3.

Matola Cement Manufacturing EHS Characterization

3.1. Facility Description and Practices

The present report is related to identifying hazards and environmental issues

associated with the operations of the Cement Factory of Matola, located in the
city of Matola, Maputo Province, Mozambique. The work has been done in the
context of the WAHSA project implementation Phase I.

The Cement Factory of Matola is part of a group of the three factories for the
production of Cement, belonging to the group CIMPOR -- Cimentos de Portugal.
The facility activities started in 1920 with a wet production line and an installed
production capacity of 45 thousand tons of cement per year. The other two units
are the factory of Dondo, in Sofala Province, and the factory of Nacala, in the
Nampula Province.

Since then, the Factory of Matola has undergone transformations in order to

achieve an annual production of about 262,200 tons in 1973. With the evolution
of technology, it has passed through a rehabilitation programme in order to work
with a new dry process line of production. With the modernization and installation
of new equipment, the factory of Matola can produce annually 640,000 tons of
clinker and 800,000 tons of cement. However, according to information from the
factory, this capacity has not been achieved yet mainly due to frequent stops of
machinery and interruptions for maintenance.

The cement facility is located amidst other industrial enterprises including the
Industrial Company of Matola (CIM), Grain Silos and Terminal of Matola
(STEMA), PETROMOC reservoirs of hydrocarbons, the coal terminal,
Matola, silos of alumina (Terminal of MOZAL), and the General Chemistry
facility (Paralysed). Close by are housing and small economic infrastructures.

The surrounding industrial companies are unanimous in saying that the dust
stemming from the cement facility accumulates in huge quantities in their sites,
forcing them to make constant cleansing and shortening the life expectancy of
their equipment and refrigeration appliances.

On the local communities, the effect of dust is most noticeable in the Saline
quarter and in quarter 17. Depending on the winds direction, the particles of dust
are deposited in these places and the assets of these communities are filled of
dust which obliges them to make constant cleaning. The communities suffer from
respiratory diseases, irritation of eyes and conjunctivitis but no scientific evidence
relates these facts to operation of the cement facility and its dust emissions.

The communities also complained about odours emanating from the usage of the
Matola cement kiln to burn hazardous substances, a task occasionally performed
at this facility. We found no evidence of such statements and the factory
management refuted such allegations ensuring that all activities of burning of
obsolete products are performed in a clean way and in the presence of
government authorities, particularly representatives of the Ministry of
Environment (MICOA).

According to one important source, the production of cement in Matola factory

has generated adverse environmental impacts either on the spot, or in the
surrounding areas, which has caused many complaints by civil society on the
poor environmental performance of the Factory.

To check the situation and verify the level of compliance of environmental, labour
and industry legislation, MICOA, in coordination with the Directorate of National
Industry, the City Council of Matola and the Provincial Directorate of
Industry and Commerce, carried out in April 2005, an audit of the factory,
having actually found several irregularities in environmental performance of
the plant, including the lack of internal written procedures for environmental,
occupational health and safety management.

3.2. The Production process

Cement is an important construction material around the world and is produced

in large, capital-intensive production plants generally located near limestone
quarries or other raw carbonate mineral sources as these sources are the
principal raw materials used in the cement production process.

There are three broad categories of cement products: Portland cement, Portland
cement with the addition of PFA or blast furnace slag and special cements. All
but certain special cements are manufactured by using substantially the same
process route (Figure 8), which is discussed in this report. A fundamental
difference between cement manufacturing routes is whether the kiln process is
wet or dry. However, all processes have the following stages in common:
• raw material procurement (from on site quarry or importing);
• raw material preparation (crushing, and grinding of raw materials -
principally limestone and clay - and blending to achieve a given
homogenous chemical specification);
• fuel handling (fuel grinding if solid fuels are used);
• kiln processing (where raw materials are chemically reacted – calcinated -
by the application of heat in a kiln system to produce clinker);
• Clinker cooling
• cement milling (addition of gypsum and clinker size reduction); and
• cement packing and dispatch.
Figure 8: Cement Production Process
Carbon dioxide is released during the production of clinker, a component of cement, in
which calcium carbonate (CaCO3) is heated in a rotary kiln to induce a series of
complex chemical reactions (IPCC Guidelines). Specifically, CO2 is released as a by-
product during calcination, which occurs in the upper, cooler end of the kiln, or a
precalciner, at temperatures of 600-900°C, and results in the conversion of carbonates
to oxides. The simplified stoichiometric relationship is as follows:

