Introduction
Global cement production and the use of cement is increasing, from prefabricated concrete walls to the use of cement in buildings. Due to this rise the production of cement must increase and there for the with an increase in production safety must be of paramount importance, in a similar aspect the sustainability of the production must also be addressed accordingly.
Cement is a mixture which is predominantly composed of limestone (calcium), with smaller quantities of clay, sand and aluminium. Cement is a very dangerous substance and is also one of the most widely used materials in the world. Due to cements composition, when contacted with water, calcium hydroxide is produces, this causes chemical burns as calcium hydroxide is very alkaline. When contacted with skin or inhaled the affected area becomes irritated.
Due to the stated properties of cement serious safety regulations and legislation must be implemented.
Due to cement being so widely used and as such a harmful material, it must also be regulated in its use with legislations implemented.
Outline Process
Limestone is are quarried. The large rocks are crushed on-site to produce smaller rocks, which are more easily transported and managed. The rocks are then transported to the cement factory, from there a sample is taken to the on site lab. The ratio of lime stone to clay is analysed. From there large wheel rollers accompanied by a rotating table are used to grind the rocks into a finer material, the rotating table is used to ensure all of the material is crushed. Following this the material is then stored. The material is then preheated using a series of vertical cyclones and recirculated gasses from the kiln. The material, then goes into the rotating furnace, the material is then heated to 1450 C. At this temperature De-carbonation occurs, this is the release of CO2 following the reaction of calcium and silicon dioxide. The method of heating this furnace is the use of natural gas and coal. Following this stage, the material is then cooled by mean force and then ground further using a ball mill. Once ground fully, the cement is then sent to be packed.
Part A:
Legislation Name Placement within Legal System
The Control of Substances Hazardous to Health Regulations 1999 UK Statutory Instruments
Management of Health and Safety at Work Regulations 1999 UK Statutory Instruments
The Construction (health, safety and welfare) Regulations 1992 UK Statutory Instruments
The Manual Handling Operations Regulations 1992 UK Statutory Instruments
Lifting operations and lifting equipment regulations 1998 (LOLER) UK Statutory Instruments
The Road Vehicles (Construction and Use) Regulations 1986 UK Statutory Instruments
The Quarries Miscellaneous Health and Safety Provisions Regulations 1995 UK Statutory Instruments
Permit to work
Personal Protective Equipment at Work Regulations 1992 UK Statutory Instruments
Health and Safety at Work etc. Act 1974
UK public General act
The Dangerous Substances and Explosive Atmospheres Regulations 2002 UK Statutory Instruments
The Quarries Regulation 1999 UK Statutory Instruments
The Gas Safety (Installation and Use) Regulations 1998 UK Statutory Instruments
Part B:
Lifting operations and lifting equipment regulations 1998:
Explanation of legislation:
The responsibilities of the employer are to ensure:
• Lifting equipment is sized sufficiently in regard to stability and strength for the desired load. The lifting attachments must also be correctly sized.
• To prevent to the best of their ability the dangers of the user utilising the lifting equipment from being harmed by the equipment crushing, trapping, striking or falling from the lifting equipment.
• Must set in place devices to free the person from being crushed or trapped in the occurrence of an incident.
• Measures must be implemented to ensure proper use of the lifting equipment occurs.
• All lifting equipment must be marked identifying its purpose (lifting people or loads) and safe working load.
• Those using the equipment are sufficiently trained, supervised and undertaken safely.
• The desired lifting equipment is thoroughly examined to ensure there are no defects and the lifting equipment must have physical evidence of its last examination.
• Defective lifting equipment is not used.
• All produced reports are available to be inspected.
The responsibilities of the employees are to:
• Report all defective equipment and compile a report of the examination.
Application and implementation within the country’s legal system:
UK Statutory Instruments
Application of legislation in the production of Cement:
Throughout the process lifting equipment is required. At the beginning of the process it is required to lift the limestone to be transported to the crusher, from there equipment is required to lift and move the crushed limestone to the cement factory. Lifting equipment is then used to move the lime stone into silos. Clay and aluminium are also stored, these are brought onto the site and lifting equipment is used to fill the silo. After being processed the cement is packed into 25kg bags, these are stacked on pallets and wrapped. The pallets are then lifted onto a lorry and distributed. Following the departure from the cement plant the legislation still applies, the cement may be sold to building merchants or directly to the user. Where the same legislation will apply, the legislation will also apply when the cement is being used by the builders as this can involve lifting equipment.
