Cement Kilns: Difference between revisions

Line 1:

The production of cement utilizes waste materials in two primary ways, firstly using specific [[Industrial Waste]] and [[Mining & Quarrying Waste]] (and waste from the kiln part of the process itself) as additives and replacement for traditional raw materials, and secondly as a fuel to substitute for the use of traditional fossil fuels in a cement kiln. In 2018 1,414,195 tonnes of waste was used as raw materials and fuel in the production of cement, with just over 43% of kiln thermal input replaced by [[Waste Derived Fuel]]. The five companies manufacturing cement together supplied 78% of the cement consumed in the market in 2018. <ref name=''ref1''>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability Report 2019]</ref>.

The production of cement utilizes waste materials in two primary ways, firstly using specific [[Industrial Waste]] and [[Mining & Quarrying Waste]] (and waste from the kiln part of the process itself) as additives and replacement for traditional raw materials, and secondly as a fuel to substitute for the use of traditional fossil fuels in a cement kiln. In 2018 1,414,195 tonnes of waste was used as raw materials and fuel in the production of cement, with just over 43% of kiln thermal input replaced by [[Waste Derived Fuel]]. The five companies manufacturing cement together supplied 78% of the cement consumed in the market in 2018. <ref name=''ref1''>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability Report 2019]</ref>

[[Category:Technologies & Solutions]]

Line 16:

The introduction of waste materials - or 'Alternative Raw Materials' as coined by the industry - can be as part of the kiln phase or the final grinding stage and it can be used as an additive or as a fuel in the process.

'''In 1995''' there were 20 cement factories in the UK producing around 15 million tonnes a year of cement each year, with the cost of energy in the process representing 40 to 50% of running costs. There was a drive to substitute traditional fuels (coal and petroleum coke) with cheaper fuels slightly before this date, and trials were still running at this time with the ramifications of these trials captured in a Parliamentary Briefing Note<ref>[https://researchbriefings.files.parliament.uk/documents/POST-PN-60/POST-PN-60.pdf Parlimentary Briefing Note 60 April 1995]</ref>. [[Waste Derived Fuel]] had already started to play a more significant role in UK cement processing, in line with other countries (especially in Europe). It started with the use of solvent based hazardous wastes, named by some operators 'Chemfuel', which was being trialed at a substitution of 50% of traditional coal fuel (although at the time 100% substitution occurred in Belgium). At around the same time shredded/chipped waste [[Tyres|tyres]] were starting to also be used in some cement kilns as a [[Waste Derived Fuel]]. '''By 1998''' the MPA reports that 446,511 tonnes of waste by-products were used as fuel and raw materials, accounting for 4% of cement production and the proportion of fuel comprising waste was 5.7%<ref name = ''ref1''/>.

'''In 1995''' there were 20 'cement factories' in the UK producing around 15 million tonnes a year of cement each year, with the cost of energy in the process representing 40 to 50% of running costs. There was a drive to substitute traditional fuels (coal and petroleum coke) with cheaper fuels slightly before this date, and trials were still running at this time with the ramifications of these trials captured in a Parliamentary Briefing Note<ref>[https://researchbriefings.files.parliament.uk/documents/POST-PN-60/POST-PN-60.pdf Parlimentary Briefing Note 60 April 1995]</ref>. [[Waste Derived Fuel]] had already started to play a more significant role in UK cement processing, in line with other countries (especially in Europe). It started with the use of solvent based hazardous wastes, named by some operators 'Chemfuel', which was being trialed at a substitution of 50% of traditional coal fuel (although at the time 100% substitution occurred in Belgium). At around the same time shredded/chipped waste [[Tyres|tyres]] were starting to also be used in some cement kilns as a [[Waste Derived Fuel]] as both the solvent based wastes and tyres had a high [[CV]] and attracted an income from taking them into a cement kiln. '''By 1998''' the MPA reports that 446,511 tonnes of waste by-products were used as fuel and raw materials, accounting for 4% of cement production and the proportion of fuel comprising waste was 5.7%<ref name = ''ref1''/>.

