Case Study: Controlling Heat Hazards from Heaters in a Plastic Extrusion Plant

Problem and Impact

1. Environment:
   • Plastic extrusion machines use electric power, causing heaters to reach temperatures of about 190-230°C
   • Machines are located in a room with an area of approximately 200 sq.m.
   • Room temperature exceeds 39°C
2. Safety:
   • Potential danger from employees touching heater surfaces while working near the machines

Causes

1. Heaters:
   • Surface area of about 10 sq.m.
   • No insulation cover
2. Building design:
   • Heat ventilation system not included in the original design
   • No circulation of outside air to replace indoor air

Improvements

1. Install removable heat insulation:
   • Capable of withstanding continuous heat of at least 500°C
   • Installed on the entire heater surface area
   • Chose removable type for convenient periodic maintenance
2. Consider installing localized cooling systems:
   • For employees working in the area

Results of Improvements

1. Temperature:
   • Heater surface temperature reduced to about 40-45°C
   • Room temperature decreased by approximately 2-3°C
2. Energy:
   • Electricity costs decreased by about 20-22% per month
3. Safety:
   • Employees no longer worried about accidents from touching heaters

Lessons Learned

• Managing heat at the source (heaters) can effectively solve problems in both energy savings and safety
• Using removable insulation is a good option for equipment requiring regular maintenance
• Solving heat-related problems can positively impact the work environment, employee health and safety, and energy savings

Additional Recommendations

• Consider improving the room’s ventilation system to further reduce overall temperature
• Develop a regular maintenance plan for heat insulation to maintain long-term efficiency
• Train employees on safety practices when working with high-temperature equipment and proper use of removable insulation
• Study the feasibility of utilizing lost heat in other factory processes
• Consider using automatic temperature control technology to increase energy efficiency of heaters.