Chemical Plant Control Techniques of

Heavy Metals Processing

Group Members:
• Aeshwini Singarajan (KQD190014)
• Nur Ismah Izzati Ismail (KQD170010)
• Poorni Letchumanan (KQD190007)
• Abdulrahman Algarnas (KQD190024)
• Piradeepan Ramachandran (KQD190022)
Elimination
1. Eliminating ignition source and accumulation of flammable and combustible substances.
• Example: Abandoned underground tanks/pipework that related, which potentially dangerous whereby residual level
of flammable gases, liquid and vapour are present. Ignitions can occur activities such as grinding, hot cutting or
welding.

Table 1: common example of ignition source

2. Any potential hazardous reaction (chemical and physical) between hazardous chemical and other substance/mixture
should be eliminated as well.
• (Many chemical reactions are exothermic – that is they give off heat during the reaction. This heat can act as an
ignition source igniting any fuels present, pressure can build up in enclosed systems (for example, containers, flasks,
pressure vessels) causing the container to rupture or even explode.)
Substitution
1.Chemical Usage (when applicable):
• Perform task without hazardous chemical when it is necessary
• Substitute hazardous chemical with less hazardous and less toxic options.
• Usage of less concentration chemical options can be applied as substitutions. (exposures to high concentrations
of sodium hydroxide may lead to immediate effects).

2. Some substances used in this industry may be virtually harmless in some forms (such as a block of metal, a piece
of wood or granulated solid chemicals) but may be very hazardous in another form (such as fine dust particles or
fume that can be readily inhaled or solutions that may be splashed and readily absorbed through skin). Risk control
through physical form.

3. Usage of gases or liquids with low boiling points or high vapour pressures can give rise to high airborne
concentrations in most circumstances, whereas high boiling point liquids such as oils are only likely to create a
hazardous airborne concentration if they are heated or sprayed
Attenuation
1.Investigation on hazardous chemicals, the quantities used, the frequency, duration of exposure, the effectiveness of the
controls already in place, and whether workers are working directly with the substance this information should then be used
to estimate the level of exposure, therefore attenuation is applied by performing jobs under less hazardous conditions.

2.Transfer of hazardous chemicals

During the transfer process, the chemicals will frequently be unconfined at some stage of the transfer process that may
include pouring or pumping from one container to another. Common methods for reducing risks during transfer operations
which makes them less hazardous includes:
avoiding spillage or overflow, including overflow protection on equipment and receiving vessels
providing emergency shut-offs to limit the amount of hazardous chemicals released during a loss of containment
providing a spill containment system
reducing static electricity and vapour generation. This is particularly important for fire risk hazardous chemicals such as
flammable liquids
ensuring transfer fittings are compatible
avoiding sources of ignition
installing flow and pressure regulators on pipe work or pumps
installing interlocking of valves and switches
implementing systems for detecting losses from pipe work and fittings, such as static pressure loss detectors,
measurement to determine losses in transfer or external sensors
 
Isolation
1. Isolated room for magnetic drill machine
• This machine is used to drill holes in structural steel objects. This machine produce noise which can affect
other worker. Thus this machine should be isolated in a room to avoid ear damage to other workers.
2. Separate room for cutting of metal
• Generally, it does not give rise to a noise problem except when cutting steel plate which is more than 40-50
mm thick or when a large number of cutting torches are used simultaneously, as in mechanised cutting. In
such cases noise levels in excess of 90 dB (A) may result.
• Thus cutting process should be done in separate place without affecting other co-workers.
3. Isolated room during processing heavy metals
• Exposure to a wide variety of hazardous dusts, fumes, gases and other chemicals can occur during smelting
and refining operations.
• Crushing and grinding ore in particular can result in high exposures to silica and toxic metal dusts which
contains lead, arsenic and cadmium. There can also be dust exposures during furnace maintenance
operations. During smelting operations, metal fumes can be a major problem.
• Thus these process should be done in isolated area as it gives much impact on workers health.
Intensification
1. Change from large batch reactor to smaller continuous reactor
• Many smelting operations involve the production of large amounts of sulphur dioxide from sulphide ores and
carbon monoxide from combustion processes. Dilution and local exhaust ventilation (LEV) are essential.
• Sulphuric acid is produced as a by-product of smelting operations and is used in electrolytic refining and
leaching of metals. Exposure can occur both to the liquid and to sulphuric acid mists. Skin and eye protection
and LEV is needed.
• Thus to avoid health impact to workers or to prevent any accidents, this process can be done in small batch.

2.  Reduce storage inventory of raw materials

• Various types of metals and alloys are used as starting materials which includes bars, strips, light section,
sheet and tubes. Thus, these material should be kept in small quantity in warehouse to avoid any accidents.
Enclosures
• Cover the High Temp and Pressure spots with Heat insulated plates and providing suitable gloves with proper hazard
signages near hazardous areas.
• Provide a proper storage area with fully closed and isolated from hazardous spots for storage of heavy metals and
hazardous chemicals.
• Proper enclosures for high voltage areas. Safety enclosures equipped with switches provide emergency breaking,
breaking for mechanical maintenance and safety isolation in the vicinity of any low voltage final circuit. Protects
operators against accidental start-up of machines.
• Cover the switches with transparent latex to prevent electric shock. Ensure that your hands and feet are dry. Wear
protective equipment such as low voltage gloves and overshoes if available.
• Dust Seal Partitioning. Quick, clean and non-disruptive to install with solutions designed and installed to any height
and width. Offers 99%+ dust tight seal.
Local Ventilation
• Ventilation control is often an extreme method for businesses to reduce dust in the working environment. Local Exhaust
Ventilation (LEV) use extractor fans to raise dust particles into ducting. Usually, these ducts lead to collection bags where
the dust can be removed for proper disposal.
 
