Table 3.

3 Description of the Main Hazards and the Corresponding Preventive Measures

Process Area
Quarrying

Specific Hazards

Drilling

- Fall from height

- Hurling of material
Movement of heavy goods vehicles
- The collapse of a floor level
- Mechanical movement of the drill

- Exposure to noise and dust

Charging and ignition
- Inappropriate use of explosives
- Fall from height

- The collapse of a floor level

- Hurling of material
- Exposure to noise and dust and vibration

- Movement of heavy goods vehicles

Storage of explosives

- Storing of explosives with triggers

- Failing to comply with the FIFO

- Insufficient security in the warehouse

area

- Insufficient maintenance of building

(electrical wiring, lighting, and

ventilation)
- Improper bordering and labelling

- Use of work and personal equipment

that create sparks or open flame

Transport of Explosives
- Use of unauthorized vehicles

- Transport of explosives together with

capsules as well as not keeping the

necessary labelling during transport

- The carrying of passengers

- Unplanned stoppage

Current Safety Measures

Job safety analysis and work permit
Implementation of operational directives
relating to the movement of
transportation of equipment and
personnel in the quarry
Existence of operational procedures for
storage and transport of explosives
during normal operations and during
unstable weather
Approved drilling and explosion plan
Use of minimum explosives
Use of approved vehicles
Check prior to working on a quarry table
for possible cracks and drops
Isolation of the charging and ignition area
Use of appropriate safety signage and
safety warning
No smoking and avoid use of naked
flames
Avoid the use of mobile or wireless
phones near explosives
Periodic checks of storage area and
maintenance of vehicles used
Implementation of FIFO (First In, First
Out) principle and stock control
Protection system of explosives from high
temperature
Good housekeeping practices
Proper training and re-training of
personnel

Crusher Area

Storage and
Material
Transport
Systems

Milling
Processes
Prehomogenizat
ion
Raw Meal
Grinding
Homogenization
Cement
Grinding

Transport during unstable weather

Loading/ Unloading
- Track movement (reversing)
- Load displacement
- Reversing into hopper
- Falling rocks during unloading
- Absence of reversing barrier
Crusher Operation
- Stacking of hopper
- Accidental start-up of crusher
- Hazards during unplanned maintenance
- Electrical hazards
- Work inside the crusher control room
Airborne dust
Conveyor moving parts
Use of unauthorized passages
Maintenance during operation
Motor overloading systems
Supervision platforms

Airborne dust in the milling area

Contact with mechanical moving part of the mill
Falling material during transport
Operators falling from height by not using
approved passageways
Maintenance/cleaning activity on operating
machinery of unauthorized personnel
Exposed to excessive noise levels due to
crushing materials inside the mill and operation

Use of adequate personal protective

equipment (PPE)

Uniformly distributed load

Worker movement segregation areas
Existence of safety signage
Implementation of approved codes of
practice
Install proper guards and barriers
Guards to isolate mechanical hazards
Maintenance by approved technicians
under supervision
Work inside the hopper only under
supervision
Concrete walls for the control room
Use of the stacker and reclaimer system
to collect dust
Implementation of dust cleaning schedule
Good housekeeping
Guarding and side guarding
Restricted entry and use of appropriate
safety signage
Use of PPEs
Use of fuel safety device (fusible link)
Use of a LOTO system during
maintenance
Use of a closed circuit surveillance
system
Use of a dust suction system (Disab)
Guarding and side-guarding
Use of proper PPEs

Preheating
Process and
Clinker
Production
Kiln Operation

of homogenization blowers
Working in confined spaces during repair of the
mill inner walls or the replacement of steel balls
Back firing of hot gases due to insufficient
respiration of the furnace
Exposure to high temperatures
Use of a safe system of work no
Contact with superheated material particles
accidental operation (LOTO procedures)

Back firing of burner

Working near hot surfaces
Working in a hot environment

Cooling System

Dusty environment
Accidental hurling of hot material
Use of a high pressure pump to clean the
area

Raw Material
and Cement
Storage Silo
Cleaning

Noise during the cleaning operation

Falling material from the silo walls
Dusty environment
Operator getting overcome by material at
the base of the silo

Packaging

Dusty environment
Falling material
Moving parts of packaging machinery
Movement of heavy trucks
Existence of third parties (truck drivers) in

Use of a closed circuit surveillance

system
Use of a safe system of work no
accidental operation (tag in/ tag out
procedures)
Use of authorised personnel
Use of a dust suction system (Disab)
Use of a safe system of work no
accidental operation (LOTO out
procedures)
Use of dust suction system
Floor preparation
Use of safety signage
Use of LOTO procedures
Use of blind flanges
Continual supervision
Provision of adequate lighting
Provision of sufficient ventilation using
bag filters
Use of a dust suction system
Use of appropriate PPEs
Training of personnel
Adequate machine guarding
Use of safety signage