CaCO3 → CaO + CO2

At higher temperatures in the lower end of the kiln, the lime (CaO) reacts with silica,
aluminum and iron-containing materials to produce minerals in the clinker, an
intermediate product of cement manufacture. The clinker is then removed from the kiln
to cool, ground to a fine powder, and mixed with a small fraction (about five percent) of
gypsum to create the most common form of cement known as Portland cement.
Portland cement is defined as an active hydraulic binder based on ground clinker
formed from a predetermined homogenous mixture of materials comprising lime (CaO),
silica (SiO2) and a small proportion of alumina (Al2O3) and generally iron oxide (Fe2O3).

3.2.1 Raw material and coal preparation

After crushing, raw materials and fuel (limestone, clay, coal) and additives (iron or silica
ore, etc) are carried to warehouses or tanks to homogenize where they are quantified
and fed into millers. In rotary kilns using wet technology, materials are ground together
with water, then mixed and pumped into the kiln. In this process, there are two main
hazardous factors as dust and noise.
- Dust: dust is emitted to working environment principally from crushing process. In
many factories, stone raw materials are crushed in an isolated site in order to avoid
widespread of dust and noise. In the cement production, the crushing process is the
most polluted. Raw materials and coal are ground in tight closed millers so dust
pollution levels in these areas are relatively low. Sources of dust are mainly the process
of quantifying, carrying and pouring materials. The coal dust of high free silica
component could also cause silicosis.
- Toxic gas: Under the shaft kiln technology, crushed clay and coal are dried to assure
the humidity of less than 2%. Here, in addition to dust, the pollutants also include CO,
CO2, NOx and SO2. In the modern technological process, these toxic gas are exhausted
by ventilation system, treated before discharged into air ambiance, so that the working
environment in rotary kiln, dry method is almost not polluted. All coal dryers and
grinder-dryers are equipped with ventilation systems incorporated to air cleaning
devices.
- Noise: emitted from crushers, millers; from the points where the lime and clay stones
are poured into conveyor. These are the main sources of noise in cement plants. The
noise level in these places could attain to 95-105 dBA. In almost of cement plants there
are the separate rooms (or cabins) for machine controllers, but the sound isolation
quality is very various, so that the efficiency of noise control is different. The high level
of noise in working environment could affect to workers’ productivity, communication,
attention and could mask sound signals and so that could create working accidents.
The workers exposed to high level of noise and during long time could stand hearing
loss; seriously it could cause occupational deafness. High level of noise nearby
crushers, millers, drillers could affect to nervous and digestive systems.
- Heat: heat pollution is mainly in the areas nearby drying kilns of clay and coal. In
cement plants equipped with rotary kilns, heat is also emitted from raw material millers
using recycled heat of kiln. Especially, in the place in front of kiln door where the
workers put the coal, they must be exposed the high radiation heat. In summer, if the
operation time is relative long, they could have some special symptoms like
dehydration, heat stroke, heat cramp, even convulsion.
- Dangerous factors could appear where the employers and employees do not respect
the safety regulations of machines, equipment, and technological procedure conducting
to electrical and mechanical accidents.

3.2.2 Clinker baking

Material powder from separation equipment of millers is stored and homogenized in
silos, then is fed into the multi-stage heat exchange tower (in rotary kiln production line)
or into water-mixer and ball forming machine (in shaft kiln production line), then is fed
into clinker baking kiln.
Generally, the working environment in this area is extremely hazardous at shaft kiln
plants where workers are exposed to dust, toxic gases, high heat radiation and high
workload. In addition, if workers do not respect safety procedure regulation, there is
always the possibility of toxic gas leakage causing by clinker collapse conducting to
fatal accidents. There are also minor accidents in this area like burn, CO poisoning,
colliding, etc.

