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Processing Specific Induction
Processing Induction - Content
• Plant Overview
• Area Access
• Communications
• The Process
• Chemicals & Reagents
• Safety Systems and General Safety
• Processing Hazards
• House Keeping
Plant Overview
• Gold Operation
– 600 tpa
– Underground ore source
– Coarse gold within quartz
• Process is a combination of:
– Crushing and Grinding
– Gravity Concentration
– Flotation
– Leaching
– Electrowinning
– Smelting
Area Access
– Crushing
– HPGR, Grinding & Gravity
– Flotation & Thickening
– CIL & Elution
– ILR & Gold Room
– Reagents
– Metallurgical Laboratory
– Tailings Storage Facilities
This induction allows you access to the following areas of the process plant
Restricted Access Areas
– ROM Pad Front End Loader Operating
Requires reflective clothing and notification of Loader driver
– CIL & ElutionHCN Generation
Requires Monotox and Mask Induction
– ILR & Gold Room
Requires Metallurgy Managers’ designated person’s Authorisation for access
The following areas of the plant have restricted access for security and safety purposes
Communications
• In an emergency dial: 222 (internal)
– State:Your Name
Your LocationLocation of EmergencyDetails of EmergencyAwait further instructions
• Security extension: 400 or 401
• Surface UHF Radio: Ch (Yet to be determined)
The Process – Crushing & HPGR
HPGR
Ore Storage
Primary and Secondary Crushing
Screening at 25 mm
Wet Screening at 4 mm
Gravity and Grinding
Gravity, Grinding & Flotation
Fines TSF
Sand Re-useSands TSF
Gravity Gold Circuit
Gravity Concentrate
Classification and Ball Mill
Concentrate
Au and Pyrite Flotation
Flotation Tailings Thickener
Flotation Feed Thickener
Fine Ore
Flotation Concentrate Leaching
Detoxified TSF
Flotation Concentrate
Flotation Concentrate Leaching
Concentrate Thickener
Tails Screen
Barren Carbon
Cyanide Detoxification
Loaded Carbon Screen
Loaded Carbon
Gold Recovery
Barren Carbon
Carbon Elution Circuit
Gold Bullion
Furnace
Loaded Carbon
Intensive Leach Reactor
Gravity Concentrate
Gravity Concentrate Tables
Electrowinning
Reagents
• Numerous hazardous reagents and materials are used in the processing plant.
• They are safe PROVIDING correct procedures and PPE requirements are followed.
• Material Safety Data Sheets (MSDS), are available on all these substances from – Control room
– Processing Office
– Reagents storage area
– Electronically (intranet) on the Chem Alert system
If you are not sure about a particular chemical …ASK!
Reagents
• Regents are delivered in a variety of forms and containers. – Delivered directly into storage tanks – Mixed with water in dedicated mixing facilities.
Some include– Sodium Cyanide– Copper Sulphate– SMBS– Sodium Hydroxide– Hydrochloric Acid
Copper Sulphate
Reagents - Cyanide Storage Area
Sodium Cyanide Key Hazards• Solid inhalation & ingestion (incl. dust)• Liquid absorption & ingestion• HCN gas inhalation
Immediate 1st aid response• Thoroughly wash victim• Oxygen administration• Seek urgent medical attention
Remember, if you find a possible victim of cyanide poisoning,DO NOT BECOME A VICTIM YOURSELF!
Don appropriate PPE before rendering assistance.
Job Safety Analysis
• A Job Safety Analysis (JSA) must be carried out
– Before any new work is carried out – When a change is made to an existing established
procedure
• Purpose:
– Review the task and the hazards associated with carrying out the task
– Determine a practical method of eliminating hazards or reducing them to a manageable risk
Permit to Work
• Permit to Work procedure ensures there is method for conducting work
• Designed to assist personnel to adhere to safe work practices
• Work permit procedure ensures that:
– Associated risks are minimised through:• JSA’s• Associated permits (hot work, working at heights, confined space
etc)• Correct isolation of equipment
– No work is undertaken without proper instruction and authorisation
– Operational integrity of the plant is maintained
• Ensures all stakeholder receive appropriate notification
Equipment Isolation
• A comprehensive isolation and lockout procedure has been developed for the site
• All personnel are required to use the system to ensure the maintenance of a safe work place and that all work is carried out in safe conditions
• Personnel will receive isolation and lockout training and be issued with locks to be used in conjunction with personal danger tags
Personal Protective Equipment
• Site Standard PPE– Hard Hat– Safety Glasses– Safety Boots– Long trousers and long sleeved shirt (Hi-Vis)
• CIL, Detox & Elution Monotox must be carried
• Other PPE is task / area dependent– Hearing protection– Gloves (PVC & latex)– Disposable overalls– Face shield– Respirator
General Safety
• Safety Showers
– Safety showers and eyewash stations are located at various points around the plant.
