australian cement industry
TRANSCRIPT
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S U S TA I N A B I L I T Y R E P O R T 2005
A U S T R A L I A N C E M E N T I N D U S T R Y
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about CIF The Cement Industry Federation (CIF) is the national body representing the Australian cement industry, comprising the three producers
■ Adelaide Brighton Ltd
■ Blue Circle Southern Cement Ltd
■ Cement Australia Pty Ltd
Together these companies account for all of the integrated production of clinker and cement. Their operations are located around Australia, and include 15 manufacturing sites, 10 mines and 74 distribution terminals. In 2004, the industry employed 1840 people and produced over nine million tonnes of cementitious materials, with an annual turnover in excess of $1.25 billion.
In collaboration with its member companies, the CIF works to advance a competitive and sustainable Australian cement industry that is committed to best practice in all areas of cement production.
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It is my pleasure to introduce the first Sustainability Report from the Australian
cement industry. In previous years we have produced two reports that highlighted
the industry’s benchmarks in environmental practice, reviewed performance and
considered future challenges. This year we have extended the environmental reporting
to include a wider range of sustainability issues as well as increasing our focus
on long-term challenges and opportunities.
In pursuit of sustainable development in the global cement industry, the World
Business Council for Sustainable Development launched the Cement Sustainability
Initiative (CSI) in 1999. The CIF and its member companies are pleased to be
participating in this initiative, and have used their actions in the six CSI criteria as a
basis for this Sustainability Report.
The Cement Sustainability Initiative aims to increase both the cement industry’s
contribution to sustainable development and public understanding of that
contribution. Each member company has already undertaken a wide range of
environmental and social actions, and are rightly proud of their achievements.
But there is still much to be done, and we must continue to find responsible
avenues to integrate strong financial performance with an equally strong
commitment to social and environmental responsibility, while always
maintaining open dialogue with stakeholders.
As part of our desire for continual improvement I welcome your feedback
on this report through our website: www.cement.org.au
Mark Chellew
CIF Chairman
message from the chairman
scope of the report
This report builds on the environment reports of 2000 and 2003 and discusses sustainability performance using the six criteria of the Cement Sustainability Initiative:
■ Climate protection
■ Fuels and raw materials
■ Employee health and safety
■ Emissions reduction
■ Local impacts
■ Internal business processes
These criteria cover all stages of cement production.
The report also focuses on the challenges to achieve sustainability, opportunities presented by new technology, and opportunities that could arise from international research. The successes are also highlighted, and include case studies from CIF member companies. The long term future will require an integrated approach, with careful investment in new technology and processes to improve sustainability and ensure financial viability.
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what is cement?In 1824, English bricklayer Joseph Aspdin took out a patent on a product he called ‘Portland cement’. The material’s colour was similar to stone quarried at the Isle of Portland. Since then Portland cement has proved a versatile and inexpensive construction product, and created an efficient industry that uses technology to advance sustainable development.
Cement making is a capital and energy intensive industry. Performance improvements increase efficiency in resource management, ecosystem protection, pollution reduction and improve quality of life.
Cement is the ‘glue’ that binds aggregates
together to form concrete, one of the key
construction materials available today.
Second only to water, concrete is the most
consumed material on earth, with three tonnes
per year used for every person. Twice as much
concrete is used in construction as all other
building materials combined. Construction
of a typical family home requires 14 tonnes of
cement, and a kilometre of freeway contains
as much as 2500 tonnes of cement. There is
little doubt that concrete will remain in use
well into the future.
Varying the mix of cement, sand and aggregate
enables concrete to be used in a range of
applications. A building can be made to
last for 100 years. 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.
The pre-mixed concrete industry consumes
the greatest volumes of cement, using it in
applications including:
■ 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.
Once the useful life of a concrete structure has
passed, the concrete can be recovered during
demolition and recycled for use as construction
roadbase and aggregate.
The industry supplies almost all the cementitious
requirements of the Australian market from
local manufacturing sites. The term cementitious
materials includes all types of cement and
supplementary cementitious materials (SCM)
such as flyash and blast furnace slag that are
used as an alternative for cement in concrete.
Imports and exports constitute between 10 and
14 per cent of the total Australian production
of cementitious materials, supplementing any
shortfall in supply as market demand changes.
Over the past 15 years, substantial capital
investment has been undertaken in new and
upgraded capacity, particularly installation of
state-of-the-art precalciner dry-process clinker
technology at the expense of older wet process
equipment. The use of modern technology
by the Australian industry is now similar
to that in highly developed countries
like Germany and
Japan.
Table 1: Technology used to manufacture cement in Australia—1990 and 2005
Clinker Production 1990 2005
Precalciner Dry process 8% 74%*
Dry process 31% 10%
Wet process 61% 16%
* Includes kilns under construction to be completed in 2005
Source: CIF Annual Survey 2004
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SocialCement manufacturing is a highly technical
industry that employs a wide range of skills
at a variety of levels. Due to its regional
nature these roles are spread across Australia.
The Australian industry works closely with
the international scene, importing world
class technology and practices. Locally the
industry uses innovation and opportunity
to introduce new ideas and involve other
industries, integrating practises that
strengthen the manufacturing base of
Australia.
EnvironmentThe cement industry has opportunities to
reduce the environmental effect of both
industry and the community through the
use of alternative fuels and raw materials.
In addition, supplementary cementitious
material (SCM) utilises suitable wastes in the
cement making process instead of clinker.
These actions not only conserve natural
resources and reduce landfill but in many
cases reduce greenhouse gas emissions.
Advances in technology also contribute to
reducing the impact on the environment.
EconomicWhile Australia is a relatively small market
by world standards it has a good supply of
raw materials for cement manufacturing.
