Risk Analysis for optimizing cleaning processes in material transfer systems: Reducing cross-contamination in port operations

Abstract: Port operations that simultaneously handle clinker, coal, and grains face complex challenges associated with cross-contamination. These issues directly affect operational efficiency, worker safety, and compliance with environmental regulations. Although advances in conveyor technology have improved material handling, there is still limited understanding of how cleaning processes mitigate contamination risks. Methods: This study applies a comprehensive qualitative risk analysis of cleaning systems in conveyor belts and hoppers, with emphasis on design and operational conditions that minimize contamination. Expert knowledge was gathered using HAZOP and SCAMPER techniques. Hazards were systematically evaluated through Fault Tree Analysis (FTA), Event Tree Analysis (ETA), and Bow Tie modeling. These methods allowed a structured identification of hazards, risk factors, and the effectiveness of preventive and mitigation barriers. Results: The analysis identified 27 design conditions (e.g., nozzle positioning, belt scraper optimization) and 21 operational conditions (e.g., cleaning frequency, inspection protocols, operator training) that contribute to reducing contamination. Failures in cleaning systems, conveyor operations, and dust collection were found to be key risk factors. A total of 34 preventive barriers, including high-pressure nozzles, automated washing systems, and pressurized air mechanisms, and 14 mitigation measures, such as vacuum trucks and dockside cleaning protocols, were assessed. Incorporating human factors into the risk framework underscored the role of operator awareness and structured decision-making in enhancing system reliability. Conclusions: The results demonstrate that integrating preventive and mitigation barriers significantly lowers the likelihood of cross-contamination events, strengthening both operational safety and environmental performance. This research provides practical guidance for port authorities and operators to optimize cleaning strategies, reduce material loss, and ensure regulatory compliance. Furthermore, it lays the groundwork for future quantitative risk analysis and highlights the potential of advanced technologies and automation to further improve cleaning effectiveness. By bridging a critical knowledge gap, this study supports safer, more efficient, and environmentally sustainable port operations. The insights presented are valuable for stakeholders across the maritime logistics chain who seek to balance productivity with environmental responsibility.

Keywords: Cross contamination, Port operations, Conveyor systems, Risk analysis

DOI: 10.54941/ahfe1006846

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