3.2.3 Clinker cooling and cement milling

After the baking process, clinkers are carried by conveyors to the cooling system and
then to the clinker crushers and grinders and finally stored in clinker tanks or silos. After
being proportioned, clinkers, gypsum and other additives are fed into millers. It is here
cement powder is created. The cement is then carried to the separators and stored in
silos. The main pollution factors in these areas are dust, noise and heat.
- Dust: Within this process, leakage during transport is the main source of pollutants.
Especially, at the shaft kiln plants where open conveyors and poor filters are still
popular, there is much greater possibility of working environmental hazards. Cement
dust could cause respiratory disease, skin and eye disease.
- Heat: emitted from hot clinker on belt conveyor, from heat recycling ducts (in rotary
kiln plants)
- Noise: emitted from clinker crushers and cement millers. The noise levels in this area
are similar to that in materials grinding area.
3.2.4 Packaging, storage and delivery
Cement is carried from silos to the place of dispatch or packaging site. The packed
cement is then conveyed to the warehouses. The considerably hazardous factors
presented in these areas are cement dust and high workload.
- Dust: Generally, packaging the most polluting process in the cement production.
Since most of the packaging machines at the shaft kiln factories are self-made or
ordered from unidentified sources and usually of low quality, it is impossible to obtain a
good functioning from them in terms of environmental protection. The lesson, which can
be learned from this, is that there is still a great possibility of environmental hazards until
fully automated packaging machines with perfect filters are used. The open conveyors
without exhaust systems should be the considerable sources of dust in cement plants.
- High workload: In almost of cement plants, this process stage concentrates the most
manual work. The workers must carry the 40-50 kg cement bags in dusty, hot and bad
lighting environment. Besides other common diseases in a cement plant, the workers in
this work stage have high risk of muscle-skeletal diseases as low back pain, spinal
column, shoulders pain, etc.

3.2.5 Auxiliary processes

Generally, in cement plants there is the mechanical workshop having maintenance and
repair function of machines and equipment. In these workshops, there would be several
hazardous factors affecting to workers’ health i.e. noise, dust, heat, work load, etc, and
several risks causing accidents like hand cutting, minor injuries. The drivers of different
transport means are also exposed to dust, noise, fume and toxic gas.

Some of the main impacts to the environment stemming from the cement production are
summarised in Figure 9.
 Lime stone-Clay-Additives

Crushing Dust, Noise

Storage

Energy Raw milling Dust, Noise

Hot air
Flue gas (CO, NOx,
Preheating
SO2, dust…)

Pre-calcining
Energy

Hot air
Rotary kiln Slag
Energy

Cooling Dust

Clinker Crushing Dust, Noise

Energy

Clinker Storage

Gypsum
Additives Crushing Cement milling Dust, Noise
Energy

Cement Storage

Packaging Packaging
Energy Bulk load Storage
waste-Dust

Figure 9: Impacts of the Cement Process

3.3. Waste Characteristics

The process generates a variety of wastes, including dust, which is captured and
recycled to the process. The generation of fine particulates is inherent in the process,
but most are recovered and recycled. Approximately 10–20% of the kiln feed can be
suspended in the kiln exhaust gases, captured, and returned to the feed. Other sources
of dust emissions include the clinker cooler, crushers, grinders, and materials-handling
equipment.

Cement production is a significant source of global carbon dioxide (CO 2) emissions,

making up approximately 2.4 percent of global CO2 emissions from industrial and
energy sources (Marland et al., 1989). Cement manufacturing is the third largest cause
of man-made carbon dioxide emissions. Carbon dioxide emissions from cement
production are estimated at 560 million tonnes per year. Carbon dioxide is emitted as a
by-product of clinker production, an intermediate product in cement manufacture, in
which calcium carbonate (CaCO3) is calcinated and converted to lime (CaO), the
primary component of cement. CO2 is also emitted during cement production by fossil
fuel combustion. However, the CO2 from fossil fuels is specifically accounted for in
emission estimates for fossil fuels.

Alongside CO2, cement production results in the emission of a certain number of

substances to the atmosphere. Dust from cement production consists of non-harmful
raw materials and clinker dust. Modern process management and equipment has now
virtually eliminated what was once a major problem.

