Cement Industry Federation
Industry Report 2013
About CIF The Cement Industry Federation (CIF) is the national body representing the Australian cement industry. Our members — Adelaide Brighton, Boral Cement and Cement Australia — account for 100 per cent of integrated clinker and cement production in Australia. More than 5000 people are directly and indirectly involved in the production of clinker and cement — mostly in regional areas — with many thousands more involved in the downstream production and distribution of concrete. In 2012–13 sales of cementitious materials in Australia were around 8.9 million tonnes, with CIF members reporting an annual turnover in excess of $2.2 billion. CIF members are continuously working to reduce greenhouse gas emissions through efficiency and innovation. In 2012–13, our industry accounted for around 6.3 million tonnes per annum of greenhouse gas emissions and the consumption of around 1.9 million tonnes of waste products from other industries — avoiding these materials heading to landfill.
Synopsis Variation on: 2012–13
2011–12
1989–90
Clinker production (1989–90 = 6.21 Mt)
6.26
+4.7%
+0.9%
Cement production (1989–90=6.86 Mt)
8.59
+0.7%
+25%
Total cementitious sales (1989–90 = 7.63 Mt)
8.92
-0.7%
+17%
Total GHG emissions (1989– 90=6.65 Mt CO2-e)
6.23
-5.8%
-6.2%
Emissions intensity (incl. non-kiln) (1989–90=0.87 t CO2-e per tonne of cementitious sales)
0.70
-5.4%
-20%
Metric
Disclaimer While all reasonable care has been taken to ensure the accuracy of the material contained herein, CIF shall not be held liable or responsible for any loss or damage incurred by any person through the use of this material.
CEO’s message It is with great pleasure that I introduce to you the 2013 Australian Cement Industry Report. This report builds on a range of earlier CIF publications and covers key aspects of the industry of interest to stakeholders — including key data on production, trade and sustainability indicators, as well as case studies from CIF member organisations. The Australian cement industry has been affected by difficult macroeconomic conditions during the period 2011–13. Historically high exchange rates have impacted trade-exposed industries such as cement, and low levels of consumer and business confidence reflect the weaker than expected economic conditions that have existed during the period. Declines in non-residential construction over the period have been offset to some extent by strong growth in heavy industry and the mining sector, with significant demand coming from major resource projects in Western Australia, Queensland and South Australia. A key focus for the Australian cement industry going forward is the continuous improvement of productivity and competitiveness conditions within an economically and environmentally sustainable framework. As part of this, a number of key areas have been identified that are critical to the successful future of our industry. These include new and continuing federal and state policies and regulations that impact on the cement industry — including in the areas of labour, transport, environmental approvals and taxes. Climate change and energy policy development remain as a key focus for our industry. CIF welcomes the government’s proposed upcoming review of the Renewable Energy Target, the development of an Energy White Paper and the proposed implementation of an Emissions Reduction Fund. However, much remains to be done in terms of the development of future policy mechanisms and CIF looks forward to continuing engagement with the government and stakeholders on these important issues. The Australian cement industry is internationally recognised for adopting fit for purpose sustainability and energy efficiency reforms where it is competitive to do so. However, alternative fuels and raw materials usage levels in the Australian cement industry are well below those in almost all other regions. CIF will continue to work with state and federal governments to identify and, wherever possible, remove barriers to alternative fuel and raw material usage, thus taking advantage of the significant opportunities that currently exist for the safe and sustainable co-processing of waste and other materials. The Australian cement industry is an important contributor to regional employment and to the growth and sustainability of the Australian economy. Our industry has the potential to prosper if it is not burdened with excessive regulation and taxes. CIF and its members will continue to work with all levels of government to target opportunities that will ensure our sector remains productive as a domestic industry and significant regional employer.
Margie Thomson Chief Executive
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about cement Cement manufacture Cement is a fine grey powder that is mixed with gravel, sand and water to form concrete — the most widely used construction material in the world.
Cement is manufactured by heating a precise mixture of finely ground limestone, clay and sand in a kiln to around 1450°C. The resulting clinker, a pebble-like material that comprises the special compounds that give cement its binding properties, is cooled and then ground with gypsum and other materials to make cement.
