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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.
Synopsis
Variation on:
Metric 2012–13 2011–12 1989–90
1
about cement
Cement manufacture
Cement is a fine grey powder that is Cement is manufactured by heating a precise mixture of finely ground limestone, clay
mixed with gravel, sand and water to and sand in a kiln to around 1450°C. The resulting clinker, a pebble-like material that
form concrete — the most widely used comprises the special compounds that give cement its binding properties, is cooled
construction material in the world. and then ground with gypsum and other materials to make cement.
Cement use
Construction of a typical family home The pre-mixed concrete industry consumes the greatest volume of cement,
requires around 14 tonnes of cement, using it in applications such as: concrete slabs and foundations for buildings,
and a kilometre of freeway contains roads and bridges; precast panels, blocks and roofing tiles; fence posts,
as much as 2500 tonnes of cement. reservoirs and railway sleepers.
Varying the mix of cement, sand
and aggregate enables concrete to Cement is also used in bulk quantities in other diverse applications including:
be used in a range of applications. stabilisation of roads and rocky surfaces; backfill mining operations and casings
Products can be designed, coloured in oil and gas wells; renders, mortars and fibre board.
and shaped to accommodate a
variety of environmental conditions, Growth in demand for cement is closely linked to Australia’s economic
architectural requirements and to growth, providing long term stability for investment and employment. Cement
withstand a wide range of loads, manufacturing and distribution provide jobs and investment in regional Australia
stresses and impacts. as well as the suburban and industrial areas of our cities.
2 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
seven integrated 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. Railton
clinker and cement c em e n t
Cement production capacity was 14.1 Mt in 2012–13, up 15.6 per cent a u s tr a l ia
facilities over 2011–12. Significant cement and clinker producers in our region
five grinding plants include China, Japan, Indonesia, Thailand, Malaysia and the Philippines.
Overall, during 2012–13 growth in the Australian cement industry was hampered
with product delivered 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
to market through
mining sectors underpinned production in the key markets of Western Australia,
around 20 distribution Queensland and South Australia.
centres.
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.
4
1990 1993 1996 1999 2002 2005 2008 2011 2013
Clinker Cement SOURCE: CIF 2013
In 2012–13 imports of Portland Cement totalled 0.56 Mt, down slightly (3%) over
Australia’s export
2011–12 and lower than the high of 0.67 Mt recorded in 2008–09 (Figure 5).
volumes are not large Imports of cement in 2011–12 came predominantly from China (48%),
Taiwan (43%) and Thailand (7%).
Exports 2.0
4 c e m e n t i n d u s t ry f e d e r at i o n
Case study
Increased milling capacity
Lower environmental impact
Reduced greenhouse footprint
Adelaide Brighton
Cement Birkenhead plant
Cement Mill 7 Project
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:
■■ 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.
■■ 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.
■■ 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.
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.
6 c e m e n t i n d u s t ry f e d e r at i o n
Case study
Decreased rates/severity
of illness and injuries
Improved employee
recruitment and retention
The Cement Australia
Health Program Enhanced employee
productivity
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.
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
■■ Improved employee morale, self esteem and job satisfaction
■■ Improved employee recruitment and retention
■■ 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.
Committed to reducing
carbon dioxide Cement industry emissions
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
Cement industry of total industry carbon dioxide emissions. Carbon dioxide emissions are also generated
emissions represent directly through the use of thermal fuels as well as indirectly through the use of electricity,
see figures 6 and 7.
around 1.1% of
Australia’s total
emissions
Figure 6: Source of greenhouse emissions in a typical cement plant.
0% 100%
As the raw material is heated and cabon dioxide Burning fuels Indirect emissions from electricity use.
liberated in the chemical conversion of limestone (coal, gas and Cement grinding is the largest single
to calcium oxide. CACO3 CaO + CO2 diesel) to create use in a cement plant. Raw meal
As long as cement making relies on the calcination of thermal energy. grinding and moving material around
limestone, these emissions will be impossible to avoid. 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.
8 c e m e n t i n d u s t ry f e d e r at i o n
greenhouse gas management
Cement Industry Federation Figure 7: Total CIF cement greenhouse gas emissions — including emissions
members have a number of from non-kiln fuels (million tonnes)
options when it comes to reducing 8
their greenhouse gas emissions,
including: supplementing clinker with 6
other, naturally cementitious materials; 4
utilising suitable alternative fuels
to offset fossil fuel use; as well as 2
through investment in more efficient
0
kiln technology and other energy 2007–08 2008–09 2009–10 2010–11 2011–12 2012–13
efficiency measures.
Process emissions Thermal emissions Power (indirect) emissions
While these options to reduce
greenhouse gas emissions are Figure 8: Cementitious material sales and emissions intensity
available to CIF members, they each 12
have their own unique set of issues
that must be addressed before the full 9
benefits can be realised. Consideration 6
of these issues must also occur within
1.0
the broader economic and commercial
focus of the operations, whilst being 0.8
mindful of the current market and 0.6
investment climate. Million tonnes of cementitious material sold Tonnes CO2-e emissions per tonne of material
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.
■■ 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.
■■ 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.
■■ Exclude process emissions — it is fruitless for government to penalise a chemical
process that cannot be altered in the production process.
SCM use results 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
in greenhouse gas
and steel and power generation industries respectively.
savings
The use of SCMs to displace energy intensive clinker results in significant savings in
SCMs provide 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
for enhanced estimated that for every tonne of fly ash or blast furnace slag used in cement, there is
performance an equivalent reduction of around 770 kg of carbon dioxide.
properties 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.
3000
2500
2000
1500
1000
500
0
1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
Fly ash used Slag used Limestone Total
in cement in cement used in cement extenders
production production production sold
10 c e m e n t i n d u s t ry f e d e r at i o n
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.
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.
12 c e m e n t i n d u s t ry f e d e r at i o n
A nationally 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
consistent National Waste Policy: Less waste, more resources, aims to provide a collaborative
framework for waste management.
approach to 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
waste policy 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.
4
Energy efficiency is a
3
key driver for industry
improvement 2
1
Technology uptake
0
and increased use of 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
alternative fuels drive Long wet kilns Semi wet/ Suspension Precalciner kilns
4 stage kilns preheater kilns
efficiency gains
The proportion of energy efficient, pre-calciner kiln technology has increased from
Since 1990 — fuel use 7 per cent in 1989–90 to over 90 per cent of total clinker production in 2012–13.
down 27%, power 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
consumption down 15%
produced since 1989–90.
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.
14 c e m e n t i n d u s t ry f e d e r at i o n
Case study
An EPA-approved
rehabiiltation and
landscaping plan
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.
0
2007–08 2008–09 2009–10 2010–11 2011–12 2012–13
Raw Potable Recycled
16 c e m e n t i n d u s t ry f e d e r at i o n
Emissions monitoring
and reporting
Site-based environmental Overall, licence requirements have been strengthened over the last
licences are designed to two years, including through requirements for more frequent monitoring
and, in some cases, public reporting of emissions — such as in NSW.
manage the impacts on
the community Licences governing emissions from Australia’s cement plants
typically cover particulates, noise, emissions from fuel burning
CIF member companies and water discharge to name a few, and CIF members employ a
number of strategies and technologies to reduce these emissions.
carry out extensive
Examples include, but are not limited to the use of: bag filters,
emissions monitoring flue gas scrubbing, dust suppressants, truck washing facilities,
and noise reduction initiatives.
Monitoring varies
All CIF members report annual emissions data under the
by jurisdiction
National Pollutant Inventory (NPI).