Sulfur dioxide (SO2) is the main gas causing acid rain. Emissions of SO2 from the
cement process originate from volatile sulfur in the raw material. Sulfur present in the
fuel is largely incorporated into the clinker itself and not emitted to the atmosphere.

Nitrogen oxides (NOx) are in part responsible for the photochemical smogs that occur
over urban areas. Emissions of around 2,000 g/tonne clinker can be achieved through
careful process control, but lower emissions require additional flue gas treatment.
Regulations in many countries do not require continuous NO x measurement. In some
cases, alternative fuels can be used to reduce NOx emissions.

Volatile organic compounds (VOCs) play a role in creating low-level ozone that can
cause respiratory problems. Emissions from cement plants largely depend on the
organic content of the natural raw materials used. To reduce emissions, it is necessary
to limit the content of organic components in alternative raw materials, and ensure
effective combustion. Regulations in most countries do not require measurement of
VOCs, except when using some waste materials.

Solid waste - cement kiln dust (CKD) and bypass dust are the only significant solid
wastes produced by the cement production process. The y are only extracted and
discarded when this is necessary to decrease the sodium and potassium concentrations
in the cement, and the chlorine content of the process. CKD is especially an issue in
North America, where cement standards require low alkali concentrations; elsewhere,
CKD is recycled back into the process. For this reason, 6% of production is discarded
as CKD in North America, compared to less than 2.5% in Western Europe and around
1% in Asia and Latin America.

Mercury is the only heavy metal that is highly volatile in the kiln system. It is important to
control the content of mercury in the wastes used as alternative fuels.

Dioxins – to prevent formation of dioxins in the cement-making process it is mandatory

to ban the addition of organic products to the raw materials.

3.4. Main findings

The present study concluded that the negative impacts associated with the factory are
basically dust in the combustion gases released into the air and Emission of noise
located, and in small quantities, generation of solid waste, and adverse impacts on
occupational health and safety of workers and local communities.

Particular attention must be given to the impact of dust on occupational health

and safety of workers as well as on communities in the vicinity of the factory.

The rate of emission of dust in the factory of the Matola cement is quite high, affecting,
first, the local environment and peripherals, and second
place, the efficiency of the production process itself. The mass balance held
By CIMPOR in 2000 shows that when the factory operates at its maximum
capacity, or 108 tons/h, the amount of dust retrieved from electrostatic filters reaches
values estimated at 5 tons/h.

The cement milling as well as the crushing of limestone are the most
Dust generating activities in the factory, followed by the cooling of clinker, the packaging
of cement and grinding of the coal.

The cement plant workers are exposed to inhalation of dust and gases of combustion, a
situation that is exacerbated by the absence of mandatory use of personal protective
equipment.

The gaseous emissions from the factory are normal for this type of activities. The
gases emitted are mainly CO2, in fact, greenhouse, result from the thermal
decomposition of CaCO3 and MgCO3.

The noise is generated in the factory especially by the system of mills of raw materials
and cement, as well as fans installed in the areas of crushing and milling of cement. We
have noticed with concern the lack of use of protective equipment, such as headsets,
personnel uniform, glasses and respiratory masks.

Solid waste usually generated in the factory includes office and household waste, as
well as refractory bricks and scrap iron. The bricks are incorporated into raw material
crushing, while household waste generated in the office is collected and removed from
the site daily by a waste management contractor. Finally, it is appropriate to state that
the factory must find appropriate solutions
to contain the emission of dust and other pollutants and adopt generally accepted
standards of environmental quality. Figure 10 gives an overview of the process in terms
of inputs and outputs.

E l e c t r o s t a t i c p r e c i p i t a t o Lr s o N wa n O - bd x u r n e r s
b a g h of ou rs e c s o l l e c t i o n a n d L o w - s u lf u r f u e l s i n t h e k i l n ( n a t u r a l
r e c y c l i n g o f f i n e p a r t i c u g l aa st e is n s t e a d o f o il )
R a w m a t e r i a l s
L i m e s t o n e
C l a y
M a r l
C o n t r o l S y s t e m s
C o n t i n u o u s m o n it o r in g o f d u s t ,
N O, S xO a 2 nV d O C
A i r E m i s s i o n s
P e r i o d i c m e a s u r e m e n t ( a t l e a s t
P a r i c u l a t e s
C 2O o n c e p e r y e a r ) o f m e t a ls ,
d io / xf u i n r , sa n s b e n z e n e a n d
E l e c t r i c i t y N xO
Q u a r r y i n g a m m o n ia
S 2O
E q u ip m e n t c a lib r a t io n ( a t l e a s t
t w ic e p e r y e a r ) b y a n e x t e r n a l,
W a t e r c o m p e t e n t o r g a n iz a t io n

