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This document provides a detailed and professional look at safety assurance measures, helping you clearly understand the challenges posed and how to address them. Join us to discover the latest principles and strategies to ensure the working environment in the cement industry becomes safe and efficient.

Table of Contents

PART I: CURRENT STATE OF SAFETY IN THE CEMENT MANUFACTURING INDUSTRY

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some Occupational Accidents in Cement Manufacturing Plants

In the cement manufacturing industry, occupational accidents are a serious issue affecting both employees and the production process. Faced with a high-risk working environment and stringent occupational safety requirements, many plants have encountered significant challenges. This section will present some notable occupational accidents in the industry and investigate their causes to better understand the situation.

1. Accidents Related to Equipment and Machinery

Some notable occupational accidents are the result of failures during the operation of cement production equipment and machinery. This often stems from technical failures, inadequate maintenance, or improper use of equipment.

2. Causes Linked to the Production Process

Some accidents also originate from the cement production process itself, including issues related to raw materials, the heating process, and waste disposal. These factors are sometimes not strictly managed, leading to risks for employees.

3. Occupational Safety Issues and Employee Training

The importance of ensuring occupational safety and training employees cannot be overlooked. Some accidents may be related to a lack of preparation and understanding of occupational safety on the part of the employees.

4. Proposing Solutions and Improvements

Finally, this section will propose some specific solutions to improve the occupational safety situation in the cement manufacturing industry. This may include improving maintenance procedures, providing regular training for employees, and applying robust safety measures.

By analyzing occupational accidents, we can better understand their causes and propose measures to enhance occupational safety in the cement manufacturing industry, aiming for a safe and sustainable working environment.

PART II: OCCUPATIONAL SAFETY AND HEALTH IN CEMENT PRODUCTION

I. Occupational safety and health for employees operating limestone and clay grinding machines for cement production preparation

1. Job characteristics of operating limestone and clay grinding machines for cement production preparation

The process of operating limestone and clay grinding machines plays a crucial role in the cement production chain. This job requires special attention and in-depth knowledge of both the production process and the properties of the input raw materials. The machine operator technician must perform several key tasks.

First, they need to control the amount of raw material fed into the grinding machine to ensure the correct mixing ratio. This requires a solid understanding of the characteristics of limestone and clay, including particle size, mineral content, and moisture. This places high demands on raw material quality control.

Next, the technician needs to monitor and adjust the grinding process to ensure the desired particle size and uniform particle distribution are achieved. This process requires sensitivity in reading and understanding data from sensors and measuring devices.

2. Types of accidents during the operation of limestone and clay grinding machines for cement production preparation

The process of operating limestone and clay grinding machines in cement production is not without the risk of accidents. Common types of accidents include falling objects, collisions, and explosions. Falling objects can occur during maintenance or component replacement, especially when using lifting equipment. This requires workers to strictly adhere to safety rules and use full protective equipment.

Collisions frequently occur during the transport of raw materials or products, especially when using conveyor belts and drive systems. Workers need to be trained to avoid collisions and use safety measures, such as sensors and warning systems.

Explosion is a serious risk, especially when working with limestone, a combustible substance. The management and storage of combustible raw materials and fuels require special attention and strict adherence to safety rules.

3. Causes of accidents when operating limestone and clay grinding machines for cement production preparation

Accidents during the operation of limestone and clay grinding machines in cement production often stem from several main causes. One of the most important causes is the lack of knowledge and training of the workers. Technicians and operating staff need extensive knowledge of the grinding process, material properties, and safety measures.

Lack of maintenance and periodic control also plays a large role. Machinery operates continuously, and failures can occur if regular maintenance is not performed. Damaged components and unstable drive systems can lead to dangerous situations.

The working environment is also an important factor. Failure to ensure safe conditions, such as poor lighting, polluted air, and exposure to chemicals, can contribute to accidents. Maintaining a clean, safe, and healthy working environment is crucial to protect the health of the workers.

4. Accident prevention measures when operating limestone and clay grinding machines for cement production preparation

To minimize the risk of accidents when operating limestone and clay grinding machines during cement production, applying preventive measures is undeniable. Occupational safety training plays a crucial role in enhancing the safety awareness and skills of employees.

The training process should focus on a deep understanding of machinery, raw materials, and the production process. Employees need to be trained on how to read data from sensors, understand safety factors, and know how to respond to emergencies.

Raw material quality control is an important part of the preventive measures. Occupational safety training should also focus on identifying and handling unsafe materials, while promoting awareness of regular machine and system maintenance.

