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Managing Dangerous Goods in Processing Operations

Learn about the regulations, examples of chemicals, classifications, and safety measures for handling dangerous goods in processing operations.

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Managing Dangerous Goods in Processing Operations

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  1. Please read this before using presentation • This presentation is based on content presented at the Mines Safety Roadshow held in October 2009 • It is made available for non-commercial use (e.g. toolbox meetings) subject to the condition that the PowerPoint is not altered without permission from Resources Safety • Supporting resources, such as brochures and posters, are available from Resources Safety • For resources, information or clarification, please contact: RSDComms@dmp.wa.gov.au or visit www.dmp.wa.gov.au/ResourcesSafety

  2. Toolbox presentation Dangerous goods in processing operations

  3. Examples of process chemicals Flammable liquids (some frothers) – Class 3 Solvent extraction – C1 Combustible Liquid Xanthates (solid) – Division 4.2 Hydrogen peroxide – Division 5.1/Class 8 Sodium cyanide (solid and solutions) – Division 6.1 Acids and alkalis – Class 8

  4. Dangerous Goods Safety Act 2004 Section 8 … must take all reasonably practicable measures to minimise risk from dangerous goods… Taking into account: severity of the risk severity of any potential injury, harm or damage public knowledge about the risk or damage public knowledge about means to reduce or eliminate risk availability, suitability and cost of those means

  5. Dangerous Goods Safety Regulations Dangerous Goods Safety (Storage and Handling of Non-explosives) Regulations 2007 Dangerous Goods Safety (Major Hazard Facilities) Regulations 2007 Dangerous Goods Safety (Explosives) Regulations 2007 Dangerous Goods Safety (Security Risk Substances) Regulations 2007 Dangerous Goods Safety (Goods in Ports) Regulations 2007 Dangerous Goods Safety (Road and Rail Transport of Non-explosives) Regulations 2007 Dangerous Goods Safety (General) Regulations 2007

  6. Storage and Handling Regulations Applies to dangerous goods in process as well as storage Question: Does this mean CIP/CIL tanks, in line leach reactors, SX/EW, thickeners, pipework etc.? Answer: Yes - if they contain dangerous goods

  7. Storage and Handling Regulations (continued)

  8. Storage and Handling Regulations (continued)

  9. Storage and Handling Regulations (continued)

  10. MHF quantity Manifest quantity Placard quantity Small quantityincludes rural DG locations Exempt Storage and Handling Regulations (continued) MHF Regulations may also apply Licensing r. 25 Manifest r. 78 Safety management system (SMS, when required) r. 50 Emergency plan r. 75 Placarding rr. 68-72Risk assessments r. 48 Limited requirementsrr. 123-133 r. 6 Increasing quantity and hazard

  11. Dangerous goods code Australian Code for the Transport of Dangerous Goods by Road and Rail, 7th Edition (ADG 7) Available from Canprint (phone 1300 889 873) NTC (www.ntc.gov.au)

  12. What are dangerous goods? How can I tell if a material (such as cyanide in process) is a dangerous good? Listed in ADG 7 Meet test criteria from ADG 7 Stated as such on material safety data sheet (MSDS) or safety data sheet (SDS) Listed in the Regulations (e.g. sulfur in any form) Determined as such by the Chief Officer

  13. What are dangerous goods? (continued) Test criteria likely to be relevant to process solutions Example - cyanide process liquor Division 6.1 – Toxic Class 8 – Corrosive (caustic in cyanide solutions…) Class 9 – Miscellaneous dangerous goods (entries for environmentally hazardous substances)

  14. Division 6.1 – Toxic substances

  15. Division 6.1 – Toxic substances (continued) For liquids evolving toxic vapours Saturated vapour concentration in air (V) of material compared with LC50 PG I: V ≥ 10 LC50and LC50 ≤ 1000 ml/m3 PG II: V ≥ LC50and LC50 ≤ 2000 ml/m3 (and not PG I) PG III: V ≥ 1/5 LC50and LC50 ≤ 5000 ml/m3 (and not PG I/II)

  16. Class 8 – Corrosive substances Classification criteria PG I - Full thickness destruction of skin within 60 minutes of a 3 minute exposure PG II - Full thickness destruction of skin within 14 days of an exposure between 3 and 60 minutes PG III - Full thickness destruction of skin within 14 days of exposure between 1 and 4 hours or exhibits corrosion rate on aluminium or steel > 6.25 mm/year at 55ºC

  17. Class 9 – Miscellaneous dangerous goods Environmentally hazardous substances, liquid, not otherwise specified - NOS (UN 3082) Classification based on acute toxicity for fish, crustacea, algae and water plants as well as octanol-water partition coefficient (OECD test 107 or 117) or bioconcentration factor (BCF) if available (test 305) Chronic toxicity is assessed for fish (test 210), daphnia reproduction (test 211) and algal growth inhibition (test 201)

  18. Requirements • Spill containment • Segregation • Impact protection • Ventilation • Emergency plan • Separation • Licensing • Placarding - tanks • Pipework labelling • Risk assessment • Manifest & site plan • Design standards

  19. Licensing Dangerous goods stored and handled on site Reagent storage Dissolution vessels Header tanks Process vessels Process pipework Autoclaves

  20. Placarding

  21. Pipework Labelling (content, flow) Secondary containment (sheathed underground) Impact protection

  22. Risk assessment

  23. Spill containment • Delivery transfer points (solution, sparge, solid) • Pipework • Storage tanks • Process tanks • Ground contouring • Deflection screens (tank top, ground level) • Leaks from base of flat bottom tanks • Double sheathing of underground and overhead lines with provision for leaks to be obvious

  24. Spill containment (continued) Crack on compound floor

  25. Spill containment (continued)

  26. Spill containment (continued) Process tank Ring beam Compacted soil

  27. Spill containment (continued) Overflow Process tank Ring beam Compacted soil Leak

  28. Segregation of incompatible goods CIP/CIL tanks versus acid wash columns Acid lines routed through cyanide areas or vice versa Acid and alkali or cyanide lines in overhead trays together Beware of sump or bund pump operation Peroxides or combustibles

  29. CIL/CIP tanks Sump pump to CIL/CIP Acid wash column Inadequate segregation

  30. Impact protection Overhead lines versus cranes or vehicles Ground level lines versus vehicles Tanks or process vessels

  31. Ventilation issues Xanthates Hazardous zones – carbon disulfide Tails screens Out of the way Elevated Well ventilated Personnel well clear when flushing tails screens

  32. Guidance Resources Safety General Storage and handling of dangerous goods – code of practice Emergency planning code Dangerous Goods Safety Guidance Notes S01/09 and S02/09 Division 5.1 Safe storage of solid ammonium nitrate – code of practice

  33. Other approved codes of practice Class 2 – AS/NZS 1596, AS 3961, AS 4332, AS/NZS 2022, AS/NZS 2927 Class 3 – AS 1940 Division 5.1 - AS 4326, AEMSC Code of good practice – precursors for explosives Division 5.2 – AS 2714 Division 6.1 – AS/NZS 4452 Class 8 – AS 3780 Class 9 – AS/NZS 4081, AS/NZS 4681 Other – AS/NZS 3833 Note: Australian Standards and AEMSC code approved as codes of practice under s. 20 of Act

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