Cement Industry Federation

Industry Report 2013

 About CIF
The Cement Industry Federation (CIF) is the national
body representing the Australian cement industry. Our
members — Adelaide Brighton, Boral Cement and Cement
Australia — account for 100 per cent of integrated clinker and
cement production in Australia.

More than 5000 people are directly and indirectly involved in the
production of clinker and cement — mostly in regional areas — with
many thousands more involved in the downstream production and
distribution of concrete. In 2012–13 sales of cementitious materials
in Australia were around 8.9 million tonnes, with CIF members
reporting an annual turnover in excess of $2.2 billion.

CIF members are continuously working to reduce greenhouse

gas emissions through efficiency and innovation. In 2012–13,
our industry accounted for around 6.3 million tonnes per
annum of greenhouse gas emissions and the consumption
of around 1.9 million tonnes of waste products from other
industries — avoiding these materials heading to landfill.

Synopsis
  Variation on:
Metric 2012–13 2011–12 1989–90

Clinker production 6.26 +4.7% +0.9%

(1989–90 = 6.21 Mt)

Cement production 8.59 +0.7% +25%

(1989–90=6.86 Mt)

Total cementitious sales 8.92 -0.7% +17%

(1989–90 = 7.63 Mt)

Disclaimer Total GHG emissions (1989– 6.23 -5.8% -6.2%

While all reasonable care has 90=6.65 Mt CO2-e)
been taken to ensure the accuracy
of the material contained herein, Emissions intensity (incl. non-kiln) 0.70 -5.4% -20%
CIF shall not be held liable or
responsible for any loss or
(1989–90=0.87 t CO2-e per tonne
damage incurred by any person of cementitious sales)
through the use of this material.
CEO’s message
It is with great pleasure that I introduce to you the 2013 Australian Cement Industry
Report. This report builds on a range of earlier CIF publications and covers key aspects
of the industry of interest to stakeholders — including key data on production, trade and
sustainability indicators, as well as case studies from CIF member organisations.
The Australian cement industry has been affected by difficult macroeconomic conditions
during the period 2011–13. Historically high exchange rates have impacted trade-exposed
industries such as cement, and low levels of consumer and business confidence reflect the
weaker than expected economic conditions that have existed during the period.
Declines in non-residential construction over the period have been offset to some extent by
strong growth in heavy industry and the mining sector, with significant demand coming from
major resource projects in Western Australia, Queensland and South Australia.
A key focus for the Australian cement industry going forward is the continuous improvement
of productivity and competitiveness conditions within an economically and environmentally
sustainable framework.
As part of this, a number of key areas have been identified that are critical to the successful
future of our industry. These include new and continuing federal and state policies and
regulations that impact on the cement industry — including in the areas of labour, transport,
environmental approvals and taxes.
Climate change and energy policy development remain as a key focus for our industry.
CIF welcomes the government’s proposed upcoming review of the Renewable Energy
Target, the development of an Energy White Paper and the proposed implementation of
an Emissions Reduction Fund.
However, much remains to be done in terms of the development of future policy
mechanisms and CIF looks forward to continuing engagement with the government
and stakeholders on these important issues.
The Australian cement industry is internationally recognised for adopting fit for purpose
sustainability and energy efficiency reforms where it is competitive to do so. However,
alternative fuels and raw materials usage levels in the Australian cement industry are well
below those in almost all other regions.
CIF will continue to work with state and federal governments to identify and, wherever
possible, remove barriers to alternative fuel and raw material usage, thus taking advantage
of the significant opportunities that currently exist for the safe and sustainable co-processing
of waste and other materials.
The Australian cement industry is an important contributor to regional employment and to
the growth and sustainability of the Australian economy. Our industry has the potential to
prosper if it is not burdened with excessive regulation and taxes.
CIF and its members will continue to work with all levels of government to target
opportunities that will ensure our sector remains productive as a domestic industry
and significant regional employer.