Preventive measures also include ensuring a safe, clean, and comfortable working environment. Safety rules must be strictly enforced, and wearing adequate protective equipment is mandatory.

5. Occupational safety regulations when operating limestone and clay grinding machines for cement production preparation

Occupational safety regulations are a system of rules and measures aimed at protecting the health and safety of workers when operating limestone and clay grinding machines during the cement production process. According to these standards, ensuring safety becomes the top priority.

First, all workers involved in the machine operation process must be fully trained in occupational safety and work procedures. This includes a clear understanding of the machinery, raw materials, and production process, as well as the correct use of protective equipment.

The regulations also cover risk control measures such as raw material quality control, periodic machinery maintenance, and management of the work environment. This helps ensure the production process runs smoothly and safely.

6. Handling emergency accident situations when operating limestone and clay grinding machines for cement production preparation

Handling an emergency accident situation when operating limestone and clay grinding machines during cement production requires quickness and in-depth safety training. In the event of an accident, an immediate response is crucial.

Employees must know how to activate the alarm system and report the accident immediately. This process includes notifying all employees in the area and contacting the emergency medical team if necessary.

Using protective equipment and having basic first aid skills is important. Employees need to know how to use a first aid kit, and apply first aid measures to the victim while keeping themselves safe.

At the same time, there should be a contingency plan and regular drills to become familiar with emergency situations. This process includes identifying safe areas, evacuation routes, and measures to prevent the accident from spreading.

II. Occupational safety and health for employees operating a kiln for heating a mixture of limestone and clay for cement production

1. Job characteristics of operating a kiln for heating a mixture of limestone and clay for cement production

The key characteristic of the job of operating a kiln for a mixture of limestone and clay in the cement production process is the decisive factor for the efficiency and final quality of the product. This process requires professionalism and extensive knowledge of the cement production process.

First, the kiln operator needs to control the ratio of the limestone and clay mixture according to the specific requirements of the cement formula. This places high demands on the quality control of input raw materials and the ability to adjust the ratio over time.

Next, maintaining the temperature and pressure in the kiln is crucial to ensure the perfect combination of limestone and clay. Stability in operating conditions ensures the melting process is strong and effective.

In addition, this process requires thorough technical supervision to monitor the process and make adjustments if necessary. This requires extensive knowledge of sensors and automatic control systems to ensure stability and accuracy in the production process.

2. Types of accidents during the operation of a kiln for heating a mixture of limestone and clay for cement production

During the operation of a kiln for a mixture of limestone and clay to produce cement, there are several types of accidents that managers and workers need to be aware of to ensure safety and production stability. Common accidents include the leakage of toxic gases from the kiln, the risk of fire and explosion due to the accumulation of methane gas, and steam pressure explosions within the kiln.

The leakage of toxic gases such as CO2 during the production process can have serious health consequences for workers. Therefore, maintaining an effective ventilation system and using personal protective equipment is important to prevent this risk.

The risk of fire and explosion due to the accumulation of methane gas, a byproduct of the heating process, requires the establishment and maintenance of effective safety systems. Ensuring proper gas exhaust and air quality control within the kiln are important measures to reduce the risk of fire and explosion.

3. Causes of accidents when operating a kiln for heating a mixture of limestone and clay for cement production

The causes of accidents when operating a kiln for a mixture of limestone and clay in the cement production process can stem from many factors. One of the main causes is a lack of equipment management and maintenance. Machinery and systems need to be periodically inspected to ensure they operate correctly, preventing incidents from occurring.

In addition, another cause is the lack of knowledge and training of the operating staff. A lack of understanding of the process and safety rules can lead to wrong decisions during kiln operation, increasing the risk of accidents.

Environmental factors such as harsh weather can also contribute to dangerous situations. Any fluctuation in environmental conditions needs to be assessed and managed to avoid negative impacts on the safety and performance of the kiln.

4. Accident prevention measures when operating a kiln for heating a mixture of limestone and clay for cement production

To ensure safety and prevent accidents when operating a kiln for a mixture of limestone and clay during cement production, several effective preventive measures must be implemented. Workplace environment monitoring is one of the crucial aspects to ensure a safe and healthy working environment.

First, conducting periodic monitoring of the air quality in and around the kiln is important. This helps to detect toxic gases such as CO2 and methane early, and to assess the level of toxicity to implement timely preventive measures.

