2 Processing Induction - Content Plant OverviewArea AccessCommunicationsThe ProcessChemicals & ReagentsSafety Systems and General SafetyProcessing HazardsHouse Keeping
3 Plant Overview Gold Operation Process is a combination of: 600 tpa Underground ore sourceCoarse gold within quartzProcess is a combination of:Crushing and GrindingGravity ConcentrationFlotationLeachingElectrowinningSmelting
4 Area AccessThis induction allows you access to the following areas of the process plantCrushingHPGR, Grinding & GravityFlotation & ThickeningCIL & ElutionILR & Gold RoomReagentsMetallurgical LaboratoryTailings Storage Facilities
5 Restricted Access Areas The following areas of the plant have restricted access for security and safety purposesROM PadFront End Loader OperatingRequires reflective clothing and notification of Loader driverCIL & ElutionHCN GenerationRequires Monotox and Mask InductionILR & Gold Room Requires Metallurgy Managers’ designated person’s Authorisation for access
6 Communications In an emergency dial: 222 (internal) State: Your Name Your LocationLocation of EmergencyDetails of EmergencyAwait further instructionsSecurity extension: or 401Surface UHF Radio: Ch (Yet to be determined)
7 The Process – Crushing & HPGR Ore StoragePrimary and Secondary CrushingScreening at 25 mmWet Screening at 4 mmGravity and Grinding
8 Gravity, Grinding & Flotation Fines TSFSand Re-useSands TSFGravity Gold CircuitGravity ConcentrateClassification and Ball MillConcentrateAu and Pyrite FlotationFlotation Tailings ThickenerFlotation Feed ThickenerFine Ore
11 If you are not sure about a particular chemical …ASK! ReagentsNumerous 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 fromControl roomProcessing OfficeReagents storage areaElectronically (intranet) on the Chem Alert systemIf you are not sure about a particular chemical …ASK!
12 Reagents Regents are delivered in a variety of forms and containers. Delivered directly into storage tanksMixed with water in dedicated mixing facilities.Some includeSodium CyanideCopper SulphateSMBSSodium HydroxideHydrochloric AcidCopper Sulphate
13 Reagents - Cyanide Storage Area Sodium Cyanide Key HazardsSolid inhalation & ingestion (incl. dust)Liquid absorption & ingestionHCN gas inhalationImmediate 1st aid responseThoroughly wash victimOxygen administrationSeek urgent medical attentionRemember, if you find a possible victim of cyanide poisoning,DO NOT BECOME A VICTIM YOURSELF!Don appropriate PPE before rendering assistance.
14 Job Safety Analysis A Job Safety Analysis (JSA) must be carried out Before any new work is carried outWhen a change is made to an existing established procedurePurpose:Review the task and the hazards associated with carrying out the taskDetermine a practical method of eliminating hazards or reducing them to a manageable risk
15 Permit to WorkPermit to Work procedure ensures there is method for conducting workDesigned to assist personnel to adhere to safe work practicesWork permit procedure ensures that:Associated risks are minimised through:JSA’sAssociated permits (hot work, working at heights, confined space etc)Correct isolation of equipmentNo work is undertaken without proper instruction and authorisationOperational integrity of the plant is maintainedEnsures all stakeholder receive appropriate notification
16 Equipment IsolationA comprehensive isolation and lockout procedure has been developed for the siteAll 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 conditionsPersonnel will receive isolation and lockout training and be issued with locks to be used in conjunction with personal danger tags
17 Personal Protective Equipment Site Standard PPEHard HatSafety GlassesSafety BootsLong trousers and long sleeved shirt (Hi-Vis)CIL, Detox & Elution Monotox must be carriedOther PPE is task / area dependentHearing protectionGloves (PVC & latex)Disposable overallsFace shieldRespirator
18 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 emergencyAlways check the operation in your work area before commencing work
19 General Health & Hygiene Personal HygieneWash hands before eating, drinking or smokingUse designated crib rooms for eating and drinkingDrinking WaterOnly drink from water dispensers and from crib room facilities where indicatedCan be very hot in summer months drink plenty of water
20 Processing Hazards Start Up Sirens Automatic Start Pumps Start up sirens may sound at any given time without warning or notice.Sirens indicate that a specific piece of equipment is about to startSirens are mainly used for conveyor and mill startsAutomatic Start PumpsAll 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.
21 Processing Hazards Thickeners Conveyor Belts A thickener is an open top vessel.Do not wear a hard hat when walking/working on top of thickenersAlways 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 BeltsConveyor belts are used within the ore crushing and grinding areasThese 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
22 Processing Hazards Magnets Radiation 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)RadiationThere 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
23 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 equipmentHot surfaces can be found on the:Carbon regeneration systemCarbon elution systemGold room furnace and calcine ovenCompressed air and blower outlet piping
24 Processing Hazards Pressurised Lines Dust Pipe work in the plant operates under pressureEnsure lines are depressurised prior to commencing any work.Dissipated pressure from water and compressed air lines before disconnectionSafety clips must be used on hoses with Minsup or quick disconnect couplings.DustDust 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.
25 Processing Hazards Gases: LPG Hydrogen Cyanide Predominantly used in the gold room for heating purposesAlso used in the elution and carbon regen areasExercise care when carrying out maintenance work in this areaReport any signs of gas leaks immediately to your supervisor.Hydrogen CyanideHCN may be present on top of the CIL and Detoxification tanks.Training in the use of HCN detectors will be required to access
26 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 equipmentCarry out noisier activities in “Daytime” wherever possibleEvening is also Saturdays from 1pm and all day Sunday and public holidays.
27 House Keeping Be proud of your work place and keep it clean and tidy. If you make a mess, clean it upDon’t leave rubbish lying about the work placeKeep areas hosed clean wherever possibleEnsure all equipment and material are stored in correct locationsKeep Crib rooms and control rooms clean and tidy