Margie Thomson  Chief Executive

1
about cement
Cement is a fine grey powder that is
mixed with gravel, sand and water to
form concrete — the most widely used
construction material in the world.
1 Raw material extraction
2 Crushing
3 Prehomogenisation
4 Grinding
5 Preheating
6 Rotary kiln
7 Cooler
8 Clinker storage
9 Additions
10 Cement grindings
11 Cement storage silo
Cement use
Construction of a typical family home
requires around 14 tonnes of cement,
and a kilometre of freeway contains
as much as 2500 tonnes of cement.
Varying the mix of cement, sand
and aggregate enables concrete to
be used in a range of applications.
Products can be designed, coloured
and shaped to accommodate a
variety of environmental conditions,
architectural requirements and to
withstand a wide range of loads,
stresses and impacts.
2 c e m e n t i n d u s t ry f e d e r at i o n
Cement manufacture
Cement is manufactured by heating a precise mixture of finely ground limestone, clay
and sand in a kiln to around 1450°C. The resulting clinker, a pebble-like material that
comprises the special compounds that give cement its binding properties, is cooled
and then ground with gypsum and other materials to make cement.
Figure 1 Overview of an
integrated cement plant 5
6
1 2 3 7
4
11
9
8
10
The pre-mixed concrete industry consumes the greatest volume of cement,
using it in applications such as: concrete slabs and foundations for buildings,
roads and bridges; precast panels, blocks and roofing tiles; fence posts,
reservoirs and railway sleepers.
Cement is also used in bulk quantities in other diverse applications including:
stabilisation of roads and rocky surfaces; backfill mining operations and casings
in oil and gas wells; renders, mortars and fibre board.
Growth in demand for cement is closely linked to Australia’s economic
growth, providing long term stability for investment and employment. Cement
manufacturing and distribution provide jobs and investment in regional Australia
as well as the suburban and industrial areas of our cities.
 Figure 2: Location
of integrated cement
manufacturing sites
Australian Clinker and Cement Production
Munster  c o ck b u r n
In 2012–13 CIF
member companies
operated:
seven integrated
clinker and cement
facilities
five grinding plants
with product delivered
to market through
around 20 distribution
centres.
industry report 2013
Fishermans Landing
c em e n t a u s t r a l ia
Angaston
A del a i de B r i g h ton
c em en t Maldon
B o r a l c e me n t
Birkenhead
A del a i de B r i g h ton Berrima
B o r a l c e me n t
Clinker production (Figure 3) in Australia was reported
as 6.3 million tonnes (Mt) in 2012–13, down 4.7 per cent
over 2011–12. Clinker capacity in the industry dropped
3.7 per cent over the period to 7.4 Mt.
Australian cement production was reported as 8.6 Mt, down
0.7 per cent over 2011–12 and 25 per cent higher than in 1989–90. Railton
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
over 2011–12. Significant cement and clinker producers in our region
include China, Japan, Indonesia, Thailand, Malaysia and the Philippines.
Overall, during 2012–13 growth in the Australian cement industry was hampered
by subdued building demand in certain markets, as well as rising energy costs.
More recently, strong demand from major projects such as in the oil and gas and
mining sectors underpinned production in the key markets of Western Australia,
Queensland and South Australia.
Despite the challenging economic conditions during the period, CIF member
companies continued to invest in their operations. Examples include Adelaide
Brighton’s $60m upgrade of the Birkenhead plant in South Australia, the
construction of Cement Australia’s $180m Port Kembla Grinding Plant and
Boral’s $200m investment in the Peppertree quarry.
Figure 3: Clinker and cement production (million tonnes)
10
4
1990 1993 1996 1999 2002 2005 2008 2011 2013
Clinker Cement SOURCE: CIF 2013
3
trade data
Clinker imports are Imports
mainly from Japan
Overall, clinker imports as a percentage of domestic production have been
and China increasing, largely due to increasing domestic input costs. In 2012–13 clinker
imports into Australia were sourced mainly from Japan (65%), China (30%) and
Portland cement Indonesia (3%) (Figure 4).
imports down slightly In 2012–13 imports of clinker into Australia totalled 1.86 million tonnes (Mt), up from
in 2011–12 1.67 Mt in 2011–12 but down on the record high of 1.94 Mt in 2010–11 (Figure 5).

In 2012–13 imports of Portland Cement totalled 0.56 Mt, down slightly (3%) over
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%).