1 Raw material extraction
Figure 1 Overview of an integrated cement plant
2 Crushing
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3 Prehomogenisation 4 Grinding 5 Preheating 6 Rotary kiln
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2
3
7 Cooler
6 7
4
8 Clinker storage 9 Additions
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10 Cement grindings 11 Cement storage silo
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Cement use Construction of a typical family home requires around 14 tonnes of cement, and a kilometre of freeway contains as much as 2500 tonnes of cement. Varying the mix of cement, sand and aggregate enables concrete to be used in a range of applications. Products can be designed, coloured and shaped to accommodate a variety of environmental conditions, architectural requirements and to withstand a wide range of loads, stresses and impacts.
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The pre-mixed concrete industry consumes the greatest volume of cement, using it in applications such as: concrete slabs and foundations for buildings, roads and bridges; precast panels, blocks and roofing tiles; fence posts, reservoirs and railway sleepers. Cement is also used in bulk quantities in other diverse applications including: stabilisation of roads and rocky surfaces; backfill mining operations and casings in oil and gas wells; renders, mortars and fibre board. Growth in demand for cement is closely linked to Australia’s economic growth, providing long term stability for investment and employment. Cement manufacturing and distribution provide jobs and investment in regional Australia as well as the suburban and industrial areas of our cities.
c e m e n t i n d u s t ry f e d e r at i o n
Figure 2: Location of integrated cement manufacturing sites
Fishermans Landing c em e n t a u s t r a l ia
Australian Clinker and Cement Production Angaston Munster c o ck b u r n
A del a i de B r i g h ton
c em en t
Maldon B o r a l c e me n t
Birkenhead
Berrima
A del a i de B r i g h ton
B o r a l c e me n t
In 2012–13 CIF member companies operated: seven integrated clinker and cement facilities five grinding plants with product delivered to market through around 20 distribution centres.
Clinker production (Figure 3) in Australia was reported as 6.3 million tonnes (Mt) in 2012–13, down 4.7 per cent over 2011–12. Clinker capacity in the industry dropped 3.7 per cent over the period to 7.4 Mt. Australian cement production was reported as 8.6 Mt, down 0.7 per cent over 2011–12 and 25 per cent higher than in 1989–90. Cement production capacity was 14.1 Mt in 2012–13, up 15.6 per cent over 2011–12. Significant cement and clinker producers in our region include China, Japan, Indonesia, Thailand, Malaysia and the Philippines.
Railton
c em e n t a u s tr a l ia
Overall, during 2012–13 growth in the Australian cement industry was hampered by subdued building demand in certain markets, as well as rising energy costs. More recently, strong demand from major projects such as in the oil and gas and mining sectors underpinned production in the key markets of Western Australia, Queensland and South Australia. Despite the challenging economic conditions during the period, CIF member companies continued to invest in their operations. Examples include Adelaide Brighton’s $60m upgrade of the Birkenhead plant in South Australia, the construction of Cement Australia’s $180m Port Kembla Grinding Plant and Boral’s $200m investment in the Peppertree quarry.
Figure 3: Clinker and cement production (million tonnes) 10 9 8 7 6 5 4 1990
1993
1996
1999
2002
2005 Clinker
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2008 Cement
2011
2013
SOURCE: CIF 2013
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trade data Clinker imports are mainly from Japan and China Portland cement imports down slightly in 2011–12 Australia’s export volumes are not large
Imports Overall, clinker imports as a percentage of domestic production have been increasing, largely due to increasing domestic input costs. In 2012–13 clinker imports into Australia were sourced mainly from Japan (65%), China (30%) and Indonesia (3%) (Figure 4). In 2012–13 imports of clinker into Australia totalled 1.86 million tonnes (Mt), up from 1.67 Mt in 2011–12 but down on the record high of 1.94 Mt in 2010–11 (Figure 5). In 2012–13 imports of Portland Cement totalled 0.56 Mt, down slightly (3%) over 2011–12 and lower than the high of 0.67 Mt recorded in 2008–09 (Figure 5). Imports of cement in 2011–12 came predominantly from China (48%), Taiwan (43%) and Thailand (7%).
