Safer chemical plants, lower cost: The case for private 5G

Earlier this year, the US Chemical Safety and Hazard Investigation Board (CSB) investigated 36 deaths in on-the-job chemical accidents over 11 months — the largest number of fatalities the agency has ever examined in a comparable time period.

The number of industrial accidents resulting in chemical releases logged in US federal reporting rose from 83 in 2021 to 131 in 2025, with incidents involving injury or death climbing from 60 to 89 during the same period. Meanwhile, just one compilation of CSB incident reports accounted for $1.8 billion in property damage across 30 incidents between April 2020 and January 2025.

These numbers are particularly concerning at a time when manufacturers are under pressure to improve safety while spending less.

But those goals don’t have to conflict. Better connectivity can improve safety while reducing operating costs, making it a very practical investment for manufacturers.

Private connectivity in manufacturing is growing

Many manufacturers are already moving in this direction.

An SNS Telecom & IT deployment tracker counted more than 9,300 private cellular network engagements in 130 countries by the second quarter of 2026 — including more than 4,600 private 5G installations. And global spending on private 5G and 4G LTE network infrastructure for vertical industries is expected to grow at a compound annual growth rate of about 18% between 2026 and 2029, with more than 80% of those investments earmarked for standalone private 5G networks.

For chemical plants, that investment is especially urgent because connectivity problems are harder to solve — and the risks of getting them wrong are much higher.

5 core connectivity problems in chemical plants

Chemical plants make conventional wireless difficult and expensive, but the consequences of poor coverage can be severe. Connectivity in these environments requires solving problems that don’t exist in a regular office.

1. Wi-Fi is expensive and difficult to deploy in hazardous areas

In hazardous areas, Wi-Fi access points need expensive explosion-proof enclosures. And because steel tanks, columns and pipes block and reflect wireless signals, many more access points may be needed for reliable coverage. The result is a network that is costly and hard to maintain.

Private 5G can cover large industrial areas with fewer radios than Wi-Fi typically needs, helping reduce the amount of equipment required in hazardous zones.

2. Poor connectivity puts workers at risk

Workers in hazardous areas require more than basic voice communications. They also need reliable access to safety alerts, location tracking, gas readings, work permits, technical information and remote experts. Traditional radio provides voice but little else.

Industrial 5G brings these capabilities together on rugged devices designed for hazardous environments.

3. Every hour counts during a turnaround

A plant turnaround — a planned shutdown for major maintenance, inspection, repairs and upgrades — can consume 60%–80% of the annual maintenance budget in just three to six weeks, and about 30% of turnarounds run longer than planned. Every extra day can cost a midsized plant between $500,000 and $2 million in lost production. With thousands of contractors coming on-site, a dependable connection is essential for everything from access and work permits to confined-space tracking and remote expert support.

Private 5G provides reliable access to the systems, permits and expert support needed to keep work moving.

4. Emissions monitoring is becoming continuous

Chemical plants are increasingly moving from periodic inspections to continuous emissions monitoring as regulations change. That means using sensors, cameras and drones to detect and document leaks as they happen rather than waiting for the next scheduled inspection. These technologies need reliable connectivity, often in parts of the plant where installing cables is difficult or impractical.

By connecting devices across hard-to-reach areas, private 5G makes continuous monitoring easier to deploy and manage.

5. New technology cannot compromise critical plant systems

The systems that control plant operations and protect workers must remain secure and isolated. Any new use of mobile devices, video or AI therefore has to demonstrate that it will not interfere with these critical systems. Conventional enterprise wireless networks struggle to provide the level of separation and control that this requires.

With private 5G, plants have a dedicated, controlled network that can support new digital tools without putting critical systems at risk.

The business case for better connectivity

In a chemical plant, the value of better connectivity comes down to three things: keeping planned shutdowns on schedule, reducing the manual work required for compliance, and preventing costly incidents.

In an incident reported by the CSB, for example, about 8,000 pounds of toxic chlorine gas were released, causing $23 million in property damage. Against losses on that scale, the cost of a plant-wide private 5G network can look very different.