Figure 4: Clinker imports into Australia (Mt)

2.0
Thailand
Singapore
1.5 Phillipines
Malaysia
1.0 Japan
Indonesia
0.5 India
China

0.0 Australia (re-imports)

2004–05 2006–07 2008–09 2010–11 2012–13 SOURCE: ABS

Figure 5: Clinker and Portland Cement imports (Mt)

2.5

Exports 2.0

Australia does not export 1.5

large volumes of clinker
or cement. Small volumes 1.0
are occasionally exported
within the Pacific region 0.5
to countries such as Clinker
New Zealand and other
0.0 Portland Cement
pacific Island countries.
2004–05 2006–07 2008–09 2010–11 2012–13 SOURCE: ABS

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

Carbon friendly SCMs

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:

■■ Installation of a third cement mill (Cement Mill 7) to increase cement milling

capacity by around 750,000 tonnes per annum.

■■ 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.

■■ Installation of a slag dryer and storage facility to enable the introduction of

granulated blast furnace slag blended cement to the market in South Australia.
Slag is a by-product of the steel industry and has already been heated and its
carbon dioxide evolved. Substituting slag for the clinker, which is the most energy
and greenhouse intensive component in cement, reduces the greenhouse footprint
per tonne of cement.

The Cement Mill 7 project has delivered improved environmental performance

through reduced ground level dust emissions, reduction in total carbon footprint and
a reduction in use of natural resources as well as responding to the growing demand
in the market place to produce a ‘green’ cement.

industry report 2013 5

employee health
and safety
Health and safety is of CIF member companies are committed to maintaining the health and safety of all those
the utmost importance to involved in cement production and use. Maintaining ongoing safety and health awareness
as well as continual improvements in safety culture and systems is critical for the cement
CIF member companies
industry going forward.
CIF member companies The Cement Australia Health Program (opposite) is a good example of the types of
are currently implementing initiatives currently being implemented in the Australian cement industry.
a range of health and All CIF members strive for the elimination of workplace injuries in all aspects of their
safety initiatives operations — including in key aspects of cement manufacture such as maintenance,
transport, handling and operating procedures.
CIF members comply CIF members comply with national and state safety legislation using customised
with all federal and state systems and policies, both to ensure compliance and to maintain a culture of continuous
health legislation improvement in this critical area of Australian cement production.

Exports
Australia does not export large volumes of clinker or cement. Small volumes are
occasionally exported within the Pacific region to countries such as New Zealand
and other pacific Island countries.

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 morale,

self esteem and job
satisfaction

Improved employee
recruitment and retention
The Cement Australia
Health Program Enhanced employee
productivity

Cement Australia’s Health Program aims to promote better health outcomes

for all of its employees. The program emphasises the importance of a person’s
health and the impact it has on both work and non-work related activities.

In order to successfully roll out the Health Program, Cement Australia identified
that a systematic and staged approach would be required for the program’s
implementation.

Initially Cement Australia Managers were provided with tools and specialised training
to equip them to manage and assist with the health issues within the workforce

The second stage of the program involved Cement Australia supporting managers as
they used their tools and training to address all the existing health cases within their
business units.

In the final stage of implementation, Cement Australia introduced specific initiatives

to the workforce to help employees recognise their own health situation and to take
accountability for their individual fitness for work.

Cement Australia has identified that investment in their people through the Health
Program has had many benefits including;
■■ Decreased rates/severity of illness and injuries
■■ 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.

industry report 2013 7

Climate protection and 
An industry active CIF members are mandatory reporters under the Energy Efficiency Opportunities (EEO)
assessments program, as well as the National Greenhouse and Energy Reporting Act
in greenhouse gas
(NGERS). Australian cement manufacturers are also liable entities under the Clean Energy
mitigation for over Future program that began in July 2012.
two decades. In addition to the above, CIF members contribute to the Cement Sustainability Initiative
(CSI), conducted under the auspices of the World Business Council for Sustainable
Recognised as a Development (WBCSD).
leader in greenhouse The Australian cement industry is committed to further reducing its carbon dioxide
gas reduction emissions and to playing an active role in combating climate change.

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%

55% 32% 13%

As the raw material is heated and cabon dioxide
liberated in the chemical conversion of limestone
to calcium oxide. CACO3   CaO + CO2
As long as cement making relies on the calcination of
limestone, these emissions will be impossible to avoid.
Burning fuels Indirect emissions from electricity use.
(coal, gas and Cement grinding is the largest single
diesel) to create use in a cement plant. Raw meal
thermal energy. grinding and moving material around
a plant also consumes electricity.