Loading/
Unloading

Maintenance
Department

Fuel Storage

Use of Fuel
Alternatives

Work
Environment,
Work Areas and
Passageways

the area
Overhead loads
Use of lifting equipment
Falling of loads
Dusty environment

Use of authorized personnel

Provision of appropriate maintenance to
the lifting equipment
Use of load limiting devices
Routine cleaning of the area
Toxic fumes from welding operations
Use of a fumes suction system
Insufficient tag in/ tag out procedures during Trained personnel
Use of hoists
maintenance
Manual handling causing Musculoskeletal
Use of approved and maintained
problems High temperatures
metering devices
Electricity
RCD s 30 mA
Use of hand tools
Routine cleaning good housekeeping
Bad housekeeping
practices
Use of approved and well maintained
hand tools USE
Use of naked flames near fuel storage
Existence of a work permit system for
The creation of hot spots during
working near the fuel storage
Maintenance and control of the antimaintenance activities
The hurling of hot material in the fuel area
discharge system
Electrical discharges (Thunderbolt,
electrostatic charges during refueling , short
circuits)
Routine cleaning of the area
Use of appropriate PPEs
Biological hazards from the use of bone
meal, used rubber tyres, olive seats, RDF
and other solid waste
Absence of safety signage
Use of appropriate safety signage
Obstructions in the passageways
indicating the passageways and
emergency exits
Inadequate environmental conditions
Insufficient protection from physiochemical Good housekeeping of the area
Assessment of the environmental
factors

Use of Work
Vehicles (Fork
lifts, Loaders,
Unloaders,
Disab)
Lifting
Equipment

Insufficient training Insufficient maintenance

Inappropriate securing of the load

Speeding

Insufficient visibility

Crush of the load or the lifting mechanism

onto operatives
Fall of the load to be lifted due to the failure

of the lifting gear

Insufficient or inappropriate securing of the
load
Tilting of the load during its transportation

Crashing of the load on the building

Electrocution as a result of lifting mechanism
contacting o/h lines

conditions and provision of adequate

protection
Authorization and training of personnel
Routine maintenance of the work vehicles
Provision of work instructions
Labelling of the vehicle movement area
Use of authorized and trained personnel
Existence and compliance with work
instructions
Safe operation of the stopping
mechanism, the breaks and the lifting
lines
Check on a routine basis the hook
mechanism
Always secure the load using the
approved straps
Always avoid the lifting of loads overhead
from working operatives.

Table 3.1 Summary of the Cement Manufacturing Process

PROCESS

FEED

PRODUCT

DESCRIPTION

Quarry
(calcareous
deposits)

Limestone
and shale
rocks

Drilling, blasting, and excavating of quarries

is done. Then the limestone and shale rocks
are transferred to the crusher using a belt
conveyor.

Limestone and
shale rocks

Grounded
limestone
and shale

The limestone and shale rocks are crushed

into smaller pieces.

Grounded
limestone and
shale,
other
corrective
materials

Raw meal

The grounded raw materials are piled and a

portion of are brought by a belt conveyor
wherein other materials are added using
feed bins or a chute.

Raw meal

Pulverized
raw meal

Homogenizing Silo

Pulverized raw
meal

Homogenize
d raw meal

Preheating

Pre-heating
Cyclone Tower

Raw meal

Pre-heated
raw meal

Calcining

Rotary Kiln
(tilted at an angle
of 3o)

Pre-heated
raw meal

Hot clinker

Cooling

Grate Cooler

Hot clinker

Clinker Storage

Clinker Silo

Blending

Ball Mill

Cement
Grinding

Ball Mill

Cooled clinker
Clinker,
gypsum
Blended
Cement

Quarrying

Crushing

Prehomogeniza
tion

Raw Meal
Grinding
Raw Meal
Homogenizatio
n

EQUIPMENT
Mechanical
Loaders, Trucks,
Fork Lifts, Power
Shovels
Primary and
Secondary Roller
crushers
Pre-Blending
Stockpile
(Stacker/Reclaimer
),
Mill feed bins and
weigh feeders
Vertical Grinders,
Ball Mills

Cooled
clinker
Clinker
Blended
Cement
Portland
Cement

The raw meal enters a ball mill which

contains steel balls that pulverize it further.
Pulverized raw meal are stacked in silos for
3 days to correct the temporary fluctuation
of the meals composition.
The raw meal is pre-heated in a five-staged
cyclone tower where it is precalcined.
Raw meal is heated to around 1,500oC for
20 30 mins. where chemical reactions take
place to form cement clinker, which
contains hydraulic calcium silicates.
The hot clinker from the kiln passes through
a grate cooler where it is cooled to 70oC.
The clinker is stored in silos.
35% gypsum is added to the clinker to
regulate how cement will set.
The blended cement is refined in series of
ball mills.

Cement
Storage

Cement Silo

Portland
Cement

Portland
Cement

Cement is stored in silos and packaged in

bags for distribution.