Environmental risk assessment and corrective measures for the metal rolling industry

Identification, assessment, elimination, and control of hazards in every workplace represent the key to success as well as a critical part of any health and safety programme. Due to the complexity of the operations, equipment, and procedures in the rolling industry, this industry always involves some degree of hazard. Hence, it is necessary to apply an effective risk assessment method to manage hazards. In this research, environmental failure mode and effect analysis (E-FMEA) was used to identify possible risks, analyze environmental risks, and determine the highest risk priorities in an aluminium rolling industry. For this purpose, the production process, equipment, and tasks were examined. Stack emissions, as well as factory sewage, were analyzed according to the standard methods. Considering the results of the analysis and according to the expert panel comments, potential harmful factors were identified and classified regarding the possibility of occurrence, capability for discovery, pollution level, and intensity of their effect on the environment. Using the E-FMEA method, 210 aspects and environmental consequences were identified where 27 cases had a low risk, 148 had a moderate risk, and 35 had a high risk. For those classes of risks with a priority number above 118, correction and control operations were accomplished. The results of the repeated risk assessment approved that the protective measures have been satisfactorily effective; the control operations were performed well and the risk priority number (RPN) was mitigated to the low- or moderate-risk levels.