent throughout the industry.

Control measures in the iron and steel industry, based on the identified hazards, include:

1. Toxic and Explosive Gases:

• Implement regular monitoring and detection systems for toxic gases like carbon monoxide and explosive gases.
• Ensure proper ventilation in areas where such gases may accumulate .

2. Handling of Liquid Metals and Slag:

• Use appropriate protective gear, including heat-resistant clothing, and implement safe handling procedures.
• Install safety barriers and automated systems to minimize manual handling .

3. Extreme Temperatures:

• Provide appropriate personal protective equipment (PPE) to workers exposed to high temperatures.
• Implement thermal insulation and cooling systems in areas where extreme temperatures are prevalent .

4. Fire Hazards:

• Store flammable materials safely and implement fire suppression systems (e.g., sprinklers, extinguishers).
• Conduct regular fire drills and train workers on emergency response procedures .

5. Electrical Hazards:

• Ensure all electrical installations are performed by qualified personnel and subject to regular inspection.
• Use lockout/tagout procedures to control hazardous energy before maintenance of electrical systems .

6. Transportation Hazards:

• Establish clear traffic management plans to separate vehicular movement from pedestrian areas.
• Implement speed limits and ensure visibility by using reflective clothing and signage .

7. Safety Around Moving Machinery:

• Install guards and safety devices on all machines to prevent access to moving parts.
• Provide training on machine safety and implement lockout/tagout procedures during maintenance .

8. Working at Heights:

• Use proper fall protection equipment (e.g., harnesses, guardrails) when working at heights.
• Conduct training on safe practices for working at heights .

9. Physical Hazards (Noise, Vibration, Dust):

• Implement engineering controls such as sound dampening and vibration isolation.
• Provide hearing protection and ensure proper ventilation to reduce dust exposure .

10. Confined Spaces:

• Develop specific entry protocols for confined spaces, including atmospheric testing before entry.
• Train personnel in confined space entry procedures and emergency rescues .

11. High-Pressure Systems:

• Regularly inspect and maintain high-pressure equipment and use pressure relief valves.
• Train workers on the safe operation and handling of high-pressure systems .

Reference : 

Google.com

Ministry of Steel Website