– Identified by the green and white signs and a green light above them to help identify their locations in an emergency
– Always check the operation in your work area before commencing work
General Health & Hygiene
• Personal Hygiene– Wash hands before eating, drinking or smoking– Use designated crib rooms for eating and drinking
• Drinking Water– Only drink from water dispensers and from crib room
facilities where indicated– Can be very hot in summer months
drink plenty of water
Processing Hazards
• Start Up Sirens– Start up sirens may sound at any given time without
warning or notice. – Sirens indicate that a specific piece of equipment is
about to start– Sirens are mainly used for conveyor and mill starts
• Automatic Start Pumps– All areas in the processing plant have numerous pumps
and drives, which may start or stop automatically without a siren.
– Do not place any part of your person near these drives unless they have been correctly isolated.
Processing Hazards
• Thickeners – A thickener is an open top vessel.
• Do not wear a hard hat when walking/working on top of thickeners• Always leave your hard hat at the entrance to the thickener bridge,
in the appropriate hard hat holder. • This is to prevent blockages of the underflow lines from falling
helmets. – Tools Should be handled and stored in a manner to prevent
accidental loss into the thickener.
• Conveyor Belts– Conveyor belts are used within the ore crushing and grinding
areas– These belts can start automatically but are preceded by a
warning start up siren. – Never place any part of your body near a moving or stationary
conveyor unless the belt has been correctly isolated
Processing Hazards
• Magnets– There are 2 magnets: over the crusher discharge conveyor
and over the fine ore bin discharge feeder.
– Care should be taken when working in this area as the magnet produces strong magnetic fields.
• Concern to people with: heart pacemakers and artificial limbs.
• Can also damage electronic equipment (incl. laptops and watches)
• Radiation– There are 7 radiation sources used in the processing plant in
density gauges.
– Identified by yellow warning signs.
– Isolation of the source by an authorised Radiation Safety Officer is required if you are working in close proximity to the devices
Processing Hazards
• Hot Surfaces– Some pipe work and equipment within the processing
plant operates at high temperatures. – Caution should be taken when working in or around
operating equipment
Hot surfaces can be found on the:• Carbon regeneration system
• Carbon elution system
• Gold room furnace and calcine oven
• Compressed air and blower outlet piping
Processing Hazards
• Pressurised Lines– Pipe work in the plant operates under pressure
– Ensure lines are depressurised prior to commencing any work.
– Dissipated pressure from water and compressed air lines before disconnection
– Safety clips must be used on hoses with Minsup or quick disconnect couplings.
• Dust– Dust may be present in the crushing, reclaim and grinding areas.
– Elimination of dust losses will not be possible in all circumstances.
• Dust masks are to be worn when working in areas where dust is being generated.
Processing Hazards
Gases:
• LPG – Predominantly used in the gold room for heating purposes
• Also used in the elution and carbon regen areas
– Exercise care when carrying out maintenance work in this area
– Report any signs of gas leaks immediately to your supervisor.
• Hydrogen Cyanide– HCN may be present on top of the CIL and Detoxification tanks.
– Training in the use of HCN detectors will be required to access
Noise
• Our neighbours are very close – Bound by prescribed noise limits
Daytime 7 am – 6 pm 46 or 47 dB (A) Evening 6 pm – 10 pm 42 dB (A) Night 10 pm – 7 am 39 dB (A)
• Be aware of the potential noise from tasks and equipment
• Carry out noisier activities in “Daytime” wherever possible
• Evening is also Saturdays from 1pm and all day Sunday and public holidays.
House Keeping
Be proud of your work place and keep it clean and tidy.
– If you make a mess, clean it up
– Don’t leave rubbish lying about the work place
– Keep areas hosed clean wherever possible
– Ensure all equipment and material are stored in correct locations
– Keep Crib rooms and control rooms clean and tidy