Figure 4: Clinker imports into Australia (Mt) 2.0
Thailand Singapore
1.5
Phillipines Malaysia
1.0
Japan Indonesia India
0.5
China Australia (re-imports)
0.0 2004–05
2006–07
2008–09
2010–11
2012–13
SOURCE: ABS
Figure 5: Clinker and Portland Cement imports (Mt) 2.5
Exports
2.0
Australia does not export large volumes of clinker or cement. Small volumes are occasionally exported within the Pacific region to countries such as New Zealand and other pacific Island countries.
1.5
4
1.0
0.5
Clinker Portland Cement
0.0 2004–05
2006–07
c e m e n t i n d u s t ry f e d e r at i o n
2008–09
2010–11
2012–13
SOURCE: ABS
Case study
Increased milling capacity Carbon friendly SCMs Lower environmental impact
Adelaide Brighton Cement Birkenhead plant Cement Mill 7 Project
Reduced greenhouse footprint
To improve environmental performance, increase the use of energy efficient technologies and reduce the greenhouse footprint at the Birkenhead plant, a significant upgrade was completed in 2012. This upgrade, referred to as the Cement Mill 7 project, covered four individual projects, each delivering beneficial outcomes: ■■
Installation of a third cement mill (Cement Mill 7) to increase cement milling capacity by around 750,000 tonnes per annum.
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The new cement mill provides capacity to manufacture cement using carbon friendly alternative cementitious materials (by-products from other industries) as a substitute for the primary cement material manufactured in the kiln process.
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An upgrade of the ship loading facilities at the Birkenhead wharf to a fully enclosed system incorporating the best available dust collection technology with improved environmental performance.
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An upgrade of the raw materials handling and feed system for cement milling. This has allowed the relocation of raw material open stockpiles to an undercover storage facility reducing environmental impacts in the community.
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Installation of a slag dryer and storage facility to enable the introduction of granulated blast furnace slag blended cement to the market in South Australia. Slag is a by-product of the steel industry and has already been heated and its carbon dioxide evolved. Substituting slag for the clinker, which is the most energy and greenhouse intensive component in cement, reduces the greenhouse footprint per tonne of cement.
The Cement Mill 7 project has delivered improved environmental performance through reduced ground level dust emissions, reduction in total carbon footprint and a reduction in use of natural resources as well as responding to the growing demand in the market place to produce a ‘green’ cement.
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employee health and safety Health and safety is of the utmost importance to CIF member companies
CIF member companies are committed to maintaining the health and safety of all those involved in cement production and use. Maintaining ongoing safety and health awareness as well as continual improvements in safety culture and systems is critical for the cement industry going forward.
CIF member companies are currently implementing a range of health and safety initiatives
The Cement Australia Health Program (opposite) is a good example of the types of initiatives currently being implemented in the Australian cement industry.
CIF members comply with all federal and state health legislation
All CIF members strive for the elimination of workplace injuries in all aspects of their operations — including in key aspects of cement manufacture such as maintenance, transport, handling and operating procedures. CIF members comply with national and state safety legislation using customised systems and policies, both to ensure compliance and to maintain a culture of continuous improvement in this critical area of Australian cement production.
Exports Australia does not export large volumes of clinker or cement. Small volumes are occasionally exported within the Pacific region to countries such as New Zealand and other pacific Island countries.
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Case study
Decreased rates/severity of illness and injuries Improved employee morale, self esteem and job satisfaction
The Cement Australia Health Program
Improved employee recruitment and retention Enhanced employee productivity
Cement Australia’s Health Program aims to promote better health outcomes for all of its employees. The program emphasises the importance of a person’s health and the impact it has on both work and non-work related activities. In order to successfully roll out the Health Program, Cement Australia identified that a systematic and staged approach would be required for the program’s implementation. Initially Cement Australia Managers were provided with tools and specialised training to equip them to manage and assist with the health issues within the workforce The second stage of the program involved Cement Australia supporting managers as they used their tools and training to address all the existing health cases within their business units. In the final stage of implementation, Cement Australia introduced specific initiatives to the workforce to help employees recognise their own health situation and to take accountability for their individual fitness for work. Cement Australia has identified that investment in their people through the Health Program has had many benefits including; ■■
Decreased rates/severity of illness and injuries
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Improved employee morale, self esteem and job satisfaction
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Improved employee recruitment and retention
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Enhanced employee productivity
In addition to the employee health benefits the program has achieved a significant reduction in the number of health claims, the length of time employees are off work and the overall cost of claims. As the health culture within Cement Australia continues to mature, the benefits of this program are only expected to grow.