'''By 2005''' the range of alternative fuels had expanded in Europe to include [[Tyres|tyres]], [[Plastic|plastic]], [[Paper|paper]], [[Refuse Derived Fuel]], dried [[Sewage Sludge|sewage sludge]], [[MBM|meat and bone meal]] and some other waste streams, with fuel costs typically accounting for 30 to 40% of operating costs<ref>[https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/291569/scho0106bjzn-e-e.pdf Environment Agency Science report on Solid Waste Derived Fuels in Cement Kilns, an International perspective]</ref>. This was driven by the cement industry looking to reduce its costs and carbon emissions, and by changes in the waste sector around the [[Landfill Directive]] and the introduction of the [[Landfill Tax]] which made cement kilns an alternative outlet for suitably prepared waste materials/[[Waste Derived Fuel]].

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'''By 2010''' the MPA reports that 1,528,315 tonnes of waste by-products were used as fuel and raw materials in UK cement manufacture, accounting for 7.2% of cement production and the proportion of fuel comprising waste was 39.7%<ref name = ''ref1''/>.

'''By 2018''' the MPA reported ~~the percentage of recycled content of~~ cement ~~was~~ 1,414,195 tonnes in UK cement manufacture, equivalent to almost 10% of cement production 2018. This same report notes that since 2013 the total waste used has not varied by much more than +/-150,000 tonnes per year, and the proportion fuel comprising waste was 43% in 2018 and has not changed by much more than +/- 1.5% since 2013<ref name = ''ref1''/>.

'''By 2018''' the MPA reported there were 12 cement kilns, with 1,414,195 tonnes of recycled content in UK cement manufacture, equivalent to almost 10% of cement production 2018. This same report notes that since 2013 the total waste used has not varied by much more than +/-150,000 tonnes per year, and the proportion fuel comprising waste was 43% in 2018 and has not changed by much more than +/- 1.5% since 2013<ref name = ''ref1''/>.

In addition to the use of [[Waste Derived Fuel]] in UK cement kilns, [[RDF]] and more commonly [[SRF]] has been increasingly exported from the UK to Europe since 2009. This has been driven by demand in Europe, combined with a ~~stagnant~~ demand in the UK cement kilns, and an increasing [[Landfill Tax]] that has has made export commercially viable/attractive.

In addition to the use of [[Waste Derived Fuel]] in UK cement kilns [[RDF]], and more commonly [[SRF]] due to its higher [[CV]] and more stringent specification, has been increasingly exported from the UK to Europe since 2009. This has been driven by demand in Europe, combined with a flat demand in the UK cement kilns, and an increasing [[Landfill Tax]] that has has made export commercially viable/attractive.

==List of UK Cement Kilns==

{{#get_db_data: db=engy |from=cementkilns |data=site=site,id=id,company=company}}

More detailed information can be found by clicking through to the site-specific page:

[[File:Cementkilns.png|600px|right|Cement Kilns in the UK]]

{|Class="wikitable"

! ID !! Site Name !! Operating Company

{{#for_external_table:<nowiki/>

{{!}}-

{{!}} {{{id}}}.

{{!}} [[{{{site}}}]]

{{!}} [[{{{company}}}]]

}}

|}

==Use of Waste - Current Context==

The UK cement kilns, on the whole, have waste permits and complete returns of the waste handled each quarter. The most recent data for each site is listed in the site specific page per cement kiln, although no returns have been made/are available for [[Cookstown]], [[Purfleet]] and [[Dunbar]]. An analysis of the waste returns for 2018 totals 753,783.67 tonnes - out of the 1,414,195 tonnes reported by the <ref name = ''ref1''/>. The difference can be accounted for via several factors:

The UK cement kilns, on the whole, have waste permits and complete returns of the waste handled each quarter. The most recent data for each site is listed in the site specific page per cement kiln, although no returns have been made/are available for [[Cookstown]], [[Purfleet]] and [[Dunbar]]. An analysis of the waste returns for 2018 totals 753,783.67 tonnes - out of the 1,414,195 tonnes reported by the MPA<ref name = ''ref1''/>. The difference can be accounted for via several factors:

* There are no returns for cement kilns

* There are no returns for 3 cement kilns

* The material may not be captured by the waste reports <ref> As an example, Blast Furnace Slag is considered a primary input for this type of cement, it is not defined as waste by the producer and therefore is not normally captured in [[UK Waste Tonnage]] figures or waste permit returns</ref>

* The grinding and blending sites are excluded from the analysis

From the information that is available, the following breakdown for all plants is available:

