Safety Training Conference for Zinc-Aluminum Alloy Casting Enterprises

Industry-specific standards such as "Safety Technical Requirements for Aluminum and Zinc Alloy Die Casting Production" (JB/T 11735—2014), dust emission limits (PM10 ≤ 30mg/m³, PM2.5 ≤ 10mg/m³), and "Dust Explosion Prevention Safety Regulations" (GB 15577-2018) have established a clear system of responsibilities for all positions, from the safety director to frontline employees.This framework ensures the proper functioning of the safety production committee.

Zinc and aluminum involve high-temperature and high-pressure processes,so the following standardized operating procedures must be followed during production:

Melting process:Regular inspections of the furnace integrity,preheating of materials to ≥200°C, and implementation of leak and explosion prevention measures;the safe operating distance should be ≥2 meters.

Pouring process:Protection against metal liquid splashes at 1500°C (using 1.8-meter steel barriers and aluminum foil insulation suits)preheating of the mold to ≥200°C and control of the sand mold moisture content to ≤3% to prevent explosions.

Mechanical and Electrical Safety:Interlocking protection devices for die-casting machines(photoelectric sensors+dual-hand operation buttons),Sensitivity testing of emergency stop buttons(response time≤1 second);Monthly inspections of lifting equipment,as well as testing of electrical system grounding and insulation measures;Strengthening the approval process for hot work operations such as welding.

Prevention and Control of Risks from Dust, Toxic Substances, and Chemicals:The explosion limit for aluminum-zinc dust is only 40 g/m³. When mixed with VOCs (such as xylene and acetone) emitted by release agents, the ignition energy can be reduced to one-third of its original level.

Source control:The illegal storage of chemicals is mandatory to implement "dust-chemical physical isolation" - the distance between the polishing area (dust production point) and the mold release agent storage area is ≥ 10 meters and the explosion-proof closed storage tank is used to store chemicals.It is strictly forbidden to stack  cleaning agents,lubricants and other combustibles in the area covered by the dust  removal system;

Process Governance: The“wet operation + VOCs co-treatment”process is adopted to remove both metal dust and organic volatiles,preventing their mixture and accumulation.A strict dust cleaning system is implemented on a shift basis to eliminate potential hazards such as excessive dust accumulation at the FAW Casting plant in Chengdu.

Specialized Emergency Response Plans:

Aluminum liquid leakage/explosion:Immediate shutdown,use of fire-extinguishing sand (water prohibited); practical drills for evacuation routes;

First aid for burns:Five-step treatment method(“Rinse, Remove, Soak, Cover, Transport”); requirements for the configuration of specialized first aid kits;

Emergency response to combined disasters:New specialized plan for “dust-chemical explosion” incidents;lessons learned from failures in fire protection systems have led to the mandatory installation of spark detection and automatic explosion suppression systems (e.g., Pt/Pd catalytic oxidation devices used in German zinc alloy plants). The procedure is to “first cut off the dust removal system, then use inert gases

to extinguish the fire”;direct use of water to extinguish metal dust fires is prohibited.

Practical training:

Proper use of Personal Protective Equipment (PPE): Guidelines for wearing heat-resistant gloves,protective face masks and flame-retardant work clothes,as well as criteria for determining when PPE is damaged;VR simulations of high-risk scenarios (mechanical entanglements,dust-chemical mixtures exploding,aluminum liquid splashes)to enhance risk identification skills;Increased cross-company collaborative drills to ensure the effective implementation of emergency response plans

The aim is to minimize the impact of unsafe behaviors and physical hazards in production,eliminate potential safety risks and ensure the long-term safety and health of personnel.This includes protecting employees from occupational diseases and enhancing their sense of security.By establishing a standardized system,safety management can be integrated with environmental protection requirements.Accident rates can be reduced by targeting risks such as heat burns and mechanical injuries;for instance,implementing measures like”control of ignition sources and isolation of combustibles”is expected to reduce dust-chemical accidents by more than 90%.This approach also reduces economic losses and the hidden costs associated with safety investments.It enhances a company’s core competitiveness,builds a reputation as a compliant entity and increases trust from customers and industry partners.Additionally,it strengthens team collaboration by fostering a culture where everyone emphasizes safety,thereby improving the efficiency of emergency response across different roles.