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Climate protection and An industry active in greenhouse gas mitigation for over two decades. Recognised as a leader in greenhouse gas reduction Committed to reducing carbon dioxide emissions Cement industry emissions represent around 1.1% of Australia’s total emissions
CIF members are mandatory reporters under the Energy Efficiency Opportunities (EEO) assessments program, as well as the National Greenhouse and Energy Reporting Act (NGERS). Australian cement manufacturers are also liable entities under the Clean Energy Future program that began in July 2012. In addition to the above, CIF members contribute to the Cement Sustainability Initiative (CSI), conducted under the auspices of the World Business Council for Sustainable Development (WBCSD). The Australian cement industry is committed to further reducing its carbon dioxide emissions and to playing an active role in combating climate change.
Cement industry emissions Cement manufacturing is unique in that carbon dioxide emissions are generated from the calcination of limestone during the process — accounting for approximately 50 per cent of total industry carbon dioxide emissions. Carbon dioxide emissions are also generated directly through the use of thermal fuels as well as indirectly through the use of electricity, see figures 6 and 7.
Figure 6: Source of greenhouse emissions in a typical cement plant. 0%
100%
55% As the raw material is heated and cabon dioxide liberated in the chemical conversion of limestone to calcium oxide. CACO3 CaO + CO2 As long as cement making relies on the calcination of limestone, these emissions will be impossible to avoid.
Burning fuels (coal, gas and diesel) to create thermal energy.
32%
13%
Indirect emissions from electricity use. Cement grinding is the largest single use in a cement plant. Raw meal grinding and moving material around a plant also consumes electricity.
Globally, cement production accounts for around 5 per cent of total anthropogenic greenhouse emissions. In Australia, significant contributions from other sectors (such as agriculture and power generation) mean that cement manufacture accounts for approximately 1.1 per cent of Australia’s total emissions. Total greenhouse gas emissions, including non-kiln fuels, from Australian integrated cement manufacturers were reported as 6.3 million tonnes CO2-e in 2012–13, 5.8 per cent lower than 2011–12. In terms of total cementitious sales the emissions intensity of cement manufacturing was 0.70 tonnes of CO2-e per tonne in 2012–13 — down 5.2 per cent over 2011–12 and 20 per cent since 1990.
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greenhouse gas management Cement Industry Federation members have a number of options when it comes to reducing their greenhouse gas emissions, including: supplementing clinker with other, naturally cementitious materials; utilising suitable alternative fuels to offset fossil fuel use; as well as through investment in more efficient kiln technology and other energy efficiency measures. While these options to reduce greenhouse gas emissions are available to CIF members, they each have their own unique set of issues that must be addressed before the full benefits can be realised. Consideration of these issues must also occur within the broader economic and commercial focus of the operations, whilst being mindful of the current market and investment climate.
Figure 7: Total CIF cement greenhouse gas emissions — including emissions from non-kiln fuels (million tonnes) 8 6 4 2 0
2007–08
2008–09
Process emissions
2009–10
2010–11
Thermal emissions
2011–12
2012–13
Power (indirect) emissions
Figure 8: Cementitious material sales and emissions intensity 12 9 6 1.0 0.8 0.6 Million tonnes of cementitious material sold
Tonnes CO2-e emissions per tonne of material
Carbon Policy Principles One of the more significant challenges facing policy makers today is to ensure that Australian industry, including cement producers, continue to maintain a competitive position in relation to our neighbours, particularly those who are not as advanced as Australia in terms of environmental standards and performance. The Cement Industry Federation considers that the following principles should underpin the development of carbon policy in Australia: ■■
Global consistency — the Australian Government should continue to advocate for a globally consistent approach to pricing carbon.