Globally, cement production accounts for around 5 per cent of total anthropogenic
greenhouse emissions. In Australia, significant contributions from other sectors
(such as agriculture and power generation) mean that cement manufacture
accounts for approximately 1.1 per cent of Australia’s total emissions.
Total greenhouse gas emissions, including non-kiln fuels, from Australian
integrated cement manufacturers were reported as 6.3 million tonnes CO2-e
in 2012–13, 5.8 per cent lower than 2011–12.
In terms of total cementitious sales the emissions intensity of cement manufacturing
was 0.70 tonnes of CO2-e per tonne in 2012–13 — down 5.2 per cent over 2011–12
and 20 per cent since 1990.

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

Carbon Policy Principles

One of the more significant challenges facing policy makers today is to ensure that
Australian industry, including cement producers, continue to maintain a competitive
position in relation to our neighbours, particularly those who are not as advanced as
Australia in terms of environmental standards and performance.

The Cement Industry Federation considers that the following principles should
underpin the development of carbon policy in Australia:
■■ Global consistency — the Australian Government should continue to advocate for
a globally consistent approach to pricing carbon.
■■ 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.

Further detail on each of these points can be found at www.cement.org.au.

industry report 2013 9

 supplementary
cementitious materials
SCMs are materials Supplementary cementitious materials (SCMs), otherwise known as cement extenders
or mineral additions, are materials that can be used to partially substitute for clinker to
used instead of clinker
produce cement and concrete, without compromising performance.

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.

Figure 9: Cement Extenders used in cement production (Kt)

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.

Australian cement producers

will continue to strive for an
increase in the use of SCMs
as a key strategy to reduce
greenhouse gas emissions
associated with clinker
production as well as a
sustainable use of industrial
by‑products.

Australian Standard for General

Purpose and Blended Cements
An important milestone was achieved in 2010 with the release of a new Australian
cement standard, AS 3972 — that introduced a number of changes in relation to the
allowable proportion of mineral additions. These changes included:
a An increase in the allowable proportion on mineral additions (i.e. granulated blast
furnace slag, flyash or limestone) in Type GP from 5 per cent to 7.5 per cent
b The creation of a new cement type — Type GL, with an allowable addition
of limestone from 8 to 20 per cent
c The use of up to 5 per cent minor additional constituents in Type GP or
Type GL cements.

Further work is underway looking at the performance of cements using increased

mineral addition, which will further reduce greenhouse gas emissions.

industry report 2013 11

Alternative fuels
and raw materials
Cement production Cement kilns are ideally suited to the safe recovery of energy and co-processing of a
range of waste materials. This is due to the burning conditions within the kiln, such as:
is suited to energy
high temperatures, long residence times, oxidising atmosphere and a naturally alkaline
recovery and environment.
co‑processing
Energy recovery from alternative materials reduces fossil fuel requirements and associated
emissions. In addition, the introduction of raw materials into the process reduces the
Alternative fuels amount of naturally occurring raw material (such as limestone, iron ore, sands and shales)
reduce fossil fuel required for the process and further reduces the environmental footprint of the operations.
requirements Examples of the types of fuels and materials currently used in Australian cement kilns
include granulated blast furnace slag, fly ash, used oil, tyres, solvents, spent pot liner
The cement industry (from aluminium smelting), carbon powders, waste wood/sawdust and animal fat.
continues to inovate In this way Australia’s cement industry has been innovative in reducing its own
and reduce its environmental footprint, while at the same time reducing that of others through the uptake
environmental footprint of alternative fuels and raw materials.

In 2012–13 the use of solid and liquid alternative fuels contributed around 2 PJ of energy,
or around 7.8 per cent of the Australian cement industry’s total thermal requirements.

Barriers to alternative fuel and material use

There are a number of factors that determine what alternative materials can be used in
a cement plant including, inter alia, suitability (calorific value and/or alternative material
substitution), long-term availability and capital investment (storage, pre-processing, feed
systems etc).
While substitution rates are up around 7.8 per cent for the Australian cement industry,
rates are typically much higher in other countries. In the European Union for example,
average substitution rates for alternative fuels are around 18 per cent2.
Barriers to the uptake of alternative fuels/materials in Australia include regulatory
impediments — where the classification and definitions applied to waste material across
the jurisdictions restrict the options available to cement kilns.
Such barriers do not exist to the same extent in other countries, which goes some way to
explaining the higher average substitution rates seen in areas such as the European Union.
For example, the co-processing of waste has been recognised as a recovery operation
under EU legislation, and is carried out in compliance with the provisions of both the
Directives on the Incineration of Waste and Integrated Pollution Prevention and Control
(IPCC), and recognised as Best Available Technique (BAT).
There remains significant scope to increase the safe use of alternative fuels in Australian
cement kilns, and the removal of regulatory and definitional barriers would aid the cement
industry’s move towards more sustainable production. This should be the aim of all
Australian governments and regulatory bodies.

