Displaying items by tag: Safety

UK: Cemex has installed Patol’s Firesense linear heat detection cable (LHDC) at its 1.8Mt/yr integrated cement plant in Rugby. The installation uses a digital interface to monitor a zonal length of LHDC which will detect any overheating in the plant’s lubrication systems.

Taiwan: Taiwan Cement has reassured the public about the quality and safety standards of its cement and other products. It follows fraud charges being issued to a former government official for supplying raw materials mixed with industrial waste to the cement producer, according to the Taipei Times. Taiwan Cement says it is conducting inspections on all raw materials, including taking random samples of the top and bottom layers of delivery trucks from suppliers.

Lai Chin-kun, a former Hualien County Council speaker, secured local government contracts for his family’s companies to dispose of industrial waste, including industrial byproducts and inorganic debris from electroplating, optoelectronics and display panel manufacturers and pulp paper processing companies. Another family company won a contract with Taiwan Cement in 2010 to supply limestone, clay, sand and other raw materials required for cement production.

Prosecutors allege that when supplying raw materials to Taiwan Cement, Lai instructed company drivers to fill the bottom half of the trucks with industrial waste and place natural materials, such as clay, sand and limestone, on the top half to fool inspectors. Lai reportedly made US$14.1m from the scheme from 2010 to 2015.

Spain: FYM-HeidelbergCement has reached a record two years without an accident at its Malaga cement plant. The milestone also includes no accidents for subcontractors working at the site. The company has operated a ‘Zero Accident’ program since 2000 that has focused on improving the safety culture for all staff.

Germany: HeidelbergCement has highlighted occupational safety and research into CO₂ reduction as priorities in its sustainability report for 2017. It reduced its accident frequency rate for employees with at least one lost working day per 1,000,000 hours across cement, ready-mixed concrete and aggregates to 1.8 in 2017 from 2.2 in 2016.

“This represents a significant improvement. A large number of locations have now been accident-free for several years, while others have seen drastically reduced accident rates. Nevertheless, serious accidents still occurred in 2017. We will therefore further intensify our efforts to prevent accidents on a permanent basis,” said Bernd Scheifele, the chairman of HeidelbergCement.

The building materials producer has also singled out its commitment to reduce its specific CO₂ emissions by 30% in 2030 compared with 1990. It plans to support this by continually increasing the proportion of alternative raw materials and fuels and, wherever possible, to make its production processes more efficient. In addition, HeidelbergCement has invested in research programmes on carbon capture and its utilisation as a raw material. In 2017, it spent Euro141m on research and technology, an increase of around Euro24m from 2016.

Following HeidelbergCement’s acquisition of Italcementi in 2016 its CO₂ emissions have increased. Its specific net CO₂ emissions (per tonne of cementitious material) rose by 1.9% year-on-year to 609kg Co₂/t in 2017 from 598 kg Co₂/t in 2016. Its overall proportion of alternative fuels has also decreased slightly dropping to 20.8% from 21.4%. However, its specific energy consumption for cement and clinker continued to fall in 2017.

Brazil: The Public Labour Ministry has signed an agreement with producers to reduce the standard weight of cement sacks sold locally to 25kg from 50kg. 33 cement producers, the local competition authority (CADE), the national cement industry union (SNIC), the Brazilian Portland Cement Association (ABCP) and Labour minister Ronalo Fleury all signed the arrangement, according to Surgiu. The agreement has been planned to reduce workplace accidents involving cement despatches.

The agreement establishes a deadline of 31 December 2028 for companies to adapt to the new standard, after which period only cement specifically for export can be over the 25kg limit, with all other sacks over 25kg to cease being sold from 1 January 2029. The agreement follows four years of negotiations.

UK: Hanson UK’s sustainability report for 2017 shows that its CO₂ emissions per tonne of product have fallen by 7.2% to reach the lowest level for five years. However, the subsidiary of Germany’s HeidelbergCement may face issues meeting its target of a 10% reduction by 2020 from its 2010 figures as its CO₂ emissions from production have rise by 5.7% since 2010.

Overall, the company described 2017 as a year of ‘solid’ progress. It passed its 2020 targets for reducing both mains water use and waste to landfill. The number of lost time injuries remained static at 21, but the frequency rate was down on the prior year and there was a three-month unbroken spell without a lost time injury. The building materials producer also launched HeidelbergCement’s Sustainability Commitments 2030, including a set of targets for the group to achieve by 2020.

US: The Portland Cement Association (PCA) has announced the winners of the 2018 Safety Innovation Awards. The awards recognise creative safety-enhancing projects in the cement industry. Winners were determined by a panel of judges that evaluated submissions from across the country for milling/grinding, distribution, pyroprocessing and general facility.

Cemex USA’s Miami plant Florida won the milling/grinding category with its new process to load ball mills. The site developed a new mill loading process that uses a small hopper for grinding media, and an incline transport system with buckets to convey the grinding media directly to the mill. This new system eliminates the interaction between the employee and the machine, reduces the number of people needed to load the mill from five to two, and eliminates the need for employees to stand on top of the mill. This new system also improves mill loading rates from seven drums/hr to 30 drums/hr.

Cemex USA’s Houston operations in Texas won the pyroprocessing category for it use of drones for hazardous inspections. It has implemented a system for using protected air drones to inspect enclosed and confined spaces. Visual inspections of enclosed areas (preheater towers, tanks, silos, process ducts, etc) normally require intrusive equipment, long delays for system cooling, and placement of employees on scaffolding in confined spaces. These drones utilise an outer protective cage to minimize the risk of breakage due to impact. The drone program has eliminated the risk of putting staff in confined spaces, reduced the cost of scaffolding, and reduced the overall time for inspections.

LafargeHolcim US’ Corporate Program in Chicago won the distribution category for its X-Factor barge cover. It has developed a process for barge cover removal that reduces the risk of falls from employees stepping on to the barge. The X-Factor barge cover, developed over the last three years with a contractor, uses the latest technology and a no-touch design to allow a crane operator to perform all functions associated with barge lid handling without additional human assistance. Barge workers will no longer be required to step onto the barge to remove or replace barge covers, eliminating a potential fall risk.

Ash Grove Cement’s Louisville plant in Nebraska won the general facility category for its use of magnets as duct hole patches. Ash Grove has developed a hole-patch technique using magnets. Magnetic patches are quick, simple, and effective at preventing or limiting the release of materials from holes created in ducts caused by abrasion, leading to a cleaner plant, reduced slip, trip and fall risks, and fewer related Mine Safety and Health Administration housekeeping citations.

Cemex USA’s Brooksville in Florida also won the general facility category for its filters moved to ground level project. It redesigned the blower housings to move the filter from the top of the blower housings to an easily accessible location at ground level. The redesigned blower housing eliminates the need for employees to climb up and down a ladder, reducing overexertion and fall hazard.