How to build connectivity for the plant floor

The same network that connects workers can also support safer maintenance, continuous emissions monitoring and AI. So, treat wireless connectivity as part of the plant’s critical infrastructure, not an office network extended into production.

Design it from the outset for the safety, reliability and regulatory demands of a chemical plant. Three initiatives put this approach into practice.

1. Connect workers with private 5G

• The approach: Use private 5G to provide reliable coverage across production areas, tank farms, loading areas and yards. Workers can use a single, safety-certified device for voice communications, emergency alerts, location tracking, live gas readings and video calls with remote experts.
• Why it works: Private 5G can cover large industrial areas with fewer radios than Wi-Fi would typically require, reducing the need for expensive, explosion-proof equipment. SIM-based authentication lets the plant control which devices can access the network, while coverage can be designed around the plant’s needs.
• The value: Workers can get help faster in an emergency, and the plant can reduce the number of devices and networks it has to manage. Documented network coverage also makes it easier to demonstrate that safety and connectivity requirements are being met.

2. Use edge AI to detect problems earlier

• The approach: Combine private 5G with edge computing and edge AI at the plant to analyze data from gas-detection cameras, equipment sensors and other monitoring systems. AI can identify leaks, spot signs of equipment failure, monitor the use of protective equipment and detect people entering restricted areas.
• Why it works: Video and sensor data can be analyzed on-site rather than being sent to the cloud first. Sensitive plant data stays within the facility; only the necessary information is shared with other systems.
• The value: Earlier detection of leaks and equipment problems can prevent costly incidents, while continuous monitoring can reduce manual inspections and provide evidence for auditing and compliance.

3. Keep planned shutdowns on schedule

• The approach: Make connectivity part of the turnaround plan from the outset. Give contractors secure network access when they arrive and remove it when they leave. Use the network for digital work permits, confined-space tracking, live progress updates and video access to remote experts.
• Why it works: Supervisors can see how work is progressing, workers can access the information and expertise they need on-site, and contractors can be connected without creating permanent accounts or compromising network security.
• The value: Better visibility and coordination help keep work moving on schedule.

Our solutions work in real industrial conditions

We deploy and manage private 5G in complex industrial environments, including continuous-process manufacturing. And because we manage the network as a service, plant teams can focus on operations rather than becoming network experts.

Proven in the chemical industry

Celanese, the global specialty materials and chemicals group, deployed our fully managed private 5G at two of their facilities in Texas to address gaps in coverage, interference and unreliable connectivity. The network gives frontline teams reliable access to the tools and information they need, which helps improve safety, efficiency and responsiveness.

Proven at scale

Global food, agricultural and industrial company Cargill has deployed our private 5G at 50 manufacturing and processing sites worldwide to connect workers and support technologies such as robotics. At their Amsterdam facility, for example, the network connects an AI-powered robot named Spot the Dog to carry out visual inspections and check for hazards such as overheating equipment in areas that may be unsafe for people.

One partner from design to operation

Every chemical plant is different, and no single technology combination will work everywhere.

As a system integrator, we’re not tied to one network vendor. We work with providers Celona and Nokia to design private 5G around each plant’s needs, while our partnerships with Ericsson and Palo Alto Networks bring together private 5G, edge AI and security.

We can integrate and secure the network, edge infrastructure and AI, and manage it 24x7 through a managed service, giving plant teams one partner across the technology stack.

We’ve been building this capability for years. NTT DATA introduced the world’s first enterprise Private 5G platform, and we were named a Leader in the 2026 Gartner® Magic Quadrant™ for 4G and 5G Private Mobile Network Services, based on Gartner’s evaluation of our “Completeness of Vision” and “Ability to Execute”.

But the technology is ultimately a means to an end. Chemical manufacturers need to make their plants safer while controlling costs. The right connectivity gives workers, sensors, machines and AI the reliable foundation they need to do both.

What to do next

Learn more about NTT DATA’s Private 5G services and experience the power of your own 5G network with greater speed, control, security and reliable coverage.