Safety & Health in the Stone Crushing Industry - Occupational ...

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28 Reliability and Cost Considerations The water spray systems described here require limited maintenance and are reliable if used regularly. The costs for the spray equipment (not including the installation) if water supply is already available, range from approximately $1,000 to $1,400 USD for small mills. Contact information: Perry Gottesfeld Occupational Knowledge International (OK International) 220 Montgomery Street, Suite 1027 San Francisco, CA 94104 USA Web: http://www.okinternational.org/ You can see an OK International video on "Reducing Silica Exposures in Stone Crushing" on YouTube (http://www.youtube.com/watch?v=6rBSL1WfNgw): Silica released from stone crushing is causing an epidemic of silicosis, cancer, other lung diseases and increases the risk of acquiring Tuberculosis (TB). This situation is particularly dire in India where the stone crushing industry employs over half a million people, many of whom are women and children. This video documents how mill owners reduced silica exposures by over 80% in one pilot study. For additional information on the use of water spray systems, see the following publication: Reduction of Respirable Silica Following the Introduction of Water Spray Applications in Indian Stone Crusher Mills, Gottesfeld, P, Nicas, M, Kephart, J, Balakrishnan, K, and Rinehart, R., International Journal of Occupational and Environmental Health, Vol. 14, No. 2, 2008 A.3.2 Reducing Dust When Water is Not Available Mr. Suvankar Bose, Mr. George S Sharma, Development Alternatives, Delhi Why use a "dry" dust reduction system? The water-using dust control system introduce moisture into the material flow by spraying water at dust generating locations so that fine particulates do not become air borne. This requires an arrangement to provide pressurized water to nozzles. Its installation includes a water tank, pump, filter, pressure gauges, flow meter and a network of pipeline, fitted along with regulating valves and spray nozzles. Though dust emissions can be effectively be suppressed, the water-based suppression technologies have some disadvantages: 1. Sometimes water is not available near the stone crushing sites, transporting it would require additional investments 2. Nozzles can get chocked and need regular maintenance 3. The dust coating on the crushed stone can look like low quality crushing and might fetch lower price in the market Because of these practical limitations of water-based spray systems, a dry control system or a wet & dry -combination system are options.
29 Picture 11: dust capture with dry ventilation and suction system Design and installation of a suitable engineering dust control system was one of the planned interventions in the project. During interactions with unit owners, four criteria were laid out for the team to develop a suitable dust abatement system: o the system should not interfere with the current operating processes o it should be energy efficient and operate within available surplus power o it should not consume water as the region suffers from water scarcity o investment cost should not exceed INR 400.000 or about USD 8.000 Before initiating the designing of the system, the team members studied different systems in other regions like Punjab, Rajasthan and Kerala in India. Thereafter, the system was designed, discussed with unit owners and their suggestions and inputs were integrated into the final product. The team installed two systems in participating stone crushing units: 1. A completely dry system using only ventilation and suction to capture and collect the dust particles and 2. A wet & dry combo technology that uses dry suction and wet capture of the dust Both systems are decentralized ventilation systems with cyclones as the main component. It is designed to suck dust from the sieves, crushers and chutes. The systems include the processes of a. Dust COLLECTION at locations where dust is generated (crushers and sieves). This includes an effective encapsulation of the dust generating machinery parts and b. Dust SEPARATION using cyclones, bag filters or water tanks to separate the dust and reduce dust emission into the environment air
Page 3 and 4: SAFETY & HEALTH IN THE STONE CRUSHI
Page 5 and 6: 3 Table of Contents Table of Conten
Page 7 and 8: 5 Foreword This manual is based on
Page 9 and 10: 7 Eulogy Mr. M. Nithiyananthan, the
Page 11 and 12: 9 A Safety & Health in Stone Crushi
Page 13 and 14: 11 how the work is done and how the
Page 15 and 16: 13 When writing down your results,
Page 17 and 18: 15 Picture 3: worker at the primary
Page 19 and 20: 17 Picture 5: electrical room used
Page 21 and 22: 19 − − − The transformers are
Page 23 and 24: 21 A.2.4 Using Gas Cylinders Safely
Page 25 and 26: 23 − − The conditions of trucks
Page 27 and 28: 25 A.3 Keeping Workers Healthy Ston
Page 29: 27 Flow Rate: The rate at which wat
Page 33 and 34: 31 Dust source with incomplete enca
Page 35 and 36: 33 Noise is mostly produced by eith
Page 37 and 38: 35 PPE might be needed throughout t
Page 39 and 40: 37 Metal sheets and other glare-ge
Page 41 and 42: 39 A.3.7 Taking care of Human Needs
Page 43 and 44: 41 Keep a system for head-count at
Page 45 and 46: 43 B Improving Heavy Physical Work
Page 47 and 48: 45 B.1 Main crusher operator Nature
Page 49 and 50: 47 Solutions: Proper platform shou
Page 51 and 52: 49 Solutions: Issue and use proper
Page 53 and 54: 51 − − Tripping and falling int
Page 55 and 56: 53 Picture 24: stone shed for worke
Page 57 and 58: 55 Picture 26: repairing the crushe
Page 59 and 60: 57 Proposed alternate for sieving o
Page 61 and 62: 59 B.11 Removal of Jammed Boulders
Page 63 and 64: 61 C How Much Does an Accident Cost
Page 65 and 66: 63 D Checklists and Benchmarks The
Page 67 and 68: 65 Area Yes No Comments / Action 3.
Page 69 and 70: 67 D.2 Checklist: Electrical Equipm
Page 71 and 72: 69 D.3 Checklist: Ergonomic Workpla
Page 73 and 74: 71 D.4 Checklist: Fire and Explosio
Page 75 and 76: 73 D.5 Checklist: Accident preventi
Page 77 and 78: 75 D.6 Checklist: Dust and noise re

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