The industry has invested and worked to
remain globally competitive by modernising
plants and opening cement standards to
the use of SCM in concrete and mineral
additions in cement. These actions also
reduce production costs.
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6
8
10
1990 1992 1994 1996 1998 2000 2002 2004
Prod
uctio
n in
tonn
es (m
illio
ns)
1990 1992 1994 1996 1998 2000 2002 2004
Prod
uctio
n in
tonn
es (m
illio
ns)
0
2
4
6
8
1990 1992 1994 1996 1998 2000 2002 2004
Mate
rials
(’000
tonn
es)
0
500
1000
1500
2000
2500
1990 1992 1994 1996 1998 2000 2002 2004
Empl
oyee
costs
($m
illio
ns)
100
110
120
130
140
150
160
1990 1992 1994 1996 1998 2000 2002 2004
Effic
iency
gain
-5%
0%
5%
10%
15%
20%
25%
30%
35%
1990 1992 1994 1996 1998 2000 2002 2004
Taxe
s and
char
ges (
$mill
ions
)
0
30
60
90
120
150
Cement
Clinker
Kiln type
■ Precalciner
■ Suspension preheater
■ Semi wet/dry
■ Long wet
■ Total SCM in concrete
■ Limestone in cement
■ Slag in cement
■ Flyash in cement
Employee costs (note: 2004 data unavailable due to company merger)
Staff at year end
= 1000 staff
■ Tonnes cement produced per employee ■ = 500 tonnes cement
Fuel
Power
Government taxes
■ Federal
■ State
Clinker and cement production
Clinker production by kiln type
SCM used in cement or on sold for contrete production
Employee productivity
Fuel and power efficiency gains since 1990
Government payments
Raw materialsThe main raw materials used in cement
manufacture are limestone, shale, clay,
sand and iron ore.
These natural materials are extracted
from mines and transported to the
cement plant, where they are blended
to manufacture the required cement
quality.
Environmental issues arising from the
handling of raw materials, including
dust and stormwater runoff, need to
be managed at both the mine and
cement plant. The industry is uniquely
positioned to responsibly use waste
products as an alternative to natural
raw materials. This reduces the
environmental impacts of mining
and landfill.
cement manufacture
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Clinker productionPrecisely combining calcium, silica,
aluminium and iron is essential to
ensure the target chemistry for clinker
is achieved. Once the correct balance
of raw materials has been achieved,
the ‘raw mix’ is very finely ground
into ‘raw meal’.
Raw meal is heated to 1000ºc
extremely quickly, ‘calcining’ the
calcium carbonate in limestone to
calcium oxide before being fed into
a rotary kiln. This process is heated
by a precalciner burner. In the rotary
kiln tube, the feed moves slowly as
the tube rotates, becoming hotter as
it approaches the kiln flame, reaching
a temperature of 1450ºc. At this
temperature a calcium silicate matrix
called ‘clinker’ is formed. The clinker is
then cooled rapidly and stored.
No ash is produced. Materials fed into
the process become part of the clinker,
ultimately forming an intrinsic matrix
in which the materials are fixed and
immobile.
High temperature, long retention times
and complete combustion are strengths
of this process.
The continuous process and strict,
highly technical control ensures the
conversion of the materials into a
new product. This is vital to produce
cement clinker with a mineralogical
structure that is highly reactive with
water.
To conserve natural resources and
reduce CO2 emissions, alternative
fuels such as waste tyres, timber,
oils and other materials are used.
The combustion of fuels, and the
conversion of limestone to clinker
releases emissions such as CO2,
metals, oxides of nitrogen (NOx)
and dust which are monitored and
regularly reported as part of each site’s
licence to operate. Manufacturing sites
in Australia monitor emissions as key
environmental indicators.
R O TA RY K I L N
R AW M I X
F U E L S
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cement manufacture
Cement grindingOnce cooled, clinker is ground with
gypsum and other minerals, such as
limestone, to produce the grey powder
commonly recognised as cement.
Changing the chemical composition of the
raw mix enables cements with different
properties to be produced for different
uses. Cement can also be blended with
supplementary cementitious materials
(SCM), such as flyash and slag, to make
blended cements. Cement is then pumped
to silos for storage and dispatch.
Mineral additions and SCM are added to
reduce the amount of clinker in cement.
This in turn reduces the fuel, power, process
emissions and raw materials associated with
cement production. At the same time it
creates a use for material considered to be
a waste product of other industries.
DistributionCement and SCM are distributed
by road, rail or sea.
The manufacture of cement is energy intensive, with each grinding stage using significant amounts of electricity which contribute indirectly to emissions of CO2 from power generation.
B A L L M I L L
C E M E N T P O W D E R
At every stage, products are chemically and
physically tested to ensure they meet the
strict specifications and performance
requirements of the customer
and Australian standards.
S C M
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CIF members recognise
that running their
operations according
to the principles of
sustainable development
is essential in today’s
world.
World Business Council for Sustainable Development The World Business Council for Sustainable
Development (WBCSD) launched the Cement
Sustainability Initiative (CSI) in 1999, and then
in 2002 the Agenda for Action, with six key areas
forming the structure of this report. Within that
agenda, action is being undertaken by the global
cement industry over a five-year term.
The CIF is a Project Partner in the CSI, and
member companies are committed to making
an effective contribution. This involvement has
included supporting the formation of common
protocols for CO2 accounting, selection of fuels
and raw materials for cement manufacturing,
health and safety guidelines, community
engagement and government interaction.
These protocols have been adopted by the
Australian industry with local manufacturers
made increasingly aware of issues affecting
the industry internationally and strategies in
operation elsewhere. The monitoring of research
and development in technology and emission
regulations has contributed significantly to
the Australian industry’s efforts to ensure its
standards are world class.