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No disadvantage — maintaining the competitiveness of Australian export and import competing industry in the absence of a truly global approach — especially in regard to the Australian cement industry’s key competitors in Asia.
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Target least cost abatement — there should be a single, national policy instrument that targets least-cost abatement strategies. High-cost, low-abatement programs should be phased out.
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Exclude process emissions — it is fruitless for government to penalise a chemical process that cannot be altered in the production process.
Further detail on each of these points can be found at www.cement.org.au.
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supplementary cementitious materials SCMs are materials used instead of clinker
Supplementary cementitious materials (SCMs), otherwise known as cement extenders or mineral additions, are materials that can be used to partially substitute for clinker to produce cement and concrete, without compromising performance.
SCM use results in greenhouse gas savings
Many SCMs originate as high-volume by-products of other industrial processes. Examples include granulated blast furnace slag and fly ash — by-products of the iron and steel and power generation industries respectively.
SCMs provide for enhanced performance properties
The use of SCMs to displace energy intensive clinker results in significant savings in terms of greenhouse gas emissions — i.e. through offsetting fossil fuel requirements, and through a reduction in the amount of limestone raw material required. Overall, it is estimated that for every tonne of fly ash or blast furnace slag used in cement, there is an equivalent reduction of around 770 kg of carbon dioxide. SCMs have the added benefit of providing cement manufacturers with the ability to enhance characteristics and performance properties of the final concrete product. Examples of some of the benefits of using SCMs in certain combinations include reduced permeability, reduced cracking and controlled heat generation during concrete setting (heat of hydration). Overall, the use of SCMs by the Australian cement industry decreased slightly in 2012–13, after two years of sharp growth in this area, see figure 9. In 2012–13 CIF members used 2.6 Mt of supplementary cementitious materials, such as fly ash and slag. These materials are used in cement blends or as direct sales to the readymix and concrete products market.
Figure 9: Cement Extenders used in cement production (Kt) 3000 2500 2000 1500 1000 500 0
1990
1992
1994
1996
Fly ash used in cement production
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1998
Slag used in cement production
2000
2002
2004
2006
Limestone used in cement production
2008
2010
2012
Total extenders sold
and cement extenders Overall there is a growing share of SCMs being sourced directly by all users. Surveys conducted by the Australasian (Iron and Steel) Slag Association and the Ash Development Association of Australia show that the cementitious use of coal combustion products and iron and steel slag was 3.1 million tonnes in 2012. Australian cement producers will continue to strive for an increase in the use of SCMs as a key strategy to reduce greenhouse gas emissions associated with clinker production as well as a sustainable use of industrial by‑products.
Australian Standard for General Purpose and Blended Cements An important milestone was achieved in 2010 with the release of a new Australian cement standard, AS 3972 — that introduced a number of changes in relation to the allowable proportion of mineral additions. These changes included: a An increase in the allowable proportion on mineral additions (i.e. granulated blast furnace slag, flyash or limestone) in Type GP from 5 per cent to 7.5 per cent b The creation of a new cement type — Type GL, with an allowable addition of limestone from 8 to 20 per cent c The use of up to 5 per cent minor additional constituents in Type GP or Type GL cements. Further work is underway looking at the performance of cements using increased mineral addition, which will further reduce greenhouse gas emissions.
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Alternative fuels and raw materials Cement production is suited to energy recovery and co‑processing Alternative fuels reduce fossil fuel requirements The cement industry continues to inovate and reduce its environmental footprint
Cement kilns are ideally suited to the safe recovery of energy and co-processing of a range of waste materials. This is due to the burning conditions within the kiln, such as: high temperatures, long residence times, oxidising atmosphere and a naturally alkaline environment. Energy recovery from alternative materials reduces fossil fuel requirements and associated emissions. In addition, the introduction of raw materials into the process reduces the amount of naturally occurring raw material (such as limestone, iron ore, sands and shales) required for the process and further reduces the environmental footprint of the operations. Examples of the types of fuels and materials currently used in Australian cement kilns include granulated blast furnace slag, fly ash, used oil, tyres, solvents, spent pot liner (from aluminium smelting), carbon powders, waste wood/sawdust and animal fat. In this way Australia’s cement industry has been innovative in reducing its own environmental footprint, while at the same time reducing that of others through the uptake of alternative fuels and raw materials. In 2012–13 the use of solid and liquid alternative fuels contributed around 2 PJ of energy, or around 7.8 per cent of the Australian cement industry’s total thermal requirements.
