Curious About Cement Industry Hazards? Share Your Insights and Experiences Here

I have been gaining a lot from the learned members of this forum. I am interested to know about the hazards related to the Cement Industry. Please share your knowledge regarding this subject.

Best Regards,
Raman

PS: Dear Mr. Dipil, you seem to be online. Please give your valuable inputs. Your inputs are really wonderful.

Regards.

Dear Mr. Raman,

First of all, sorry for being late. Yes, my status was online, but I fell asleep early yesterday. I have already raised this question on the forum earlier but did not receive any replies. You can refer to the following link: https://www.citehr.com/294160-proces...ent-plant.html. This indicates that there are not many professionals from the Cement Industry present in our forum, or they are not sharing.

Now, I would like to request you to go through the link below and download the Process Safety ppt shared with us by our forum member, Mr. Terry Penny: https://www.citehr.com/304170-safety...ml#post1393091

Hazards in Cement Plant

We can categorize it into two types:
1. Hazards arising from the process
2. Normal hazards that exist elsewhere like Electricity, Work at Height, Confined Space, Excavation, etc.

The second part, I think, we don't need to discuss here. Let's try to solve the process safety issues.

Process safety starts from Mining and ends at Packing. At each step, we need to analyze the hazards involved and take suitable preventive measures accordingly. This can be achieved by conducting an Internal Cross-Functional Safety Audit. Let's emphasize that safety is everybody's responsibility. Line Managers and Engineers should reflect on this and conduct the audit. Safety Professionals can be part of the team, but it's not necessary for them to conduct the entire audit. Let people from process and other technical departments also be part of the audit. I am confident that once this is done seriously and genuinely, almost all the Process Safety Parameters will be aligned.

I am sharing an incident that occurred in Pakistan, where an entire Pre-Heater and ESP explosion took place. This is one of the most significant process hazards in cement plants. Photos of the incident and a detailed study on explosion protection from Fike (Supplier of Fire & Explosion Prevention Products) are attached.

I also request other members to contribute what they have regarding Process Safety. If it's not from the Cement Industry, that's fine too. Please share your insights.

Thank you.

If you are able to collect something related to Process Safety in Cement Plants, please share it with me as well. Thanks in advance. Keep on sharing and keep up the pace. Do participate in the forum discussions whenever you find free time.

Regards.

Dust Suppression in Cement Plants

The biggest hazard in a cement plant is dust suppression. Most of the cement companies in India don't operate their JPFs effectively, primarily to reduce power consumption.

Regards,
Pon

Thank you for your continuous inputs into the discussions related to EHS. As of today, I do not feel that dust generation is the biggest hazard in Cement Plants. Modern cement plants like ours are installed and ensure the effective running of the following modern dust control equipment:

1. Bag House
2. Electrostatic Precipitator
3. Bag Filter

In addition to this, we are providing covered conveyor belts for the transportation of raw materials, covered sheds for additives, concrete roads for truck parking, and green belt development beyond what the laws require.

Thank you.

Regards