Performing regular inspections and proper maintenance of equipment and safety systems is another important measure. Sensors, safety valves, and automatic control systems must be kept in good working condition to prevent incidents.

Training and raising awareness for operating staff about safety is a key factor. Combining safety rules with solid knowledge of the production process helps to minimize the risk of accidents.

5. Occupational safety regulations when operating a kiln for heating a mixture of limestone and clay for cement production

Occupational safety regulations when operating a kiln for a mixture of limestone and clay during cement production play a crucial role in protecting the health and lives of employees. Managers and workers must adhere to safety measures to minimize the risk of accidents.

First, the use of personal protective equipment is mandatory. Everyone involved in operating the kiln must be fully equipped with protection, including helmets, masks, gloves, safety glasses, and chemical-resistant clothing. This helps prevent direct contact with toxic substances and protects against the risk of fire and explosion.

Safety training is another crucial factor. All employees must be trained on safety rules, work procedures, and how to respond to emergency situations. This helps to raise safety awareness and reduce the risk of accidents due to confusion or lack of knowledge.

Risk management is an important part of safety regulations. Assessing and managing potential risks helps to identify necessary preventive measures and ensure that they are implemented correctly.

6. Handling emergency accident situations when operating a kiln for heating a mixture of limestone and clay for cement production

Handling an emergency accident situation when operating a kiln for a mixture of limestone and clay in cement production requires rapid and precise coordination from employees and management. In the case of a toxic gas leak or risk of explosion, ensuring safety is the top priority.

Employees must immediately report the emergency situation and activate the warning system so that everyone can evacuate quickly. At the same time, they must wear full personal protective equipment and avoid direct contact with toxic substances.

Management needs to initiate the prevention scenario and support the workers. Using firefighting equipment and water spray systems is also a crucial part of the process to control the situation. They must also notify the local emergency medical services and fire department for timely assistance.

III. Occupational safety and health for employees operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

1. Job characteristics of operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

The operation of a rapid cooling machine in cement production presents unique and important job characteristics. First, the machine is designed to process a heated mixture of clay and limestone, the two main components that form the basic raw material for the cement production process.

During operation, the machine must ensure a perfect combination of clay and limestone, while maintaining an ideal temperature to ensure the heating process is effective. Precision in controlling the temperature and mixture ratio is a crucial decision to ensure the high quality of the final cement product.

The machine also needs to be able to handle large quantities of raw materials efficiently, ensuring continuity in the production process. This requires stability and synchronization between the basic components, thereby creating a cement product with solid characteristics and uniform quality.

2. Types of accidents during the operation of a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

During the operation of a rapid cooling machine to process a heated mixture of clay and limestone for cement production, several types of accidents can occur that can affect the process and occupational safety. One of the common risks is temperature failure, where a lack of strict control can lead to an uneven or uncontrolled heating process, affecting the final quality of the cement product.

Accidents related to machinery and equipment can also occur due to technical failures, breakdowns, or power loss. This poses a challenge in maintaining stability and continuity in the production process. Furthermore, the potential for dust and other contaminants to enter can harm the machinery, reducing efficiency and increasing the risk of failure.

3. Causes of accidents when operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

There are many causes that can lead to accidents during the operation of a rapid cooling machine when processing a heated mixture of clay and limestone for cement production. One of the most significant causes is technical failure, including breakdowns or power loss in machinery and equipment. When stability and control are not ensured, the machine can operate incorrectly, causing failures in the production process.

Another cause is a lack of temperature control. When the ideal temperature is not maintained, the heating process can be affected, leading to non-uniform or poor-quality cement products. The synchronization between the components in the mixture is also a crucial factor to avoid accidents and ensure product quality.

4. Accident prevention measures when operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

To ensure safety and prevent accidents when operating a rapid cooling machine processing a heated mixture of clay and limestone for cement production, several specific measures should be applied. First, employee training is crucial, helping them to clearly understand the work process, safety measures, and how to handle emergency situations.

Temperature control is a key factor, and a strict monitoring system should be established to ensure that the heating process is stable. Tools and equipment must be periodically inspected to prevent technical failures and reduce the risk of accidents.

5. Occupational safety regulations when operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

To ensure occupational safety when operating a rapid cooling machine during the processing of a heated mixture of clay and limestone for cement production, safety regulations must be strictly implemented. First, employees involved in operating the machine must be trained on safety measures and work procedures.

Wearing the correct personal protective equipment is mandatory, including helmets, safety glasses, gloves, and heat-resistant shoes. In particular, the equipment must be periodically inspected to ensure its effectiveness and safety.