Barriers to alternative fuel and material use There are a number of factors that determine what alternative materials can be used in a cement plant including, inter alia, suitability (calorific value and/or alternative material substitution), long-term availability and capital investment (storage, pre-processing, feed systems etc). While substitution rates are up around 7.8 per cent for the Australian cement industry, rates are typically much higher in other countries. In the European Union for example, average substitution rates for alternative fuels are around 18 per cent2. Barriers to the uptake of alternative fuels/materials in Australia include regulatory impediments — where the classification and definitions applied to waste material across the jurisdictions restrict the options available to cement kilns. Such barriers do not exist to the same extent in other countries, which goes some way to explaining the higher average substitution rates seen in areas such as the European Union. For example, the co-processing of waste has been recognised as a recovery operation under EU legislation, and is carried out in compliance with the provisions of both the Directives on the Incineration of Waste and Integrated Pollution Prevention and Control (IPCC), and recognised as Best Available Technique (BAT). There remains significant scope to increase the safe use of alternative fuels in Australian cement kilns, and the removal of regulatory and definitional barriers would aid the cement industry’s move towards more sustainable production. This should be the aim of all Australian governments and regulatory bodies.
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A nationally consistent approach to waste policy
CIF supports a nationally consistent approach to waste policy that allows for the efficient and safe use of alternative fuels and secondary materials. The 2009 National Waste Policy: Less waste, more resources, aims to provide a collaborative framework for waste management. The policy identifies the wide variety of waste policies and legal instruments that exist at all levels of government across the country, which have evolved over time and, in most cases, in isolation: ‘Their evolution has resulted in a patchwork of approaches that does not clearly articulate the respective roles of governments, objectives, or the basis for collaboration and national leadership on waste.’ Despite the complexities that exist in this area, work to date under the 2009 National Waste Policy has led to improvements — particularly in New South Wales, Queensland and Victoria. The Australian cement industry recognises the positive progress made so far by all concerned, and CIF members will continue to work constructively with state and federal governments in their efforts to create a more collaborative and consistent waste policy environment.
Local impacts The Australian cement industry continues to recognise the vital importance of maintaining its community licence to operate. CIF member companies have pursued this goal primarily through established community liaison groups and through communication tools such as community websites. The industry is committed to regular, open and cooperative communications between CIF member companies and community stakeholders. CIF member companies have adopted the Cement Sustainability Initiative’s Environmental and Social Impact Assessment Guidelines, and have committed to utilising the guidelines as a reference point. A range of local impacts resulting from plant operations require specific management by CIF member companies, including: water use, mine site rehabilitation, air quality monitoring, evaluation and improvement as well as noise management.
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Kiln technology and energy efficiency The Australian cement industry is continually working to remain competitive in a difficult commercial and regulatory environment Energy efficiency is a key driver for industry improvement Technology uptake and increased use of alternative fuels drive efficiency gains Since 1990 — fuel use down 27%, power consumption down 15%
Figure 10: Clinker production by kiln type (million tonnes) 8 7 6 5 4 3 2 1 0
1990
1992
1994
Long wet kilns
1996
1998
Semi wet/ 4 stage kilns
2000
2002
2004
2006
Suspension preheater kilns
2008
2010
2012
Precalciner kilns
The proportion of energy efficient, pre-calciner kiln technology has increased from 7 per cent in 1989–90 to over 90 per cent of total clinker production in 2012–13. This, alongside other energy efficiency measures has led to a 27 per cent reduction in fuel use and a 15 per cent reduction in power consumption per tonne of cement produced since 1989–90. However, continual improvements in energy efficiency will become increasingly difficult going forward. Further improvements will require innovation within the industry alongside collaboration with relevant jurisdictions to facilitate the increased use of alternative fuels and materials. Australian cement producers, as energy intensive operations, are always focussed on finding ways to improve their energy efficiency. Mandated programs, such as the Energy Efficiency Opportunities program, do not drive energy efficiency improvements in the cement industry. The requirement for mandatory reporting under EEO does nothing other than burden industry with yet another reporting requirement. In this context CIF supports the government’s decision to terminate EEO funding from 1 July 2014. At the very least, removing the mandatory reporting requirements under EEO for large energy users would fit well with the government’s policy objective of boosting productivity and reducing red tape. CIF members recognise that there will always be a requirement for industry to report, whether it is under programs such as the EEO or the National Greenhouse and Energy Reporting Scheme (NGERS). However the reporting systems associated with such programs must be pragmatic and proportional.