F u e l
F u e l - o i l I m p r o v e d q u a r r y m a n a g e m e n t
D i e s e l R a w M a t e r i a l s C o m p u t e r o p t i m i z a t i o n o f l a y - o u t s
P r e p a r a t i o n R a w m a t e r i a l s u s e a n d o p e r a t i o n s
C h e m i c a l s P a r t ia l s u b s t it u t io n o f c lin k e r b y
PLA N T

C o
o l i n g w a t e r t r e a t m e n t c e m e mn t ai t to e u r s i a l s ( f ly a s h , b la s t
W a s t e w a t e r t r e a t m e n t f u r n a c e s la g )
L a b o r a t o r y c h e m i c a l s
S o l v e n t s & c l e a n e r s

N o n - c o m b u s t i o n S o l i d
CEM EN T

L u b r i c a n t s K i l n P r o c e s s i n g W a s t e
O i l s T
r a s h & g a r b a g e C o m m e r c ia l L a n d f ill
G r e a s e U n r e c o v e r a b l e e q u i p m e n t & s u p p l i e s
C o n s t r u c t i o n d e b r i s
A s b e s t o s
P a c k a g i n g
P a l l e t s & c r a t e s
C a r d b o a r d
P a p e r
C e m e n t M i l li n g D r y p r o pc r e e s h s e a ( a n w t de i r t s h
p r e c a ) l c i n i n s e t er sa d o f W e t p r o c e s s
M i. s E c q u i p m e n t & S u p p l i e s
e hV i c l e s
E n e r g y
S p a r e p a r t s
T o o l s E n e r g y r e c o v e r y b y u s i n g g a s e s
L i g h t i n g f r o m c l i n k e r c o o l i n g a s s e c o n d a r y
R a g s & t o w e l s c o m b u s t i o n a i r
P a c k a g i n g a n d
D i s p a t c h R e
c o v e r a b l e
C o o l a n t s &
R e
c y c l a b l e M a t e r i a l
M e t a l s R e c y c l in g V e n d o r s
P a p e r & O f f i c e S u p p l i e s U s e d o il & f il t e r s
P a p e r W o o d & p a lle t s
C o m p u t e r s & C o p i e r s L a m p s & b a t t e r ie s
P a p e r & c a r d b o a r d

H a z a r d o u s / T o x i c
w a s t e H a z a r d o u s W a s t e D is p o s a l
S o l v e n t s

Figure 10: Inputs and outputs of cement production

3.5. Proposed Pollution Prevention and Control Measures

3.5.1 Engineering and technical measures

Collection and control of fine particulates

The priority in the Matola cement facility is to minimize the emissions of particulates by
reducing the mass load emitted from the stacks, from fugitive emissions, and from other
sources. Collection and recycling of dust in kiln gases is required to improve the
efficiency of the operation and to reduce atmospheric emissions. Electrostatic
precipitators (ESPs) and fabric filter systems (bag houses) are the principal options for
collection and control (achieving over 99% removal efficiency) of fine particulates. ESPs
are sensitive to gas characteristics, such as temperature, and to variation in voltage;
bag houses are generally regarded as more reliable.

