Ensuring safe transitions with eLITHE’s comprehensive approach in ceramic furnace electrification

The introduction of high-temperature and electric heating technologies, as tested by the eLITHE project at its pilot sites, involves a set of risks that are not typically present in traditional fossil-fuel-based heating systems. These new systems bring electrical hazards, exposure to extreme heat, high pressure, and the risk of unintended start-ups during maintenance or intervention phases.

Moreover, the introduction of new technologies requires a redefinition of work practices and risk management systems to account for the specifics of operations in high-energy industrial environments. eLITHE has based its safety approach on an integrated philosophy that considers every phase of the plant and operations lifecycle. The goal is not only to protect workers from hazardous situations but also to create an environment that optimises safety without compromising operational efficiency.

The solutions studied in this project propose a comprehensive approach to worker safety. From the design of electric heating systems to daily maintenance and operation management, every phase has been examined and optimised to ensure maximum protection.

From the initial phase of the project to its implementation, operation, and maintenance, the study resulted in the following documents supporting all these phases:

• Design Safety Philosophy: designing for safety from the start 

The Design Safety Philosophy is a fundamental approach that incorporates safety from the earliest design stages of the systems. The eLITHE project has established specific guidelines for the engineering of electric heating systems, including measures to eliminate, control, and mitigate risks related to thermal and electrical hazards.

• Human Factor Engineering (HFE) Philosophy: focusing on worker well-being

The Human Factor Engineering (HFE) Philosophy emphasises the importance of designing plants that account for the physical and psychological needs of workers. This approach recognises that safety is not only about technology but also about how humans interact with systems.
In the context of the eLITHE project, HFE involves creating workspaces that are not only safe but also ergonomic and tailored to the people who work there. For example, workstations are designed to reduce physical and mental stress, improve visibility and command handling by operators, and make interactions with systems more intuitive and secure.

• Permit to Work (PTW) Procedure: managing high-risk activities:

The Permit to Work (PTW) Procedure is one of the most critical measures for managing risks in industrial environments. This procedure requires that certain high-risk activities, such as maintenance on high-voltage equipment or handling pressurized systems, be carried out only with written permission granted by an authorized person.
In the context of the eLITHE project, PTW has been strategically integrated to prevent incidents during the most hazardous operations. Any intervention on electrical systems or near thermal energy sources is regulated by this system, which ensures that personnel are properly trained and that working conditions are safe before proceeding.

• Lock-Out / Tag-Out (LOTO) Procedure: isolating risks for safety

The Lock-Out / Tag-Out (LOTO) Procedure is a vital safety measure to prevent the accidental start-up of machines or systems during maintenance. When working on electrical or high-temperature systems, all energy sources must be completely isolated to prevent fatal accidents.
In the eLITHE project, the LOTO procedure requires that all energy sources (electrical, thermal, mechanical) be deactivated, “locked,” and clearly labelled to prevent accidental reactivation. Labels or locks applied to control devices ensure that only authorised personnel can restore the system and restart the equipment, avoiding the risk of accidental start-ups that could cause physical harm or material damage.

Tomé Pintão, SGS Technical Specialist, commented on the work done: “Implementing identified health & safety requirements and conducting a thorough gap analysis is not just about compliance—it’s about fostering a safer, more resilient work environment. This work ensures that we proactively address risks, bridge critical gaps, and implement best practices that enhance both safety and operational efficiency. Overcoming key challenges, such as aligning diverse regulatory standards and driving a culture of accountability, has been instrumental in achieving a robust and sustainable safety framework for the project’s success.”

The advanced measures developed by eLITHE are not just a response to the immediate challenges of the energy transition but also a commitment to a safer and more sustainable future.

Photo credits: Smederevac on iStock