The four basic principles for the cement industry’s
contribution to sustainable development are:
commitment to sustainability
Through the CSI, the
Australian cement
industry has widened
its focus from
environmental to
sustainability reporting,
which is a progressive
step for all stakeholders
involved in the
industry’s evolution.
■ Promoting quality of life
Producing high-quality cement products
for all types of construction projects, while
protecting health and safety. Providing
preferred employment opportunities
and working with our local communities.
■ Protecting ecosystems: Actively preventing mining or related activities
from systematically degrading natural systems
beyond rehabilitation or recovery.
■ Managing resources
Increasing the efficiency with which
the industry uses energy and material
resources, and identifying new ways
to use by-products from other industries.
■ Reducing pollution
Minimising concentrations of polluting
substances that are present in the air, ground,
or water as a result of cement manufacturing
activities.
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Greenhouse ChallengeReflecting the industry commitment to
climate protection, the CIF has been a
member of the Australian Government’s
Greenhouse Challenge Program since 1997.
After this agreement lapses in 2005, the CIF
will commit to fresh targets for 2012 under
the new cooperative agreement, part of the
Greenhouse Challenge Plus program.
The Australian Government mandates annual
reporting of emissions in the public National
Pollutant Inventory (NPI). CIF members have
combined their resources to improve accuracy in
reporting across the industry, raising the usefulness
of the NPI data base. The CIF has used an industry
wide investigation into process emissions to further
Australian Government work in verifying a national
dioxins inventory. The CIF will continue to support
the development of the government’s National
Implementation Plan for Persistent
Organic Pollutants.
commitment to sustainability
Environmental reporting
Sustainable
development:
“development that
meets the needs of
the present without
compromising the
ability of future
generations to meet
their own needs”
WORLD COMMISSION ON
ENVIRONMENT AND DEVELOPMENT
climate protectionNational greenhouse reporting
Climate protection
is recognised as an
important challenge
for the cement industry
as it directly contributes
1 per cent to Australia’s
GHG signature.
■ heat recovery initiatives
■ low-energy conveying systems to transport
plant materials
■ substitution of low GHG emission fuels for coal
■ substitution of low GHG emission raw
materials for limestone
■ use of SCMs as alternatives to cement in concrete.
The top five abatement projects highlighted in the
2004 Greenhouse Challenge Report are:
■ upgrade of a pre-heater kiln to best available
technology (BAT)
■ upgrade of a clinker cooler to increase power
efficiency
■ installation of a high efficiency separator on a
cement mill
■ addition of slag, a waste from steel production,
to replace limestone in raw mix
■ optimising raw mix composition through
improved mine modelling and extraction
techniques.
International GHG reportingAs a participant in the CSI Agenda for Action,
the Australian industry furthers its involvement
in global climate protection initiatives. Joint
activities nominated by the Agenda for Action
include developing a universal framework
for measuring and reporting greenhouse gas
(GHG) emissions from the cement industry.
The CIF has been active in helping develop
this framework, to ensure consistent, relevant
greenhouse emissions inventory reporting and
practicability.
An early industry initiative came through
a voluntary agreement with the Australian
Government using the Australian Greenhouse
Challenge Program. Greenhouse emission
(GHG) reduction plans commenced at the
signing of this agreement in 1997. This required
annual greenhouse gas emissions reporting to
the Government through an industry-developed
protocol, the Greenhouse Energy Management
System (GEMS).
The CIF’s 2004 survey shows abatement projects
are expected to yield a 2005 benefit that is 70 per
cent better than the reduction target set in the
1997 agreement. The combined industry inventory
in the report shows emissions have been reduced
by 21 per cent per tonne of cementitious material.
This has been achieved by investment in world
class technology including:
■ precalciner kilns to make clinker
■ high-efficiency classifiers fitted on grinding
operations
■ power controls on filters
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The CIF’s experience in GHG reporting has
enabled the cement industry to maintain
comprehensive data from 1990. The industry
has focused on efficiency indicators that
monitor performance within its control, such
as reducing GHG emissions from the amount
of fuel required to produce one tonne of clinker.
Other measures such as the absolute amount
of GHG emitted from the process are also
reported.
climate protection
■ Participating in national greenhouse debate through the Industry Action Agenda
Working Group on Energy and Greenhouse issues.
■ Discussing the industry’s role post-Kyoto.
■ Investigating technologies that have benefits in sustainable building materials and
GHG mitigation.
■ Reviewing the Australian Greenhouse Office, Greenhouse Challenge Plus program.
■ Reviewing the development of state and commonwealth greenhouse policy.
■ Participating in streamlined government reporting of energy efficiency and
greenhouse emissions.9
The second joint project
identified by the CSI
Agenda for Action is to
work with the WBCSD
and other bodies to
develop public policy and
market mechanisms for
reducing CO2 emissions in
the industry. In Australia
the CIF is supporting
this by:
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The next agreement will be aligned with the WBCSD
CO2 protocol and will set abatement targets for the
industry in 2012. Other activities focused on
improving inventory accuracy include:
■ verification of calcination factors by site
for the Australian cement industry
■ lodgment of supporting documentation
for the industry’s 1990 baseline inventory
■ development of a common greenhouse calculator
for estimating CO2 savings from site projects.
We are in
an industry
that can
make a
difference
A new commitment to greenhouse gas reductionOne of Cement Australia’s first greenhouse
projects at Railton was to plant a tree farm
to help offset the generation of greenhouse
gases. More than 300 000 Eucalyptus
globulus (Tasmanian Blue Gum) trees
were planted over 275 hectares at the plant.
Growth rates have been excellent, with the
trees currently over 10 metres high. It is
estimated that the trees will absorb over
40 000 tonnes of carbon dioxide over 15 years
until harvesting. This project forms one of
Cement Australia’s abatement projects under
the Greenhouse Challenge program.