Although lifting equipment is required in the process it is required to maintain the plant, conduct checks of the equipment and infrastructure. These are required to ensure that it is safe to operate. To do this lifting equipment may be required to lift people for the inspection. Similarly, if a defect or broken piece of equipment is found lifting equipment will be required to fix or replace the broken equipment. To apply this to legislation tagging of lifting equipment which states the last time it was inspected, clear labelling of the maximum load the equipment it can handle and the purpose of the equipment. To further apply this legislation all employees are educated thoroughly in the use and application of lifting equipment. Alongside this regular spot checks should be conducted by the safety officer to ensuring the equipment is being used correctly and all the relevant documentation which is required is there and correct.
The dangerous substances and explosive Atmospheres Regulations:
Explanation of legislation:
The responsibilities of the employer are to:
• Train their employees completely to deal with any possible risks or dangers that may arise when working.
• Asses risks sufficiently.
• Implement emergency procedures in the case of fire, explosions or the release of dangerous substances.
• Classify areas where a where explosive atmospheres would occur.
Application and implementation within the country’s legal system:
UK Statutory Instruments
Application of legislation in the production of Cement:
Dust is a major cause of explosive atmospheres and one of the factors taken into account in this piece of legislation. Dust is formed during the quarrying stage, following the controlled explosion conducted in order to break up the lime stone from the quarry. However, this does not often produce an explosive atmosphere assessment must be made and plans implemented. Dust is also formed when the rocks are crushed in the crusher, this must be maintained in order to prevent an incident by following these regulations. The largest danger in a cement factory is the bag filters, these are used to collect dust and air pollutants from the flue gas of combusted materials in the production of energy. The regulations must be utilised in this part of the plant as the atmosphere has the potential to be explosive. Furthermore, this legislation is implemented throughout the plant as areas will have to be classified into zones (0, 1, 2, 20, 21, 22). Zones 20, 21, 22 are in the zonings for dust clouds. 0, 1, 2 are in regard to the potential of an explosive atmosphere of dangerous substances. Due to the vast quantities of energy required the kiln which can be heated by ground coal which has a small diameter. The reduced size of the coal makes it more susceptible to the potential of a combustible atmosphere. Alternatively, natural gas can be used to heat the kiln to the required temperature, this legislation is also applicable to this as if there is a leak in a furnace gas feed line an explosive atmosphere may occur. Therefore, equipment in the surrounding area must be assed in order to ensure there are no sources of ignition in the area, furthermore measures must be put in place in order to minimise the risk of an explosive atmosphere.
To apply this legislation emergency procedures are then in place in case of a fire or explosion, so it can be dealt with quickly and safely. Mobile phones, lighters and vehicles must not be in the area where an explosive atmosphere can occur, furthermore none electrical ignition sources such as switches and controllers are to be in place as opposed to traditional switches and controllers. Sensors should be placed around possible areas where an explosive area may arise, allowing potentially dangerous areas to be monitored. Enabling suitable controls to be put in place to reduce the risk of an incident.
Sustainability
Social pillar, ecological pillar and economic pillar:
Both of these pieces of legislation promote sustainability. The first piece of legislation discussed promotes social sustainability, as an injury when utilising lifting equipment has the potential to severely damage company’s image if it is found to not be using lifting equipment in a safe manner or using the correct equipment for the correct task. In this case the economic pillar would therefore be effected because if the employer is found to be guilty of not implementing this piece of legislation and an injury occurred they would be liable, tarnishing the company’s reputation and costing them financially.
Similarly the second piece of legislation promotes social, ecological and economic sustainability. Ecological sustainability is promoted as the legislation requires areas are classified as explosive atmosphere zones, and ignition sources are avoided. If this legislation was not in place the probability of an explosion would be more likely. An explosion would be damaging ecologically, therefore by implementing this piece of legislation explosions are avoided. The effects of an explosion would effect social sustainability as it would be damaging to the company and seen as being negligent. An explosion would effect the economic sustainability as an explosion would damage the surround infrastructure and require money to be replaced, this would be damaging economically