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MALDON WORKS Community Liaison Committee meeting November 2017
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Maldon is strategically located Close to the motorway into Sydney, on a rail line with a siding
and close to a port
Maldon
Berrima
Marulan
Peppertree
Dunmore
Enfield & Clyde
St Peters
Port Kembla
Boral Terminal / Quarry
Rail & road connections
50 km
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Maldon is an integral operation in Boral’s network Maldon produces bulk cement products and is Boral’s only cement
and dry mix packaging operation
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Packaged products
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1
3
1 1
0
10
5 7
5
4
3
5
1
0 0
1
2
3
4
5
6
7
8
9
10
FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 YTD
LTI MTI
Maldon’s Employee & Contractor Injury Count Lost time injuries (LTI) and medical treatment injuries (MTI)
Safety performance Our goal is to achieve ZERO HARM TODAY for all employees and contractors
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Maldon’s Hazard Report Count
Second chart with
lead indicators
Safety performance We are increasingly monitoring leading indicators of safety, including hazard
reporting and corrective action management
• A 145% increase in hazards
reported in 4 years?
• An 82% increase in safety
conversations
• A 66% increase in safety
observations
• An 89% increase in Near Misses
reported
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Safety: learning from recent incidents Through toolbox discussions and induction processes we use recent incidents
to raise awareness and improve performance
CHANGE MANAGEMENT
During completion of a task,
hazards may change.
We need robust change
management systems to
recognise new hazards:
• Review SWMS at start of every
shift
• Complete new Take 5 after each
rest break
• During audits ask “what has
changed”
ISOLATION
Develop our people and
systems to verify isolation
done correctly with sources of
stored energy identified and
correctly isolated.
• Isolation lists to be developed
by cross functional team
• Verification of isolation must be
robust
• Appropriate isolation devices
provided to enable stored
energy is dissipated
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BORAL CEMENT – OTHER SITES
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- Berrima: Starting construction of the new Solid Waste Derived Fuels (SWDF) plant
and equipment.
- Marulan: Planning applications being developed to secure approval to continue the
mining of limestone for the next 30 years.
- Geelong: Planning approval is pending for a new clinker grinding facility in the Port
of Geelong precinct, potentially replacing the Waurn Ponds Cement site.
All of these projects are being pursued and implemented to strengthen Boral
Cement’s position into the future and in the face of increasingly higher demand.
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After almost three years of work, during October approval was received by the
Cement Works for use of fuels derived from waste as part of production.
Current approvals amended to allow use of wood waste-derived fuel (WWDF) and refuse-
derived fuel (RDF) for the kiln’s energy.
Up to 100 000 tonnes per year of these fuels allowed, replacing equivalent amount of coal.
Approval incorporates changes to various air emission limits, to be included in the
Environmental Protection License (EPL).
Build something great™
Use of Waste-Derived Fuels at Berrima – APPROVED! Boral Berrima Cement Community Meeting 10 November 2016
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Build something great™
Waste-Derived Fuels at Berrima Boral Berrima Cement Community Meeting 10 November 2016
There are now three Waste Derived Fuels which can be used at Berrima.
The first, tyre ‘chips’, has been approved for use for many years. We do not,
however, propose to use tyre chips for the start of this program.
The other two are:
Wood waste-derived fuel (WWDF)
Refuse-derived fuel (RDF)
‘Leftovers’ from other industries
Untreated waste like sawdust,
pallets, chipped bark, mill off-cuts
NOT commercial or native
forestry material
Combustible materials recovered
from ‘mainstream’ waste
Papers, cardboards, packaging,
some plastics, C&D material
Screened and processed to
specification X
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Marulan Quarry
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Boral Cement Geelong -Victoria
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Water Usage
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Annual EPA Dust Emissions
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Test 1 Test 2
1 No 2 Cement Mill Baghouse mg/m3 100 26-Jul-17 36 29 32
2 No 3 Cement Mill Precipitator mg/m3 100 26-Jul-17 29 26 28
Aggregate mg/m3 30 25-Jul-17 6.4 NA
Sand mg/m3 30 25-Jul-17 6.2 NA
NA Slag Drier Stack Normal Total solid particles mg/m3 NA 28-Jul-17 88 100 94
Date
Tested
Average
Detected
values
6.35
EPA Parameter UnitsLicence
limit Location Description
Dryer Stack
Total solid particles
Normal
Condition
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Road intersection
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Upgrade to Blending Plant
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Installation of new bulk bag machine
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®
Existing CM2 Circuit
Existing Cement Mill
2 Installation:
Two 1st generation
Hyde Separators
installed in parallel.
Over sized product
goes back to the mill
inlet.
Finished product
goes to the process
bag filters for
collection, before
passing to the
cement coolers.
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Self Supply to South Australia
• Isotainer loaded at cement plant, taken to Sydney and railed to South Australia
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Kiln Stack demolition
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IlluminARTE 2017 (May)
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Wollondilly Anglican Country Fair 2017 (Sep).
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