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|[[EWCChap01|01 04 08]]||waste gravel and crushed rocks other than those mentioned in 01 04 07||style='text-align:right;'|796

|-

|[[EWCChap02|02 02 02]]||animal-tissue waste||style='text-align:right;'|1,639

|[[EWCChap02|02 02 02]]||animal-tissue waste ''- the code typically used for [[MBM]]''||style='text-align:right;'|1,639

|-

|[[EWCChap02|02 02 03]]||materials unsuitable for consumption or processing||style='text-align:right;'|8,360

Line 71:

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|[[EWCChap19|19 12 04]]||plastic and rubber||style='text-align:right;'|5,469

|-

|[[EWCChap19|19 12 10]]||combustible waste (refuse derived fuel)||style='text-align:right;'|251,730

|[[EWCChap19|19 12 10]]||combustible waste (refuse derived fuel) ''- the code typically used for [[SRF]]''||style='text-align:right;'|251,730

|-

|[[EWCChap19|19 12 11*]]||other wastes (including mixtures of materials) from mechanical treatment of waste containing dangerous substances||style='text-align:right;'|100

Line 77:

Line 95:

|[[EWCChap19|19 12 12]]||other wastes (including mixtures of materials) from mechanical treatment of wastes other than those mentioned in 19 12 11||style='text-align:right;'|66,865

|}

~~==List of UK Cement Kilns==~~

~~{{#clear_external_data:}}~~

~~{{#get_db_data: db=engy |from=cementkilns |data=site=site,id=id,company=company}}~~

~~More detailed information can be found by clicking through to the site-specific page:~~

~~[[File:Cementkilns.png|600px|right|Cement Kilns in the UK]]~~

~~{|Class="wikitable"~~

~~! ID !! Site Name !! Operating Company~~

~~{{#for_external_table:<nowiki/>~~

~~{{!}}-~~

~~{{!}} {{{id}}}.~~

~~{{!}} [[{{{site}}}]]~~

~~{{!}} [[{{{company}}}]]~~

}}

|}

~~<br clear="all" />~~

==List of UK Grinding and Blending Sites==

The following sites are listed as grinding and ~~blenidng~~ sites only, with no cement kiln on site<ref name = ''ref1''/>:

The following sites are listed as grinding and blending sites only, with no cement kiln on site<ref name = ''ref1''/>:

{| class="wikitable"