Some additional measures could include:

• Install equipment covers and filters for crushing, grinding, and milling operations.
• Use enclosed adjustable conveyors to minimize drop distances.
• Wet down intermediate and finished product storage piles.
.
• Use low sulfur fuels in the kiln. SOx emissions are best controlled by using low-
sulfur fuels and raw materials. The absorption capacity of the cement must be
assessed to determine the quantity of sulfur dioxide emitted, which may be up to
about half the sulfur load on the kiln. Pre-calcining with low-NOx secondary firing
can reduce nitrogen oxide emissions. Use low-NOx burners with the optimum
level of excess air. NOx emissions should be controlled by using proper kiln
design, low-NOx burners, and an optimum level of excess air. NOx emissions
from a dry kiln with pre-heater and pre-calciner are typically 1.5 kg/t of clinker, as
against 4.5 kg/t for the wet process. The nitrogen oxide emissions can be
reduced further, to 0.5 kg/t of clinker, by afterburning in a reducing atmosphere,
and the energy of the gases can be recovered in a pre-heater/Pre-calciner
• Burning natural gas instead of oil the fuel consumption can reduce the energy
consumption, with a reduction in CO2 emissions. The major environmental
benefits are related to the reduction of gases emissions.
• Operate control systems to achieve the required emissions levels.

Raw-material substitution

Reduction of clinker use by substitution with secondary cementitious materials - to

reduce the content of the energy and emissions intensive clinker in its final product
probably is the most powerful way to mitigate emissions of a cement company. Because
strict quality standards are set for cement, the range of materials that can be used is
limited, but suitable materials include fly ash from the power generation industry and
blast furnace slag from iron production.
Improved quarry management

Other than fuel, the essential raw materials for cement production are limestone, marl
and clay, which are obtained by quarrying. An operating quarry obviously has major
impacts on the local landscape and ecology, and can cause noise and traffic problems
for local communities.

Using computer-generated quarry maps, materials with the required qualities can be
extracted and homogenized in the correct proportions, to minimize wastage of natural
resources. Quarry layouts and operations are also optimized with respect to location of
crushers and haulage roads, to minimize noise, transport and visual impact.

Energy recovery

Since the process is very energy-intensive, gases from clinker cooler should be used as
secondary combustion air. The dry process, using pre-heaters and pre-calciners, is both
economically and environmentally preferable to the wet process because the energy
consumption - 200 joules per kilogram (J/kg) - is approximately half of that for the wet
process.

• Application of several cleaner production measures as follows:

- Process control optimisation, including computer - based automatic control
systems.
- Minimising energy use by mean of heat recovery from waste gas, reuse
wastes from other industries and improvement of power management
systems and efficiency of electric equipment.
- Selection and control of substances entering the kiln; reducing of NO x and
CO emissions by improvement of firing and adjusting oxygen
concentration.
- Reducing of SO2 emissions by using of lower sulfur content raw material
and fuel.
• All production machines as stone and clay crushers, millers, clay and coal dryers,
kilns and bag packagers must be equipped to exhaust systems incorporating with
dust collectors to clean emission gas before discharging to ambient environment.
• Prevention of environmental incidents caused by malfunction of electrostatic
precipitators when the dust and carbon monoxide concentrations are too high.
The preventive methods may include:
- Monitoring and controlling the dust and carbon monoxide concentration in
the ingress to the equipment;
- Maintaining appropriate operational modes and timely repair when
problems arise;
- Conducting regular maintenance;
- Employing properly trained and skilled workers.
 • Baking and drying kilns must equipped with automatically watching and
controlling systems of firing regime. Shaft kiln cement plants should pay
attention to respecting of production process regulation and organizing of training
and retraining course for workers operating shaft kiln.
• Il should be applied the noise control measures to production machines
(crushers, millers) as maintaining and lubricating periodically machines, installing
rubber layer and anti-vibration springs, building strong machine stands which has
high cement concentration, and is isolated from the foundation by dry sand,
isolating control room from manufacturing areas, etc.
• Reducing at maximum manual carrying of cement bags by installing of
automatically packaging machines, and in case of semi-automatically packaging
machines, it should provide conveyor systems to transport cement bags directly
to warehouse. The transport of cement bags from conveyors to different places
in warehouse and from these places to lorries should be realized by trolleys or
forklifts.

3.5.2 Control at source

• Sources of dust emission (manufacturing machines, conveyors) should be
enclosed at maximum.
• The exhaust ventilation should be located as close as practicable to the
emission sources.
• Transporting, loading and unloading cement bags should be planned so as to
avoid damage to the bags and injury to people; and provisions should be made
for recovery of material after spills or transport incidents.
• Stores should be designed and maintained in order to minimize dust emission.

