INTRODUCTION TO THE MODULE

Scope of the module

This training Module aims to present the main hazards that are embedded in the Cement production processes as well as the risk assessment including the management of the corresponding risk.

The basic principles and the risk assessment methodology are described in training module M00, within which the risk assessment form used in this module is provided.

For every production process a representative Risk Assessment Table has been prepared, while for all the supporting processes there is a description of the hazards as well as an indicative Check List for managing the identified hazards.

Purpose of the training module

The goal of the module is for the participants to have by the end of the course to have:

• basic realisation of all the main hazards in the cement industry.
• basic knowledge and experience of the ways in which accidents can be prevented
  
• basic knowledge for managing risk
  
  

Classification of hazard in the cement industry

In all the cement production processes there are hazards that can be classed in:

• Routine and general hazards such as:
  
  • Safe behaviour
    
  • Environment, work and passage areas
    
  • Work equipment
    
  • Safety labelling
    
  • Personal Protective Equipment (PPE)
    
  • Manual load handling
    
• Special hazards during the cement production phases such as:
  
  • Quarrying
    
  • Crushing
    
  • Clinker production
    
  • Milling processes at raw mill, cement milling and coal milling
    
  • Material transport
    
  • Filtering
    
  • Storage
    
  • Loading and delivery of final products
    
  • Fuel storage activities
    
  • Use of hazardous material
    
  • Generating units
    
• Special hazards as a result of the work environment:
  
  • Dust
    
  • Noise
  • Fire
    
  • Emergency response
    
    

Cement manufacture process flow

The following diagram shows the process flow of a typical cement factory