|-

@@ Line 1: / Line 1: @@
-The production of cement utilizes waste materials in two primary ways, firstly using specific [[Industrial Waste]] and [[Mining & Quarrying Waste]] (and waste from the kiln part of the process itself) as additives and replacement for traditional raw materials, and secondly as a fuel to substitute for the use of traditional fossil fuels in a cement kiln. In 2018 1,414,195 tonnes of waste was used as raw materials and fuel in the production of cement, with just over 43% of kiln thermal input replaced by [[Waste Derived Fuel]]. The five companies manufacturing cement together supplied 78% of the cement consumed in the market in 2018.  <ref name=''ref1''>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability Report 2019]</ref>.
+The production of cement utilizes waste materials in two primary ways, firstly using specific [[Industrial Waste]] and [[Mining & Quarrying Waste]] (and waste from the kiln part of the process itself) as additives and replacement for traditional raw materials, and secondly as a fuel to substitute for the use of traditional fossil fuels in a cement kiln. In 2018 1,414,195 tonnes of waste was used as raw materials and fuel in the production of cement, with just over 43% of kiln thermal input replaced by [[Waste Derived Fuel]]. The five companies manufacturing cement together supplied 78% of the cement consumed in the market in 2018. <ref name=''ref1''>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability Report 2019]</ref>
 [[Category:Technologies & Solutions]]
@@ Line 16: / Line 16: @@
 The introduction of waste materials - or 'Alternative Raw Materials' as coined by the industry - can be as part of the kiln phase or the final grinding stage and it can be used as an additive or as a fuel in the process.
-'''In 1995''' there were 20 cement factories in the UK producing around 15 million tonnes a year of cement each year, with the cost of energy in the process representing 40 to 50% of running costs. There was a drive to substitute traditional fuels (coal and petroleum coke) with cheaper fuels slightly before this date, and trials were still running at this time with the ramifications of these trials captured in a Parliamentary Briefing Note<ref>[https://researchbriefings.files.parliament.uk/documents/POST-PN-60/POST-PN-60.pdf Parlimentary Briefing Note 60 April 1995]</ref>. [[Waste Derived Fuel]] had already started to play a more significant role in UK cement processing, in line with other countries (especially in Europe). It started with the use of solvent based hazardous wastes, named by some operators 'Chemfuel', which was being trialed at a substitution of 50% of traditional coal fuel (although at the time 100% substitution occurred in Belgium). At around the same time shredded/chipped waste [[Tyres|tyres]] were starting to also be used in some cement kilns as a [[Waste Derived Fuel]]. '''By 1998''' the MPA reports that 446,511 tonnes of waste by-products were used as fuel and raw materials, accounting for 4% of cement production and the proportion of fuel comprising waste was 5.7%<ref name = ''ref1''/>.
+'''In 1995''' there were 20 'cement factories' in the UK producing around 15 million tonnes a year of cement each year, with the cost of energy in the process representing 40 to 50% of running costs. There was a drive to substitute traditional fuels (coal and petroleum coke) with cheaper fuels slightly before this date, and trials were still running at this time with the ramifications of these trials captured in a Parliamentary Briefing Note<ref>[https://researchbriefings.files.parliament.uk/documents/POST-PN-60/POST-PN-60.pdf Parlimentary Briefing Note 60 April 1995]</ref>. [[Waste Derived Fuel]] had already started to play a more significant role in UK cement processing, in line with other countries (especially in Europe). It started with the use of solvent based hazardous wastes, named by some operators 'Chemfuel', which was being trialed at a substitution of 50% of traditional coal fuel (although at the time 100% substitution occurred in Belgium). At around the same time shredded/chipped waste [[Tyres|tyres]] were starting to also be used in some cement kilns as a [[Waste Derived Fuel]] as both the solvent based wastes and tyres had a high [[CV]] and attracted an income from taking them into a cement kiln. '''By 1998''' the MPA reports that 446,511 tonnes of waste by-products were used as fuel and raw materials, accounting for 4% of cement production and the proportion of fuel comprising waste was 5.7%<ref name = ''ref1''/>.
 '''By 2005''' the range of alternative fuels had expanded in Europe to include [[Tyres|tyres]], [[Plastic|plastic]], [[Paper|paper]], [[Refuse Derived Fuel]], dried [[Sewage Sludge|sewage sludge]], [[MBM|meat and bone meal]] and some other waste streams, with fuel costs typically accounting for 30 to 40% of operating costs<ref>[https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/291569/scho0106bjzn-e-e.pdf Environment Agency Science report on Solid Waste Derived Fuels in Cement Kilns, an International perspective]</ref>. This was driven by the cement industry looking to reduce its costs and carbon emissions, and by changes in the waste sector around the [[Landfill Directive]] and the introduction of the [[Landfill Tax]] which made cement kilns an alternative outlet for suitably prepared waste materials/[[Waste Derived Fuel]].
@@ Line 22: / Line 22: @@
 '''By 2010''' the MPA reports that 1,528,315 tonnes of waste by-products were used as fuel and raw materials in UK cement manufacture, accounting for 7.2% of cement production and the proportion of fuel comprising waste was 39.7%<ref name = ''ref1''/>.
