Alcoa fined $400,000 after caustic spill injures workers and students at Kwinana refinery
, , , , , , , ,
, ,
Alcoa of Australia has been fined $400,000 and ordered to pay court costs after a caustic soda spill at its Kwinana alumina refinery injured multiple workers—including school students on work experience placement.
The incident occurred in September 2022 when an uncontrolled discharge of hot caustic solution sprayed from a pipe during a failed pump changeover. The chemical splash caused burns to several people nearby.
Alcoa pleaded guilty in the Rockingham Magistrate’s Court to breaching the Work Health and Safety Act 2020 (WA), admitting it had failed to ensure, as far as reasonably practicable, the health and safety of its workers and others at the site.
The court heard that a contract worker first noticed smoke and debris coming from a pump and reported it to his shift supervisor. The supervisor, aware of the risk of explosion if pressure built up, opened a discharge valve before leaving the area to direct the work experience students to safety. While he was away, another worker—unaware the valve was still open—attempted to start the pump, triggering the spill.
The hot caustic solution sprayed from the drainpipe, making contact with a metal step and splashing onto workers and students nearby.
Emergency response teams attended the scene, providing first aid before the injured were transferred to the site’s medical centre.
WorkSafe Commissioner Sally North said it was fortunate the injuries were not more serious.
“Companies must ensure all people at a workplace, including work experience students, are kept safe,” Ms North said. “They must also have robust controls in place and ensure these controls are monitored so they continue to be effective.”
The $400,000 fine, along with the $5,536.70 in legal costs, serves as a warning to industry to uphold stringent safety protocols and reinforce communication procedures during critical tasks.
The Kwinana refinery is one of Alcoa’s major operations in Western Australia, supplying alumina to global markets.
WorkSafe WA has urged other operators to review their emergency procedures and training measures to prevent similar incidents.