Following eight
years of involvement
in the Greenhouse
Challenge, the CIF is
renewing the industry’s
targets, and will sign
another cooperative
commitment in 2005.
1998 1999 2000 2001 2002 2003 2004
Tonn
es C
O 2 abate
d(m
illio
ns)
0.50
1.00
1.50
0.75
1.25
The abatement of CO2 through the Greenhouse Challenge Program
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1990 1992 1994 1996 1998 2000 2002 2004
Prod
uctio
n of
cem
entit
ious
mate
rial
in to
nnes
(mill
ions
)To
nnes
CO 2 em
issio
nspe
r ton
ne o
f cem
entit
ious
mate
rial
6
0.95
0.65
0.75
0.85
8
10
7
9
21% reduction in CO2 emissions per tonne of production since 1990.
Cementitious material sales and CO2 emissions
A new commitment to greenhouse gas reduction
calcined, driving off any CO2 during the steel making process.
As the slag has been heated previously, less fuel is required to be burnt in the kiln, reducing the CO2 emissions from combustion. In addition, the calcined calcium in the slag replaces limestone in the raw mix, which is another source of CO2. Furthermore, as a raw material the slag doesn’t require crushing, saving indirect emissions of CO2 from power generation.
The team at Angaston has demonstrated a total of 9000 tonnes of CO2 reduction per year when using slag.
Diminishing supplies of Birdwood clay prompted Adelaide Brighton’s Angaston operations to seek an alternative raw material to assist in the manufacture of its popular Brightonlite cement.
After implementing an action plan and gaining the appropriate approvals, Angaston began conducting trials using blast furnace slag, a by-product of steel manufacturing. Results found that the slag is an ideal alternative to Birdwood clay in making Brightonlite clinker.
Slag contains calcium, silica, and alumina with very low iron oxide, all of which have been
Use of blast furnace slag as a calcined raw material in kiln feed
Adelaide Brighton
Angaston
fuels and raw materialsThe versatility of the cement making process
enables the safe use of by-products from other
industries as raw materials, fuels or constituents
of cement. These by-products meet strict quality
specifications to ensure the cement meets
customer performance specifications, and their
use contributes to sustainability by reducing
both landfill and emissions and preserving
valuable natural and non-renewable resources.
Use of alternative fuels such as demolition
timber results in a GHG benefit because the
emissions from combustion are lower than
would otherwise be released if the material
went to landfill.
Other alternative fuels—such as tyre chips or
used oils—also reduce landfill and are lower
emitters of GHG than their fuel equivalent
in coal.
A cement kiln using waste materials retains ash
and other residual constituents incorporating
them into the clinker. Using by-products
provides a whole-of-life waste management
option that can be economically viable,
regionally available and environmentally sound.
The industry’s viability is dependent upon
minimising costs, utilising less expensive
alternative raw materials and fuels, and
advancing the industry toward greater
sustainability.
Steel slag, mill scale, fibre board waste and
spent catalysts from the petroleum industry are
Manufacturing cement
requires intensive use of
energy and resources,
however, sustainable
development can be
achieved through
increased efficiency.
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Adelaide Brighton
Birkenhead
In an effort to reduce its reliance on fossil fuels and cut energy costs, Adelaide Brighton’s Birkenhead plant trialled a number of alternative fuels before finding a solution, demolition timber.
Traditionally reliant on natural gas, Birkenhead developed a strategic plan which had a focus on alternative fuels. The plan had plenty of clout, not only including both plant and management resources, but was driven and monitored by the Managing Director and Board of Adelaide Brighton.
Through modelling and researching the effects of demolition timber in the Birkenhead plant, it was decided that
the proposal could meet the specific requirements of the calciner and environmental standards. Discussions were conducted with the EPA and community to ensure that the burning of demolition timber was not only within government health guidelines, but met with the approval of local residents.
Trials were conducted and emissions monitoring found there was no increase in heavy metals or organics, which include dioxins. In fact a drop in nitrogen dioxide emissions proved an environmental win for all involved.
Birkenhead’s use of demolition wood as an alternative fuel means that the 75 000 tonnes available in South Australia no longer end up as landfill.
Demolition timber as an alternative fuel
used at Blue Circle Southern Cement’s Berrima
plant to substitute for 21 000 tonnes of natural
materials. The company’s Waurn Ponds plant
has been using waste oil for fuel since 1990.
Tyres followed and the plant now consumes
1.2 million a year, about half of Victoria’s annual
tyre dump. Some 45 per cent of Waurn Ponds
conventional fuel needs are being met using
alternatives.
Other cement companies are using these
and other materials. At Cement Australia’s
Gladstone plant spent solvents provide fuel,
while at Adelaide Brighton’s Birkenhead plant,
wood from the construction and demolition
waste stream will replace 30 per cent of the fuel
requirement by 2007.
At its Gladstone plant, Cement Australia is
using spent cell liners (SCL) from Comalco’s
aluminium smelter. SCL is a carbon-based waste
from the electrolytic cells that convert alumina
to aluminium. It is a valuable fuel replacement
for coal, and its silica and aluminium content
are needed for making clinker. The use of
calcined SCL as an alternative fuel has been
positive; Cement Australia has seen no change
in cement strengths with only benefits flowing
to local industry and the environment.
The Australian cement industry will continue
to work with regulators and local communities
to improve sustainability by using alternative
fuels and materials in cement manufacturing.