-'''By 2018''' the MPA reported the percentage of recycled content of cement was 1,414,195 tonnes in UK cement manufacture, equivalent to almost 10% of cement production 2018. This same report notes that since 2013 the total waste used has not varied by much more than +/-150,000 tonnes per year, and the proportion fuel comprising waste was 43% in 2018 and has not changed by much more than +/- 1.5% since 2013<ref name = ''ref1''/>.
+'''By 2018''' the MPA reported there were 12 cement kilns, with 1,414,195 tonnes of recycled content in UK cement manufacture, equivalent to almost 10% of cement production 2018. This same report notes that since 2013 the total waste used has not varied by much more than +/-150,000 tonnes per year, and the proportion fuel comprising waste was 43% in 2018 and has not changed by much more than +/- 1.5% since 2013<ref name = ''ref1''/>.
-In addition to the use of [[Waste Derived Fuel]] in UK cement kilns, [[RDF]] and more commonly [[SRF]] has been increasingly exported from the UK to Europe since 2009. This has been driven by demand in Europe, combined with a stagnant demand in the UK cement kilns, and an increasing [[Landfill Tax]] that has has made export commercially viable/attractive.
+In addition to the use of [[Waste Derived Fuel]] in UK cement kilns [[RDF]], and more commonly [[SRF]] due to its higher [[CV]] and more stringent specification, has been increasingly exported from the UK to Europe since 2009. This has been driven by demand in Europe, combined with a flat demand in the UK cement kilns, and an increasing [[Landfill Tax]] that has has made export commercially viable/attractive.
+==List of UK Cement Kilns==
+{{#clear_external_data:}}
+{{#get_db_data: db=engy |from=cementkilns |data=site=site,id=id,company=company}}
+More detailed information can be found by clicking through to the site-specific page:
+[[File:Cementkilns.png|600px|right|Cement Kilns in the UK]]
+{|Class="wikitable"
+! ID !! Site Name !! Operating Company
+{{#for_external_table:<nowiki/>
+{{!}}-
+{{!}} {{{id}}}.
+{{!}} [[{{{site}}}]]
+{{!}} [[{{{company}}}]]
+}}
+|}
+<br clear="all" />
 ==Use of Waste - Current Context==
-The UK cement kilns, on the whole, have waste permits and complete returns of the waste handled each quarter. The most recent data for each site is listed in the site specific page per cement kiln, although no returns have been made/are available for [[Cookstown]], [[Purfleet]] and [[Dunbar]]. An analysis of the waste returns for 2018 totals 753,783.67 tonnes - out of the 1,414,195 tonnes reported by the <ref name = ''ref1''/>. The difference can be accounted for via several factors:
+The UK cement kilns, on the whole, have waste permits and complete returns of the waste handled each quarter. The most recent data for each site is listed in the site specific page per cement kiln, although no returns have been made/are available for [[Cookstown]], [[Purfleet]] and [[Dunbar]]. An analysis of the waste returns for 2018 totals 753,783.67 tonnes - out of the 1,414,195 tonnes reported by the MPA<ref name = ''ref1''/>. The difference can be accounted for via several factors:
-* There are no returns for cement kilns
+* There are no returns for 3 cement kilns
 * The material may not be captured by the waste reports <ref> As an example, Blast Furnace Slag is considered a primary input for this type of cement, it is not defined as waste by the producer and therefore is not normally captured in [[UK Waste Tonnage]] figures or waste permit returns</ref>
 * The grinding and blending sites are excluded from the analysis
 From the information that is available, the following breakdown for all plants is available:
@@ Line 39: / Line 57: @@
 |[[EWCChap01|01 04 08]]||waste gravel and crushed rocks other than those mentioned in 01 04 07||style='text-align:right;'|796
 |-
-|[[EWCChap02|02 02 02]]||animal-tissue waste||style='text-align:right;'|1,639
+|[[EWCChap02|02 02 02]]||animal-tissue waste ''- the code typically used for [[MBM]]''||style='text-align:right;'|1,639
 |-
 |[[EWCChap02|02 02 03]]||materials unsuitable for consumption or processing||style='text-align:right;'|8,360
@@ Line 71: / Line 89: @@
 |[[EWCChap19|19 12 04]]||plastic and rubber||style='text-align:right;'|5,469
 |-
-|[[EWCChap19|19 12 10]]||combustible waste (refuse derived fuel)||style='text-align:right;'|251,730
+|[[EWCChap19|19 12 10]]||combustible waste (refuse derived fuel) ''- the code typically used for [[SRF]]''||style='text-align:right;'|251,730
 |-
 |[[EWCChap19|19 12 11*]]||other wastes (including mixtures of materials) from mechanical treatment of waste containing dangerous substances||style='text-align:right;'|100
@@ Line 77: / Line 95: @@
 |[[EWCChap19|19 12 12]]||other wastes (including mixtures of materials) from mechanical treatment of wastes other than those mentioned in 19 12 11||style='text-align:right;'|66,865
 |}
-==List of UK Cement Kilns==
-{{#clear_external_data:}}
-{{#get_db_data: db=engy |from=cementkilns |data=site=site,id=id,company=company}}
-More detailed information can be found by clicking through to the site-specific page:
-[[File:Cementkilns.png|600px|right|Cement Kilns in the UK]]
-{|Class="wikitable"
-! ID !! Site Name !! Operating Company
-{{#for_external_table:<nowiki/>
-{{!}}-
-{{!}} {{{id}}}.
-{{!}} [[{{{site}}}]]
-{{!}} [[{{{company}}}]]
-}}
-|}
-<br clear="all" />
 ==List of UK Grinding and Blending Sites==
-The following sites are listed as grinding and blenidng sites only, with no cement kiln on site<ref name = ''ref1''/>:
+The following sites are listed as grinding and blending sites only, with no cement kiln on site<ref name = ''ref1''/>:
 {| class="wikitable"
 |-