6. Handling emergency accident situations when operating a rapid cooling machine for a heated mixture of clay and limestone for cement preparation

In the event of an emergency accident while operating a rapid cooling machine processing a heated mixture of clay and limestone for cement production, handling the situation requires quickness and proactivity from the staff. First, workers must immediately report the incident to the manager and colleagues in the area.

First aid and rescue processes should be activated immediately, with the use of personal protective equipment. Employees must know how to use safety equipment such as fire extinguishers and first aid kits. At the same time, the accident area should be cordoned off and safety measures must be strictly adhered to to prevent the spread of danger.

IV. Occupational safety and health for employees operating a mill for cooled limestone and clay to make cement powder

1. Job characteristics of operating a mill for cooled limestone and clay to make cement powder

The process of operating a mill for cooled limestone and clay to create cement powder requires professionalism and precision. A prominent feature of this work includes selecting high-quality raw materials and managing the grinding process to achieve fineness and uniformity in the final product.

The process begins by feeding limestone and clay from a stable supply into the mill. The mill is designed with precision blades to grind the raw material into a fine powder. This places high demands on controlling particle size and uniformity during the grinding process.

In addition, a cooling process is used to control the temperature inside the mill and ensure that the grinding process does not raise the temperature excessively. This is important to keep the cement powder from changing or losing quality due to high heat.

2. Types of accidents during the operation of a mill for cooled limestone and clay to make cement powder

During the operation of a mill for cooled limestone and clay to produce cement powder, there are accident risks that need attention. Some common types of accidents include the risk of fire and explosion due to the interaction between raw materials and high temperatures in the mill. This requires the temperature control and fire safety systems to be carefully maintained.

Other accidents can occur when the grinding process is not tightly controlled, leading to machine overload and the risk of breakdown or damage. Regular maintenance and inspection of the mill are important to prevent these incidents.

3. Causes of accidents when operating a mill for cooled limestone and clay to make cement powder

Accidents during the operation of a mill for limestone and clay to produce cement powder often stem from many causes. One of the main causes is a lack of temperature control in the mill, leading to an increased risk of fire and explosion. This incident frequently occurs when the cooling or temperature control system is not working properly.

Another cause is related to an inefficient grinding process, which can be due to an uneven supply of raw materials or an overloaded mill. This can lead to a loss of control and machine damage, posing a serious accident risk.

The transportation system can also cause accidents if not properly maintained. Failures during the process of lifting, moving raw materials via conveyor belts, or using unsafe transport equipment are all potential causes.

4. Accident prevention measures when operating a mill for cooled limestone and clay to make cement powder

To ensure safety when operating a mill for limestone and clay to produce cement powder, there are important preventive measures that must be taken. First, regular maintenance and inspection of the mill are crucial to prevent failures and reduce the risk of machine damage. Training operating staff so they have a clear understanding of safe work procedures and know how to handle emergency situations is key to minimizing accidents.

Controlling the temperature in the mill is important to prevent the risk of fire and explosion. The cooling system needs to be maintained and periodically checked to ensure it operates correctly. At the same time, tightly managing the grinding process to avoid overloading the machine is also an important measure.

During the transport of raw materials, using safety equipment and performing regular maintenance is important to minimize the risk of accidents. The company needs to establish clear safety rules and ensure that all employees comply with these regulations.

5. Occupational safety regulations when operating a mill for cooled limestone and clay to make cement powder

Occupational safety regulations are a major focus when operating a mill for limestone and clay to produce cement powder. Employees are regularly trained on safe work procedures and the use of personal protective equipment. This includes ensuring the correct wearing of helmets, masks, hearing protection, and fire-retardant clothing.

The regulations also set guidelines for controlling the temperature in the mill to prevent the risk of fire and explosion. This includes maintaining the cooling system and performing periodic checks to ensure safe operation.

Safety measures are also applied during the transport of raw materials, especially when using lifting equipment and conveyor belts. Clear instructions on how to perform these operations safely help to minimize the risk of accidents.

6. Handling emergency accident situations when operating a mill for cooled limestone and clay to make cement powder

Handling an emergency accident situation when operating a mill for limestone and clay to produce cement powder requires thorough preparation and a quick response from staff. In the case of a fire or explosion risk, the use of an alarm system and regular drills helps to enhance awareness. Employees must know how to use firefighting equipment and systems for handling toxic gases to ensure their own safety and that of their colleagues.