Alter
nativ
e fue
l as p
erce
ntag
eof
total
ther
mal
fuel
use
Equi
valen
t coa
l con
serv
ed b
y use
of al
terna
tive f
uels
(’000
tonn
es)
Tonn
es ra
w m
ateria
lspe
r ton
ne ce
men
t pro
duce
d
0%
1%
2%
3%
4%
5%
6%
1990 1992 1994 1996 1998 2000 2002 2004
1.00
0
1.50
1.25
1.75
0
50
100
150
200
The industry
is proactive in
using alternative
raw materials
and fuels to
reduce the
use of fossil
fuels and natural
materials
Use of alternative raw materials and fuels
fuels and raw materials
13
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employee health and safetyThe cement manufacturing process is a complex
heavy industry, employing many people in a
variety of roles, and utilising road, rail and
maritime transport to supply customers all
over Australia.
Significant hazards exist in all areas of cement
plant operations, requiring a proactive approach
with management, employees and contractors
working together to control and prevent harm.
CIF members comply with national and state
safety legislation as a minimum, using customised
systems and policies to ensure compliance and
a culture of continual improvement.
As the Australian cement industry is small by
world standards, it is important for member
companies to share information and best
practices. The CIF provides the opportunity
for such involvement, establishing an Australian
taskforce in 2004 to share resources and work
with the CSI taskforce to improve conditions in
the local industry and globally.
The safety performance of the industry has
improved markedly over the past few years,
with the number of lost time injuries reducing
by 48 per cent in the three years to 2004. CIF
member companies are adopting lead safety
indicators as well as traditional lag indicators
such as the lost time injury frequency rate.
The industry strives to continually improve
practices and site conditions to control and
reduce risks. Risk management focuses on
investigating the likelihood and consequences
of incidents.
The global cement industry is high risk when
judged against other comparable manufacturing
industries. The Australian performance, however,
has been significantly better than that of
overseas cement producers, with no fatalities
since 2000. Nevertheless, the CIF launched an
important initiative to prepare 18 ‘fatal risk
control protocols’ to guide management toward
holistic systems that prevent serious injuries
CIF members
are committed
to protecting
the health and
safety of their
employees,
contractors and
visitors in all
areas of their
operations.
Blue Circle Southern Cement Safety Leadership
Team
By thoroughly re-evaluating safety practices at its NSW operations, Blue Circle Southern Cement has successfully applied a vision that takes safety from simply compliance to true belief.
An unacceptable injury record in 2002 prompted the company to enlist consulting expertise to define where it could improve. After conducting one-on-one employee
interviews, a report was tabled identifying
key areas in need of change.
A meeting of ‘top 20’ BCSC NSW managers was organised to review the report. A safety leadership team was promptly established to bring about cultural change. The team committed to meeting every six weeks and became responsible for executing an annual safety action plan.
Under the Think Safe, Work Safe, Live Safe, Drive To Zero banner, BCSC NSW has seen a remarkable improvement over the last two years, with hours lost reduced by 80 per cent, workers compensation cost down by 60 per cent and the 12 month rolling lost time injury frequency rate reduced from ten to less than two.
From compliance to belief
employee health and safetyor fatalities. This was prompted by a serious
incident that resulted in burns to two employees
at Blue Circle Southern Cement’s Waurn Ponds
plant in 2003. Even though the likelihood
of such serious injuries is low, the industry
recognises that it must engender a culture of
‘safety first’ as its highest value and not become
complacent.
The protocols are targeted at eliminating
hazards that, according to research, cause
serious incidents in cement plants worldwide.
CIF member companies are undertaking pro-
active initiatives to develop and implement
integrated management systems. These
measures have demonstrated benefits in
improved morale, increased employee
involvement, and substantial reductions in
injuries leading to overall improved safety
performance. Examples of such initiatives
include:
■ Adelaide Brighton’s implementation of a
comprehensive safety, health and
environment management system.
■ Cement Australia has developed a safety,
health, environment and quality management
program and is currently seeking system
certification at key plants.
■ Cement Australia’s use of video as a medium
to illustrate issues relating to lessons from
incidents and good practices.
■ Blue Circle Southern Cement’s implementation
of an injury management provider service
which targets the early intervention in all
cases of injury, as well as a health and
wellbeing program.
2001 2002 2003 2004
Lost
time
inju
ries
Lost
time i
njur
iespe
r mill
ion
hour
s
0
10
20
30
50
40
60
70
80
90
Lost time injuries
CIF members
are committed
to the effective
control of all
hazards in daily
operations,
nothing but
a zero harm
approach
to safety is
tolerable
15
emission reductionThe cement industry operates under both
national and state legislation for the management
of the environment and also has specific licence
conditions and reporting requirements for the
operation of plant equipment.
Commonly monitored air emissions include the
typical parameters of dust, and various products
of combustion, such as oxides of nitrogen and
sulphur. Also parameters that may be present
in trace amounts include inorganic substances
such as heavy metals and organic compounds
like volatile organics, dioxins and furans.
In its effort to better understand emissions,
industry investment is being directed toward
new technologies that test and model emissions.
Protocols have been established and computer
models developed to relate stack emissions to
ground level concentrations (GLC) for correlation
with environmental and health standards. The
industry works closely with government to
ensure quality information is readily available.
Adelaide Brighton’s Munster plant used advanced
computer technology in atmospheric modelling to
determine the benefits of installing a state-of-the-
art dust filter. Under a range of meteorological
conditions the reduced GLC of dust were
calculated from real emission data.
The CIF has joined with government to provide
resources for assessing air quality in Australia.
Direct measurement data from cement plants
has been used to establish Australia’s national
dioxin inventory and show that cement industry
emissions are low regardless of the plant type and
fuels. Dioxins belong to the persistent organic
pollutants group which is of worldwide concern.
In supporting Australia’s commitment to
international treaties the industry participates
in discussions internally, with other industries,
and with environment and government groups.
These discussions lead to policy setting and
prepare the cement industry for changes in
emission measurements and standards. Sharing
information about new technologies and process
improvements is valuable and the industry regularly
monitors developments in air quality standards
in Europe to compare with local performance.