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Case study Boral Cement Berrima embarks on an ambitious revegetation program
Minimising fugitive dust Native species local to the geographic area were selected An EPA-approved rehabiiltation and landscaping plan Over 60 planting areas
Berrima Cement Works is situated close to a residential village of New Berrima. As a result Boral take great care to ensure fugitive dust generated at the site is minimised. They have implemented a dust management plan that progressively addresses the main dust sources on the land. To date, most of the dirt haul roads have been sealed or closed, a wheel wash station was installed at the exit from the shale quarry and various dust-minimising plant improvements were implemented. Boral has also embarked on an ambitious revegetation program aimed at the landscaping of unsealed surfaces and the creation of vegetative screens to minimise windblown dust generation from the premises. A local provider, Wariapendi Nursery, was selected to deliver the project. Mostly native species, local to the geographical area therefore adapted to the soil and climatic conditions, have been chosen for revegetation as per an EPA-approved rehabilitation and landscaping plan. Over 60 planting areas have been identified, with the main objective of providing effective screening of fugitive dust and reducing the generation of dust at the source. Wind barriers around the quarry, the stockpile areas and the cement plant itself will reduce dust generation from strong westerly, southerly and northerly winds. Additional screens to the north of the cement plant will further reduce fugitive dust impacts on New Berrima. Stage 1 of the program has already been completed. Approximately 3500 seedlings of native trees and shrubs were planted in the high priority areas last autumn. Most of the seedlings survived the winter and are doing very well. Stage 2 involves planting of over 12,000 seedlings by end April 2014. Lastly, Stage 3 will see planting of further 9500 seedlings in 2015. Altogether, approximately 25,000 seedlings of native species, a mix of small trees, large shrubs and large trees, will be planted. The total cost of the project is estimated to be in excess of $110,000.
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Water usage Water usage has decreased dramatically with the move towards long dry kilns Water use has continued to decrease
Historically, water was an essential ingredient for the clinker and cement production process, as the so called ‘long wet’ kilns required a raw material slurry mix to produce clinker. While the wet technology is still in use today, it represented only around 8.3 per cent of production in 2012–13. This technology has been replaced in Australia by ‘long dry’ kilns that represent a dramatic improvement over earlier wet process plants. Figure 11 shows that, in total, CIF member companies used 59761 ML of water in 2012–13, compared with 6877 ML in 2011–12 and 7067 ML in 2010–11. This usage equates to 670 L per tonne of cementitious production in Australia, 13 per cent lower than that recorded for 2011–12 and 17 per cent lower than 2010–11.
Figure 11: CIF integrated cement plants total water usage 8 7 6 5 4 3 2 1 0
2007–08 Raw
2008–09
2009–10 Potable
1 Cement industry water usage numbers have been updated to include all water sources — including bore water.
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2010–11 Recycled
2011–12
2012–13
Emissions monitoring and reporting Site-based environmental licences are designed to manage the impacts on the community CIF member companies carry out extensive emissions monitoring Monitoring varies by jurisdiction
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Overall, licence requirements have been strengthened over the last two years, including through requirements for more frequent monitoring and, in some cases, public reporting of emissions — such as in NSW. Licences governing emissions from Australia’s cement plants typically cover particulates, noise, emissions from fuel burning and water discharge to name a few, and CIF members employ a number of strategies and technologies to reduce these emissions. Examples include, but are not limited to the use of: bag filters, flue gas scrubbing, dust suppressants, truck washing facilities, and noise reduction initiatives. All CIF members report annual emissions data under the National Pollutant Inventory (NPI).
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www.cement.org.au