In the case of a mill breakdown or overload, activating the emergency stop system and performing safety check procedures is crucial. Employees must be trained on how to use safety equipment such as emergency ladders, how to make emergency calls, and safe locations.

For accidents involving the transport of raw materials, employees must know how to use transport vehicles and lifting systems safely. The training process also needs to focus on handling emergency situations during transport to ensure safety and efficiency.

V. Occupational safety and health for employees operating a cement bagging machine

1. Job characteristics of operating a cement bagging machine

During the operation of a cement bagging machine, experts and staff need to pay attention to several important characteristics to ensure efficiency and safety in the production process. Cement bagging machines are often designed to be automatic or semi-automatic, with the ability to package cement into bags or sacks containing the final product.

The most important thing is to ensure the machine operates accurately and stably to achieve the best packaging quality. Technical parameters such as pressure, flow rate, and packaging time need to be strictly controlled to ensure each bag of cement meets quality standards.

In addition, maintaining the bagging machine requires careful observation and regular maintenance to avoid failures and minimize production downtime. This includes inspecting and maintaining the main parts of the machine, such as the packaging system, control unit, and drive mechanism.

2. Types of accidents during the operation of a cement bagging machine

During the operation of a cement bagging machine, there are many accident risks that the operating team needs to be aware of. Some common problems include the risk of injury from contact with the moving parts of the machine. This risk is particularly high when performing maintenance or cleaning tasks on the machine.

Fire is also a potential risk when working with cement. Cement dust can be combustible, especially when it interacts with high-temperature sources. Therefore, keeping the work environment clean and safe is important.

Another important aspect is chemical accidents, where contact of cement raw materials with the skin or eyes can be harmful. The use of full personal protective equipment, such as safety glasses and gloves, is important to minimize this risk.

3. Causes of accidents when operating a cement bagging machine

Accidents when operating a cement bagging machine are often due to several main causes. First, a lack of knowledge and inadequate training on work procedures and safety can lead to risky situations. Employees who do not fully understand how to use the machine, as well as safety rules, can create favorable conditions for accidents to occur.

The second cause is often related to improper maintenance or a lack of periodic inspection of the machine. Moving parts need to be regularly inspected and maintained to avoid breakdowns and reduce the risk of failure.

Negligence in implementing safety measures is another important factor leading to accidents. Failure to wear adequate personal protective equipment, or a lack of technical preparation for special tasks, can increase the risk of injury and incidents.

4. Accident prevention measures when operating a cement bagging machine

To prevent accidents when operating a cement bagging machine, preventive measures play a crucial role. First, ensuring that employees are fully trained on safety procedures and machine use is important. This training should not only focus on how to operate the machine but also include safety measures and rules of conduct in the work environment.

Periodic maintenance of the machine is another important preventive measure to ensure that moving parts are working correctly and not posing a danger. This not only helps maintain machine performance but also reduces the risk of failures and accidents.

In addition, establishing default rules for the use of personal protective equipment is important to protect employees from the risk of injury. This includes wearing safety glasses, gloves, and ear protection depending on the nature of the specific job.

5. Occupational safety regulations when operating a cement bagging machine

Occupational safety regulations when operating a cement bagging machine play a crucial role in protecting employees and ensuring a safe work environment. Employees are often required to strictly adhere to prescribed safety measures, including wearing full personal protective equipment such as helmets, safety glasses, gloves, and safety shoes.

In addition, training employees on safety rules and work procedures is a crucial step. This not only helps them understand how to operate the machine but also makes them aware of the risks and necessary preventive measures in the work process.

The regulations also often refer to periodic inspection and maintenance of the machine, ensuring that moving parts are always working correctly. Furthermore, fire prevention measures and special waste disposal rules are also mentioned to ensure a safe and legal work environment. Adhering to occupational safety regulations is not only a personal duty but also a significant contribution to production efficiency and quality.

6. Handling emergency accident situations when operating a cement bagging machine

Handling an emergency accident situation when operating a cement bagging machine requires thorough preparation and a quick response from the staff. In the event of an accident, the first procedure is to report it immediately to management and the safety team. This notification will help to immediately deploy first aid measures and prevent the risk from spreading.

Employees must be trained to use first aid equipment such as fire extinguishers, first aid kits, and personal protective equipment. The most important thing is to remain calm and follow safety procedures when performing first aid measures.

In an emergency, moving the injured needs to be done carefully to avoid further injury. At the same time, notifying management and authorities is important to ensure prompt and effective support.