Various projects have been implemented to
reduce other emissions such as water, noise, and
waste to landfill. Harvesting storm water for dust
supression or diversion to specially prepared
seasonal wetlands has been successful. Cleaner
production initiatives to segregate site waste for
recycling into cement making or facilitating other
recycling opportunities continue to reduce waste
to landfill. Cement kiln dust (a waste product
in some plants) is, however, likely to increase
as more alternative fuels and raw materials are
used. In 2004, the manufacture of cementitious
material utilised 60 times more waste than it
produced for landfill.
Emissions from the
cement manufacturing
process are primarily
airborne. The industry is
committed to emission
control and reduction
in line with government
and company health and
environmental codes.
16
emission reductionEmissions from cement manufacturing facilities
in Australia are monitored regularly to:
■ control manufacturing processes for product
quality and protection of equipment
■ meet operating licence conditions
■ meet national reporting requirements such
as the National Pollutant Inventory, National
Dioxin Program, Stockholm Convention,
NEPM Air Quality (National Environmental
Performance Measures)
■ monitor specific effects of interest to local
communities
■ investigate the outcome of changes in process
operations.
Blue Circle Southern Cement’s Berrima works
installed best available technology in low-
NOx precalciner and kiln burners. Following
installation NOx emissions were shown to have
reduced by 60 per cent, and are now amongst
the lowest for Australian cement kilns.
2000 2001 2002 2003 2004
Dust
emitt
ed to
atm
osph
ere
from
kiln
exha
ust (
tonn
es)
NOx e
miss
ions
from
kiln
exha
usts
(’000
tonn
es)
Cem
ent k
iln d
ust d
umpe
d (’
000
tonn
es)
400
600
800
1000
1200
10
20
30
40
50
20
30
40
50
25
35
45
Emissions
17
Blue Circle Southern Cement
Berrima
‘A beautiful outcome for the environment’ is how Blue Circle Southern Cement Berrima describes the environmental benefits resulting from the upgrade of Kiln 6.
A study identified an annual 400 000 tonne shortfall in the supply of clinker on the Eastern seaboard. After looking at alternatives, BCSC decided that an upgrade of Kiln 6 offered the best solution, economically and environmentally.
The upgrade installed world best technology into Berrima’s clinker production, meeting the objectives of the CSI to lower emissions while ensuring BCSC could meet demands for clinker with a modern, efficient plant.
Overall the project successfully reduced process emissions by:
■ 24 per cent reduction in greenhouse gasses (GHG)
■ 75–95 per cent reduction in dust emissions
■ 60 per cent reduction in oxides of nitrogen
■ 95 per cent reduction in sulphur dioxide
■ 85 per cent reduction in carbon monoxide
■ 70 per cent reduction in heavy metals
The reduction in GHG is the equivalent of removing close to 38 000 cars from the road. Berrima is proposing to use alternative fuels to further improve its performance and commitment to sustainable cement production.
A beautiful outcome for the environment
local impactsThe cement industry recognises the impact
a large manufacturing facility can have on
a local community and the need for open
communications between all stakeholders.
Improved process technology has significantly
reduced emissions from cement manufacturing.
This investment in new technology and
environmental monitoring, combined with
active community participation, are essential to
building relationships.
CIF members have regular contact with
their communities through public forums
such as meetings, open days and newsletters.
Furthermore there is voluntary and mandatory
public reporting through government
environmental programs.
Receiving and investigating a community
report on impacts is important for any site in
its effort to construct an open and transparent
relationship with its community.
Environmental improvement plans registered
by state environmental authorities offer
opportunities for interested stakeholders to
participate and monitor site improvements.
Community relations are also a high priority for
the CIF’s Sustainable Development Taskforce.
The taskforce shares information so that
member companies can learn from each other
and continually build better relations with local
communities.
The industry also looks for opportunities
to celebrate events with the community by
supporting local initiatives and celebrating its
own milestones. All manufacturing sites are part
of their local community and many employees
of the cement industry are themselves
concerned local residents.
Examples of community projectsConservation projects include:
■ Preservation and restoration of a traditional
resting place of the local Watherong people in
Waurn Ponds, VIC
■ Agricultural education project, Gladstone, QLD
■ Sponsorship of Conservation Volunteers
Australia and support of the Bushcare Group
at Berrima, NSW
Revegetation projects incude:
■ Rehabilitation of Darra cement works site
to build the community Riverside Park in
Brisbane, QLD
■ Funding world first research in deep water
seagrass rehabilitation at Cockburn Sound, WA
■ Seed collection for propagation in other local
areas from remnant vegetation located in a
quarry. Angaston, SA
18
local impactsExamples of community projects
Assistance to non profit organisations:
■ Providing equipment for Little Athletics
Devonport, TAS
■ Sponsorship of local charities as employee
safety incentives during annual plant
maintenance weeks, Adelaide, SA
■ Sponsorship of the Juvenile Diabetes
Research Foundation, NSW
■ Indigenous employment initiative to identify
opportunities for local people in Maldon,
NSW
■ National Youth Science Forum — Bronze
Sponsor and Industry Partner since 2002,
Canberra, ACT
In 2002, Adelaide Brighton’s Munster plant
community consultation program was broadened
and upgraded as a stakeholder reference group.
It included representatives from state and local
government as well as local residents and interest
groups from outside the surrounding area.
■ The stakeholder reference group meets regularly,
with an independent chairperson and a
community working group charter.
■ The Department of Environment has accepted
the reference group as able to review the
company’s environmental licence performance.
Three licence renewals have now been agreed
upon by all stakeholders.
■ Most importantly a greater openness and
transparency exists in communication between
the company and the community.
