This document summarizes risk analysis methods that can be used to identify and prevent occupational health and safety risks in mineral processing plants. It applies the Fine-Kinney and fault tree analysis methods to potential risks in ore dressing plants. Fine-Kinney analysis quantitatively evaluates risks based on the probability and severity of hazards. Fault tree analysis uses logic diagrams to identify causes of unwanted events. The analyses identified working with chemicals and radioactive materials as high-risk activities. Personal protective equipment and automation were recommended to mitigate risks. Wet processing and noise reduction measures were also suggested.

1. ABSTRACT: All the inorganic equipment used for simplifying the life of
human being was obtained from the mines. Ore processing is the most
important step in the transformation of mines into products. The
prevention of risks in these areas is vital because mining and ore
preparation operations are in labour-intensive occupational groups. The
measures to prevent problems related to occupational health and safety
in the mineral processing processes in which physical and chemical
methods are applied are emphasized. In this study, Fine-Kinney analysis,
a quantitative method, and fault tree analysis (FTA), a qualitative
technique, have created simple road maps to eliminate the risks posed
by common hazards. It is believed that the work will contribute to the
mining and mineral processing sectors.
INTRODUCTION
The mining industry has a position where work accidents are more
likely to take place due to the workload and working environment.
However, despite the difficulties arising from the nature of the
business, almost all of the business accidents can be avoided when
necessary measures are taken. Mining is the main industrial sector
that has existed since the most primitive ages and has become the
basic locomotive of the industry by developing at a dizzying pace in
the last few decades.Despite the fact that the construction industry
is the sector with the highest number of job losses in Turkey, the
mining sector is in the first place when the frequency of employees'
work accident is taken into consideration. Mineral processing has an
important place in the mining industry. In this study, the
measurements to prevent work accidents that may occur during ore
preparation are emphasized using 2 different risk analysis methods.
RISK ANALYSIS METHODS
Fine-Kinney Risk Analysis Method
Fine-Kinney method, established by A.D. Wiruth and G.F. Kinney in
1976, is a user-friendly and popular method performed in order to
arithmetically predict accident control. The technique is frequently
used in building, constructing and cement industries. It is accepted
that it is also one of the simple methods that can be applied to the
small and medium-sized processes or enterprises (Oturakçı et al.,
2015). In Kinney method, the risks are recognized as the appearance
of dangers and hazards. The valuation of risk is the result of three
measurements:
The possibility of an accident/damage (Table 1);
The severity of consequences for a worker when the dangers and
hazards are occurred (Table 2);
Rate of happening of dangers/hazards (Table 3).
Criterion - probability (P) is classified ranging from 0.1 - almost
impossible, to 10 – foreseeable (Stankovic and Stankovic, 2013;
Ersoy, 2013).
EMPIRICAL APPLICATIONS OF FINE-KINNEY AND FAULT
TREE RISK ANALYSIS METHODS FOCUSED ON THE RISKS
IN ORE DRESSING PLANTS
FINE KINNEY VE HATA AĞACI RİSK ANALİZİ YÖNTEMLERİNİN CEVHER
ZENGİNLEŞTİRME TESİSLERİNDEKİ RİSKLERE YÖNELİK AMPİRİK UYGULAMALARI
S. Top1, E. Demirel Top, H. Vapur
Cukurova University, Mining Engineering Department, Adana, TURKEY
Evaluation of risk R is executed by the following formula:
R = P x S x F
Then, the risk levels are observed and the precautions that can be applied are
performed according to the Table 4.
Table 4. Explanation of risk cataloguing (Stankovic and stankovic, 2013)
Fault Tree Risk Analysis Method
FTA is a logical analysis technique concentrated on an
unwanted event of a structure and describes its origins. FTA
could be basically labelled as an investigative technique,
with itemised undesired state of the process (and the most
prevalent state vital for the security situation). Used symbols
for the FTA are described in Figure 1. OR gate refers an event
occurs as long as at least one of the input events takes place
while AND gate refers an event occurs only if all input
conditions are met.
Figure 1. Used symbols for the FTA.
RISKY SITUATIONS AND PRECAUTIONS
Some potential OHS risks in mineral processing plants are shown
in Table 5. It was determined that “Working in plant using
chemical process” and “working with radioactive device or
radioactive material” are found to be activities with a high level of
risk (R IV). Therefore, personal protective equipment (PPE) must
be used or interaction of people with chemicals and radioactive
materials must be removed especially in source. Automatic
machines should be used for these type activities and the human
effects must be vanished. PPEs must be used during repair and
maintenance of the machines using hazardous materials. Risks
associated with working in noisy and dusty environments with
lower risk rates can also be reduced by the use of PPEs.
It should not be forgotten that work activities with low risk levels
can lead to serious damages and loss of life. Therefore, solutions
should be sought not only for high risk but also for less risk level
activities. Applying wet processes to get rid of the dust and
changing the routine working order over time to overcome
psychological problems are some measures that can be taken in
this direction.
Figure 2 presents 4 scenarios related to OHS problems that
could occur in ore preparation plants and possible results of
these scenarios.
By using wet processes, dusts can be eliminated from the
sources without the need for dust collectors (Figure 4).
The timely change of the mill rubber linings and the
appropriate periodic control of the machines and equipment
allow to reducing noise in mineral processing plants. It is also
an effective and inexpensive method the providing
headphones as personal protective equipment (PPE) for
employees who are close to noise generating equipment
(Figure 5). Extreme care should be taken when processing the
radioactive ores such as uranites and monazites. PPEs must be
worn. Otherwise, death or injury is inevitable as a result of
the fourth scenario (Figure 6).
CONCLUSIONS
Within the scope of the study, basic measures to be taken in
respect of OHS in the mineral processing processes have been
examined; empirical 2 risk analysis draft have been established.
REFERENCES
1. Ersoy, M., 2013. The role of occupational Safety Measures on Reducing Accidents
in Marble Quarries of Iscehisar Region.
2. Haimes, Y.Y., 2009. Risk Modeling, Assessment and Management.
3. Kinney, G.F. and Wiruth, A.D., 1976. Practical Risk Analysis for Safety
Management.
4. Oturakçı, M., Dağsuyu, C. and Kokangül, A., 2015. A New Approach to Fine
Kinney Method and an Implementation Study.
5. Stamatelatos, M. and Vesely, W., 2002. Fault Tree Handbook with Aerospace
Applications.
6. Stankovic, M. and Stankovic, V., 2013. Comparatıve Analysıs of Methods for Risk
Assessment - “Kinney” and “Auva”.
7. Top, S. and Vapur, H., 2015. Problems and Proposed Solutions for Mineral
Processing Plants from the point of OHS.
8. Top, S. and Vapur, H., 2016. OHS Problems in Basic Ore Beneficiation Plants of
Adana Region and Investigation of Dangers in terms of Risk Analysis.
In the FTA analysis, only employee health was taken into account
and material losses and loss of working time were neglected. Four
scenarios were examined in more detail in subtrees. The OHS rules
have a major precaution in mineral processing enterprises using
chemicals. In advanced technology, mineral processing processes
usually involve extraction or flotation. For this reason, the
implementation of the processes in closed tanks will prevent the
source of the problem. In processes where this is not possible, the
chemicals are degraded before they are sent to waste dams, or they
are brought to neutral (mostly harmless) from acidic or basic
conditions by applying pH elevation procedures. In Figure 3, it appears
that employees who do not use PPE will suffer as a result of the
damage of a constituent detoxification system that applies chemical
detoxification.