3.5.3 Housekeeping and waste handling

• The dry dust from air cleaning devices as fabric filters, cyclones, electrostatic
precipitators could be directly returned to the process using as raw material or
collected in bags using as material or for other purposes. In case of scrubbers,
wastewater can be collected in sedimentation tanks and reused after a simple
setting process. The solid setting in tanks can be returned to the process using
as raw material.
• Waste solids including useless stone and land, coal residue should be collected
and reused for other purposes as road building and repairing, coal-residue brick
or buried in approved landfields.

3.5.4 Implementing corporate standard for emissions monitoring and

reporting
• Total dust concentration should be measured according to standards for Air
quality at workplace.
• Noise levels should be measured according to standards for Allowable noise
levels at workplace.

• Continuous monitoring of dust, CO, NOx, SO2 and VOC

• The content of information, training and education should be designed properly
for each scope: employer, supervisors and employees, and as a minimum, meet
the requirements of the competent authority. It is recommended that the
information and training contain the following:
- applicable laws, regulations and codes of practices;
- labels and material safety data sheets;
- preventive and control measures of hazards and risks;
- working environment monitoring data in related workplace;
- potential acute and chronic health effects which may result from exposure
to hazardous and risk factors, especially to silica dust;
- the responsibilities of manufactures, supplies, installers, employers and
workers, as well as the need for cooperation between them, etc.
MATOLA CEMENT MANUFACTURING FACILITY
IDENTIFICATION OF HAZARDS
QUESTION YES NO
Can workers get to their place of work safely? ◙
Is the site fenced so that the public cannot get in? ◙
Are measures in place to protect members of the
◙
public (such as people passing by the site)?
Are traffic routes cleaned and lit well? ◙
Are vehicles equipped with sirens that beep when
◙
they move backwards?
Is the site tidy and well laid out? ◙
Is the site lit well? ◙
Are appropriate safety signs in place (e. g., traffic
◙
routes, authorised personnel)?
Are workers’ facilities sufficient (changing rooms,
◙
washrooms, etc.)?
Are there facilities for the workers to eat their
◙
meals (canteen, etc.)?
Are there first-aid facilities; is health surveillance
◙
ensured?
Have workers been instructed and trained on safe
◙
manual handling?
Is appropriate lifting equipment provided for
◙
handling heavy loads?
Are existing power lines (buried or overhead)
◙
identified?
Is there a system of work that deals with live
◙
electric lines in place?
Are precautions taken to ensure that electrical
systems and equipment are maintained and ◙
frequently inspected by a competent person?
Have lifts and hoists been properly installed and
◙
checked by competent people?
Do employees use appropriate guards or wear
◙
safety belts when working at a height?
Are measures in place to stop workers and objects
◙
from falling?
Do all people on the site wear correct protective
◙
equipment (e. g., footwear, hard hat)?
Are suitable protective measures used to prevent
◙
or to reduce exposure to dust?
Are suitable protective measures used to prevent
◙
or to reduce exposure to noise and vibration?
Is work equipment and machinery maintained in a
◙
safe condition?
 Do the machines’ safety devices (i. e., sound
◙
signals, guards) work?
Are vehicle and plant operators suitably trained? ◙
Do all employees get information about potential
risk and the established preventive measures
in a language and at a level that they understand? ◙
Can high noise levels arise as a result of work
◙
processes (e. g., metal-on-metal impact, engines)?
Can operating noise mask alarm signals? ◙
Is the noise so loud that you would have to raise
◙
your voice to talk to people at your workplace?
Are there any hazardous moving parts in the
machines (including auxiliary parts) without ◙
safeguards?
Do machine safeguards sufficiently prevent
workers‘ hands, arms, or other parts of the body ◙
from contact with dangerous moving parts?
Are all machine guards secured firmly and not
◙
easily removable?
Can an object fall onto the moving parts of a
◙
machine?
Do safeguards make the operation of a machine
◙
inconvenient or more difficult?
Can a machine be oiled without removing the
◙
safeguard?
Is it possible to remove safeguards without
◙
stopping dangerous movements?
Are there any unguarded gears, sprockets,
◙
pulleys, or flywheels?
Are there any exposed belts or chain drives? ◙

Summary: major occupational and environmental health hazards identified, and

recommendations for their control