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