• Use properly designed vent hoods to remove excessive heats and dusts from the working environment.
• Ducting, which safely transports the contaminants to a filter/cleaner/exhaust point
 
• The degree of containment around the emission point is crucial. The hood should be structured and placed at the
emission point so as to entrain/contain the emission. For example, the air-flow rate to a circular extraction duct with no
hood attached will fall to about 10% of the in-duct flow rate at one diameter distance from the duct opening. As the
distance of the emission point from the hood increases, the LEV effectiveness decreases dramatically.
 
• The contamination removal/filtering system should be fit for purpose. The type of system used will be very much dictated
by the type of contaminant being extracted from heavy metals and can vary from a simple filter system to a multi-
component system with pre-filters and scrubbers, for example. Whatever the filtering system, it should be designed so
that it can cope with the contaminant load and remove/filter it effectively without affecting flow performance. It should
be easily changed, cleaned and maintained without causing exposure to operations or maintenance staff.
  
Figure 1 : Comparison/Effectiveness on Hood
installations at Industries
Dilution Ventilation
1. Location in Workplace
• Design exhaust system close to contaminant source to increase effectiveness and reduce spread of
contamination.
• Workplace location should be designed to allow workers to work near ventilation for improved efficiency.
• Workplace arrangement to allow makeup air to be located behind the workers.
• Installment of fans in appropriate locations helps guide contaminated air out of workplace.
• Separate ventilation systems to prevent contaminated air from spreading to other parts of the plant.
• Designated areas with ventilation for contaminated equipment and clothes.

2. Heat control
• Fans help cool down workplace, and workers.
• Fans help blow dust away from work place.
• Placement of fans to blow cool air from outside into workplace improves heat control.
 
3. Inspection
• Daily - apply visual inspection of exhaust systems and fans.
• Weekly - air cleaner capacity, fan housing, pulley belts.
• Monthly - inspection of air cleaner components.
4. Prevention
• Preventive maintenance program for checkups of ventilation systems on a regular scheduled basis.
• Provide guides and instructions for possible problems and solutions associated with ventilation system.
• Worker training on ventilation systems, how to use safely, how and where to position.
Wet Methods
1. Workplace
• Installment of water station in workplace.
• Keep water station/spray/hose away from electric sources.
• Use of water to clean work space frequently.
• Provide equipment used when cleaning with water (gloves, boots, ladders)
• Well mopped floor reduces workplace contamination, and chance of injury of workers.
• Clear safety signs to indicate wet floor, and areas that should not be accessible by workers.
2. Workers
• Proper worker training and sharing responsibility and understanding of the importance of work place cleanliness.
• Having correct posture and technique when using cleaning equipment to reduce chance of injury.
• Regular cleaning schedule to maintain the condition of the workplace.
3. Inspection
• Apply regular inspection on water stations, cleaning equipment.
• Inspection of the cleanliness of floor and work place to prevent injuries to workers.
Housekeeping
1. Accident prevention
• Floors should be clean and dry.
• Adequate drainage should be provided where wet processes are conducted.
• Any spillage or leakage should be reported and cleaned up.
• Worn, ripped or damage flooring should be replaced.
2. Fire hazards elimination
• Combustible waste should be stored in enclosed metal containers and disposed properly.
• Combustible materials that are used in the work space could be kept in the required quantities only with an
allocated safe storage zone.
• Clothes that have been contaminated by flammable liquids should be changed.
• Hazards in electrical areas should be avoided and reported.
3. Explosion hazards elimination
• Buildup of dust covering at least 5 percent of an area’s surface postures a major explosion hazard.
4. Falling objects prevention
• Protections such as a toe board, toe rail or net could avoid falling of objects that endangers workers
wellbeing and property damage.
• Heavy objects should be located on lower shelves and placed away from the edges of desks and tables.
• Stacking objects should be situated in areas far from work space as well as aisles.
5. Frequency determination
• A combination of deep cleaning and extra lighter cleaning that comprises sweeping and reacting to leaks.
• Written practices could be stipulated which cleaners, tools and methods to use.
• Awareness of the workers should be stimulated as to follow the correct procedures.
• The initiative should be continuous over monitoring and auditing.
PPE
1. Compliancy
• Type of PPE should be determined on the type of work and the potential risks associated.
• PPE and tools should be utilized, cleaned, maintained and inspected regularly as needed.
• Some basic PPE could be used i.e. closed-toe shoes, hard helmet, face mask and safety glasses.
2. Good consequences
• High safety performance
• Encourage revenue
• Company’s good or excellence image
• Promote awareness and participation
3. Bad consequences
• Worker’s compensation
• Company’s bad or mediocrity reputation
• Property damage
• Bankruptcy
• Death
• Loss of revenue
• Blacklisted
4. Removal
• Any broken tools should be removed from the work space.