Determination of chemical risk factors in mine enrichment facilities and assessment with Fine-Kinney and hazard and operability analysis (HAZOP): Gümüşhane example

The mining sector is considered one of the high-risk sectors in terms of occupational health and safety due to the chemicals used, heavy equipment, and process-related hazards. In particular, the chemicals used in ore processing plants pose significant risk factors in terms of worker health, process safety, and environmental sustainability. The purpose of this study is to assess the risks associated with the chemicals used at a mining processing plant operating in Gümüşhane Province from an occupational health and safety perspective. As part of the study, conditioning tanks, chemical preparation and transfer systems, mixing equipment, valves and pipelines, and process control mechanisms were examined; hazards that could arise from sulfuric acid, sodium silicate, zinc sulfate, lime, and various flotation reagents were analyzed. The study employed both the Fine-Kinney risk analysis method and the Hazard and Operability Analysis (HAZOP) method. Using the Fine-Kinney method, risk scores were determined by considering the probability, frequency, and severity of risks; the HAZOP method was used to evaluate the causes and potential consequences of deviations that could occur in the processes. As a result of the analyses conducted, it was determined that communication gaps, uncontrolled chemical flow, maintenance deficiencies, automation shortcomings, equipment failures, and operator errors lead to high risk levels. In particular, it was found that workers in processes involving sulfuric acid and flotation chemicals are at serious risk of chemical exposure, skin and eye burns, and respiratory problems. Furthermore, it was assessed that process deviations could lead to equipment damage, environmental contamination, and workplace accidents. The study concluded that, in order to ensure process safety, automation systems, engineering controls, regular maintenance practices, employee training, and effective communication systems must be implemented in conjunction. Furthermore, it was determined that the combined use of the Fine-Kinney and HAZOP methods contributes to a more comprehensive and systematic assessment of chemical risks in mineral processing plants.