What leaves
our site
boundaries
is of great
concern
to our
neighbours
19
Cement Australia
Rehabilitation of the old Kandos Shale MineOnce described as a terrible eyesore, Cement Australia and the local community worked to transform the disused Kandos Shale Mine into a conservation site that now supports several thousand young plants and trees.
The rehabilitation project required the sorting of mine debris, installation of drainage systems, leveling out and stabilisation of unstable and steep surfaces, and with assistance from 300 local schoolchildren, the planting of trees.
To minimise waste, Cement Australia used much of the former mine’s refuse in the rehabilitation and beautification process.
During the mine’s glory days, little consideration was given to the concept of rehabilitation so what was essentially a mined and forgotten site has been reborn as a place for nature conservation.
The project also fostered a greater relationship between Cement Australia and the Kandos–Rylstone community.
internal business processesThe CIF’s annual survey provides a
comprehensive review of the industry’s
performance, costs and profitability. It
includes sustainability items such as the
use of alternative fuels and resources, and
greenhouse gas generation. The survey provides
key indicators that are used to monitor industry
performance. This survey has been carried out
since 1989 and is independently prepared by
PriceWaterhouseCoopers.
Individual member companies are integrating
sustainable development requirements into their
businesses, so that sustainable development is
part of their operating culture. Examples include:
■ Cement Australia has an integrated safety,
health, environment and quality management
system designed to comply with international
and Australian standards. All major plants
have iso9001 quality management system
certification, and the company has embarked
on having the system certified against the
iso14001 environment standard and the
as4801 safety standard at five key plants,
by mid 2006.
■ All of Adelaide Brighton Cement’s South
Australian operations are iso14001 certified,
while all operations have iso9001 Quality
Management Systems Certification.
■ Blue Circle Southern Cement employs a
sustainability diagnostic tool to measure
and improve sustainable development
performance. Assessments and independent
reviews are undertaken every two years.
Business ethics are integral to sustainable
development. As part of the CSI Agenda for
Action, member companies are required to
develop and publish statements of business
ethics. Cement Australia has developed a
The CIF and its member
companies are integrating
sustainable development
into internal business
processes, so that
sustainable processes
become part of everyday
operations, and create
long-term value for the
industry and community.
comprehensive group of values and guiding
principles. Blue Circle Southern Cement has
implemented a code of corporate conduct, and
Adelaide Brighton has incorporated business
ethics into its corporate vision.
CIF members have integrated the industry
greenhouse gas calculator for evaluation of
projects into their planning and capital approval
processes, and are also using it to report green-
house gas reductions from abatement projects.
The industry has combined its technical
knowledge and initiative to forecast the effects
on its performance of technological improve-
ment to 2012 and beyond, and to address global
sustainability issues such as waste management,
resource conservation, energy efficiency and
greenhouse gas reduction.
The CIF has undertaken a number of initiatives
in 2005 to promote sustainable development
in the industry, and is proud to have published
its first Australian industry-wide sustainability
report. Other initiatives include the Cement
Industry Sustainability Conference, which
includes the presentation of the industry’s
first Sustainability Awards. The awards have
created strong competition and opportunities to
showcase the leading initiatives of the industry
in all areas of sustainability.
20
The Cement
Industry
Sustainability
Awards will
recognise
contributions
to a more
sustainable
industry.
internal business processesA sustainability diagnostic tool A sustainability
diagnostic tool developed
from international
methodologies has
been used within Blue
Circle Southern Cement
to assess the level of
sustainability practised in
the business. It comprises
twenty elements that
represent a cross-
section of the financial,
environmental and social
aspects of sustainability.
Each element has four
levels of achievement.
Sustainability aspects 1 Corporate and business
unit management for sustainability
1.1 Scope of commitment
1.2 Management systems: Quality, environmental, health and safety
1.3 Accountability
1.4 Risk management: New business and/or new development, plant and equipment
1.5 Compliance, review and reporting (CRR)
1.6 Continuous improvement
1.7 Marketing, procurement and supply chain
2 Business financial planning for sustainability
2.1 Planning and budgeting
2.2 Cost controls
3 Human resources 3.1 Communications, awareness and training
3.2 Employee and labour relations
3.3 Health, safety and wellbeing
4 Social responsibility 4.1 Community relations and engagement
4.2 Business ethics and corporate governance
4.3 External relations and communications
5 Environment 5.1 Land protection, remediation and rehabilitation
5.2 Environment and ecosystem protection
5.3 Waste and resources management, recycling and re-use
5.4 Energy conservation and climate change
5.5 Water conservation, extraction and protection
21
progressing sustainabilityClimate protection
The Australian cement
industry’s sustainability
journey will continue. Its
objective is to be one of the
world’s most sustainable
manufacturing industries.
While significant progress
has been attained, future
actions of the member
companies will support
the goal, contributing to a
modern sustainable lifestyle
for all Australians.
Fuels and raw materials
Commit to a new, national
Greenhouse Cooperative
Agreement with the
Commonwealth in 2005.
Incorporate the findings
of the CIAA Energy and
Greenhouse Working Group
into Australian operations.
Make reporting of GHG
management an industry
key performance indicator.
Advocate — to government,
communities, standards
bodies and the market — the
benefits of using alternative
fuels and materials and
gain national acceptance
of the role of cement
manufacturing in waste
utilisation.
Have all sites in Australia
make the procedures in the
CSI Guidelines standard
practice.
Take the findings of the
CIAA—Sustainable
Development Working
Group and encourage the
industry to take a leadership
position in driving
sustainable development.
22
In 2005 the cement
industry is working
with the Australian
Government to
produce the Cement
Industry Action Agenda
(CIAA) that identifies
opportunities for and
barriers to the cement
industry’s development
to 2025.
