• HEALTH AND SAFETY
The anatomy of a catastrophe Once the immediate danger had passed , I escorted my team to the control room , ensuring paramedics checked them . People from nearby pot lines began gathering , trying to make sense of the chaos . I shouted to keep them back : the site wasn ’ t safe .
While the plant underwent a complete shutdown — a rare , lastresort measure in aluminium smelting — I sat down with Sizwe to unravel what had gone wrong .
The team had been conducting beam raising , a high-risk operation that involves manually raising the superstructure beams by loosening the clamps holding the large metal anode stems in place .
The team had been conducting beam raising , a high-risk operation that involves manually raising the superstructure beams by loosening the clamps holding the large metal anode stems in place . A specialised tool secures the anodes during this process , preventing them from falling into the molten aluminium bath .
But that day , things went catastrophically wrong .
As the team began the operation , one of the anodes developed an anode effect . In this phenomenon , greenhouse gases form at the base of the carbon anode , disrupting the electrical flow . The gas bubble expanded , creating energy surges and causing the molten aluminium bath to move unpredictably .
Operators tried to dislodge the gas bubble with bamboo poles — a standard response — but it only worsened . Sparks flew from the superstructure as the electrical instability deepened . To make matters worse , one of the anodes wasn ’ t adequately secured to the unique tool , causing it to drop further into the bath .
The final warning This was when Sizwe first radioed me . His voice sounded calm , almost routine . “ Previn , can you come to Pot Room B , please ?” “ Sure ,” I radioed back , setting off on a brisk walk . Seconds later , his voice crackled through again , tinged with urgency . “ Previn . Come quickly . I think we ’ ve got a problem here .” I broke into a jog , my pulse quickening . Then came the crescendo . “ It ’ s out of control ! It ’ s out of control ! Help ! We can ’ t … it ’ s too bad … we can ’ t —” His transmission cut out , replaced by static .
The explosion By the time I reached the pot room , the scene was chaos . The cell was in a completely open circuit , the current spiking uncontrollably . Several anodes had dropped into the bath , triggering a chain reaction . The ground shook beneath me . The walls crackled with energy , vibrating as if alive .
And then the world erupted . The aftermath As the smoke cleared , I saw what was left of the cell : a crater of destruction . The 75-tonne structure was half-sunken into the basement , its remains smouldering . The floor was shattered , and debris was scattered everywhere .
My team stood outside , shaken but unharmed . The Emergency Response Team was on-site , with paramedics performing quick checks on everyone . In the control room , senior leaders huddled to assess the situation .
A shutdown in aluminium smelting is a last resort ; prolonged power loss risks the entire plant freezing , potentially costing billions . But in that moment , production didn ’ t matter . People did .
Lessons forged in fire That day changed how I saw leadership . I realised that no procedure or protocol can fully prepare you for the reality of a crisis . It ’ s in those moments that your true priorities emerge :
• Safety is a culture , not a checklist : Protocols are only as effective as the culture that upholds them .
• When in doubt , stop : “ Nearly safe ” is NOT safe . Full stop .
• Leadership requires presence : In a crisis , being there — visible and calm — can make all the difference .
• The team comes first : No machine or process is worth more than the people who run it .
A legacy of resilience Reflecting on that day , I don ’ t think about the destruction . I think about Sizwe , the team , and our choices that saved lives .
Leadership isn ’ t about titles or strategies . It ’ s about showing up when it matters most . It ’ s about standing in the fire , making the hard calls , and walking out with integrity and people intact . •
But in that moment , production didn ’ t matter . People did .
Introducing Previn Pillay : Pillay , FAusIMM TFIEAust CEngT NER IntET ( Aus ), is a visionary leader and seasoned operational strategist with over two decades of experience transforming industrial operations across mining , natural resources and manufacturing sectors . As the founder and CEO of Pyromin Consulting , Pillay specialises in driving operational excellence , optimising processes , and
Previn Pillay , founder of Pyromin Consulting .
delivering million-dollar savings to businesses worldwide . A Fellow of Engineers Australia and AUSIMM , he combines deep technical expertise with a commitment to sustainable , innovative solutions that leave a lasting impact . Pillay ’ s passion lies in empowering organisations to thrive in complex environments while harmonising profitability with purpose .
30 • African Mining • February 2025 www . africanmining . co . za