The agenda covers:
■ energy and greenhouse
■ trade
■ sustainable development
■ workforce and community.
progressing sustainabilityLocal impacts on land and communities
Employee health and safety
Emission reduction
Internal business processes
Integrate the protocols of
the CSI Guidelines into
company reporting, and
prepare a standard report
structure on employee
health and safety.
Ensure fatal risk control
protocols are part of
every member company’s
management system.
Develop lead indicators to
reduce incidents of injury
and risk.
Develop the NPI reporting
system to provide a
consistent industry
standard for reporting
stack emissions.
Review emission criteria
with local authorities
and determine common
reporting targets.
Extend the data gathered
for industry environmental
indicators.
Implement the recom-
mendations of the CIF
Technology Taskforce’s
‘Cementing our future’
report, to guide the
industry to a technical
vision that includes current
research and the capacity
to incorporate future
technologies.
Produce an industry
report every two to three
years covering items of
community interest relating
to the performance and
future of the industry.
Review and develop the CSI
protocol for environment
and social impact assess-
ment, and implement it
with local community
consultation groups.
Exchange best practice
information in quarry
management and
rehabilitation, based
on successful projects
undertaken by member
companies.
23
Industry profile
Munster
BirkenheadAngaston
Waurn Ponds
Kandos MaldonBerrima
Fishermans Landing
AcknowledgementsThe CIF wishes to recognise and thank the following for their assistance to compile and review the Australian Cement Industry Sustainability Report, 2005.
Authors: CIF Sustainable Development Taskforce
Adelaide Brighton Ltd Joseph Mazzone Mark Smith
Blue Circle Southern Cement Ltd Michael Leggo Stuart Waldon Grant Williams
Cement Australia Pty Ltd Bob Reid (chair) Stuart Ritchie
Cement Industry Federation Robyn Bain Ros DeGaris
Contributors
CIF Technology Taskforce
Member companies of the CIF
Cement Concrete & Aggregates Australia
Ms Robin Tennant-Wood, Director of Canberra Environment and Resource Centre, Australian National University
Glossary
BAT best available technology
CIF Cement Industry Federation
CO2 carbon dioxide
CSI Cement Sustainability Initiative (part of the World Business Council for Sustainable Development)
GEMS Greenhouse Energy Management System
GHG greenhouse gases
NOx oxides of nitrogen
NPI National Pollutant Inventory
SCL spent cell liners
SCM supplementary cementitious materials
WBCSD World Business Council for Sustainable Development
Web references
www.wbcsdcement.org CSI website
www.wbcsd.org World Business Council for Sustainable Development
www.deh.gov.au/industry/chemicals/dioxins National Dioxin Program
www.npi.gov.au National Pollutant Inventory
www.greenhouse.gov.au Australian Greenhouse Office
www.dfat.gov.au\environment Stockholm Convention (POPs)
24
Railton
Morgan
Kooragang
Bulwer Island
Rockhampton
Darwin
Cement plant
Grinding mill
Sunstate
25
Raw materials: LimestonePhoto: Kelly O’Rourke
Raw materials: Marine limestonePhoto: Kelly O’Rourke
Alternative raw material:SlagPhoto: Kelly O’Rourke
Raw mixPhoto: Kelly O’Rourke
Alternative fuel: Demolition timberPhoto: Kelly O’Rourke
Alternative fuel: Polyester resinPhoto: Kelly O’Rourke
Cement powder being pouredPhoto: Kelly O’Rourke
Bags of cementPhoto: Cement Australia
Alternative raw material: Slag surface Photo: Kelly O’Rourke
Alternative raw material: Slag (surface)Photo: Kelly O’Rourke
Alternative fuel: Polyester resin (surface)Photo: Kelly O’Rourke
Raw material: Granulated blast furnace slag (surface)Photo: Kelly O’Rourke
Alternative fuel: Carbon dust (surface)Photo: Kelly O’Rourke
‘Stepstone’ pavers, non-slipPhoto: Adelaide Brighton Ltd
Thermal House, Toorak Photo: Cement Concrete & Aggregates Australia
Bolte Bridge, MelbournePhoto: WinkiPoP Media
Rocks Riverside Park, BrisbanePhoto: WinkiPoP Media
Chimney, Railton worksPhoto: WinkiPoP Media
New dust filter, Munster kiln 4Photo: Adelaide Brighton Ltd
Kiln 6 construction, Berrima works Photo: Blue Circle Southern Cement
Kiln 6, Berrima worksPhoto: Blue Circle Southern Cement
Alternative fuel: Off spec wax (surface)Photo: Kelly O’Rourke
Raw material: Limestone (surface)Photo: Kelly O’Rourke
Alternative fuel: Demolition timber (surface)Photo: Kelly O’Rourke
Tour of Berrima worksPhoto: Naomi Brown Photography
Water testingPhoto: WinkiPoP Media
Rehabilitation of the shale mine at Kandos works into beautiful parklandPhoto: WinkiPoP Media
Alternative fuel: Tyre chipsPhoto: Kelly O’Rourke
Alternative fuel: Carbon dustPhoto: Kelly O’Rourke
ClinkerPhoto: Kelly O’Rourke
Grinding ballsPhoto: Kelly O’Rourke
SCM: Granulated blast furnace slagPhoto: Kelly O’Rourke
SCM: FlyashPhoto: Kelly O’Rourke
Children participate in a tree planting programPhoto: Naomi Brown Photography
Blue Circle Southern Cement open dayPhoto: Naomi Brown Photography
Blue Circle Southern Cement open dayPhoto: Naomi Brown Photography
Tour of Berrima worksPhoto: Naomi Brown Photography
Shrine of Remembrance, Melbourne Photo: Cement Concrete & Aggregates Australia
PO Box 4178 Manuka ACT 2603 ■ Telephone +61 2 6260 7222 ■ Facsimile +61 2 6260 7333 ■ www.cement.org.au