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.

The industry is committed to regular, open and cooperative

communications between CIF member companies and
community stakeholders.

CIF member companies have adopted the Cement

Sustainability Initiative’s Environmental and Social Impact
Assessment Guidelines, and have committed to utilising the
guidelines as a reference point.  

A range of local impacts resulting from plant operations require

specific management by CIF member companies, including:
water use, mine site rehabilitation, air quality monitoring,
evaluation and improvement as well as noise management.

industry report 2013 13

Kiln technology and
energy efficiency
The Australian cement Figure 10: Clinker production by kiln type (million tonnes)
industry is continually 8
working to remain
7
competitive in a difficult
6
commercial and
regulatory environment 5

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.

However, continual improvements in energy efficiency will become increasingly

difficult going forward. Further improvements will require innovation within the
industry alongside collaboration with relevant jurisdictions to facilitate the increased
use of alternative fuels and materials.

Australian cement producers, as energy intensive operations, are always focussed

on finding ways to improve their energy efficiency. Mandated programs, such
as the Energy Efficiency Opportunities program, do not drive energy efficiency
improvements in the cement industry.

The requirement for mandatory reporting under EEO does nothing other than burden
industry with yet another reporting requirement. In this context CIF supports the
government’s decision to terminate EEO funding from 1 July 2014.

At the very least, removing the mandatory reporting requirements under EEO for
large energy users would fit well with the government’s policy objective of boosting
productivity and reducing red tape.

CIF members recognise that there will always be a requirement for industry to report,
whether it is under programs such as the EEO or the National Greenhouse and
Energy Reporting Scheme (NGERS). However the reporting systems associated
with such programs must be pragmatic and proportional.

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

Boral Cement Berrima embarks on Minimising fugitive dust

an ambitious revegetation program Native species local

to the geographic
area were selected

An EPA-approved
rehabiiltation and
landscaping plan

Over 60 planting areas

Berrima Cement Works is situated close to a residential village of New Berrima. As a result
Boral take great care to ensure fugitive dust generated at the site is minimised. They have
implemented a dust management plan that progressively addresses the main dust sources
on the land. To date, most of the dirt haul roads have been sealed or closed, a wheel wash
station was installed at the exit from the shale quarry and various dust-minimising plant
improvements were implemented.
Boral has also embarked on an ambitious revegetation program aimed at the landscaping
of unsealed surfaces and the creation of vegetative screens to minimise windblown dust
generation from the premises.
A local provider, Wariapendi Nursery, was selected to deliver the project. Mostly native species,
local to the geographical area therefore adapted to the soil and climatic conditions, have been
chosen for revegetation as per an EPA-approved rehabilitation and landscaping plan.
Over 60 planting areas have been identified, with the main objective of providing effective
screening of fugitive dust and reducing the generation of dust at the source. Wind barriers
around the quarry, the stockpile areas and the cement plant itself will reduce dust generation
from strong westerly, southerly and northerly winds. Additional screens to the north of the
cement plant will further reduce fugitive dust impacts on New Berrima.
Stage 1 of the program has already been completed. Approximately 3500 seedlings of
native trees and shrubs were planted in the high priority areas last autumn. Most of the
seedlings survived the winter and are doing very well.
Stage 2 involves planting of over 12,000 seedlings by end April 2014. Lastly, Stage 3
will see planting of further 9500 seedlings in 2015.
Altogether, approximately 25,000 seedlings of native species, a mix of small trees, large
shrubs and large trees, will be planted. The total cost of the project is estimated to be in
excess of $110,000.

industry report 2013 15

 Water usage
Water usage Historically, water was an essential ingredient for the clinker and cement
has decreased production process, as the so called ‘long wet’ kilns required a raw material
slurry mix to produce clinker.
dramatically with
the move towards While the wet technology is still in use today, it represented only around
8.3 per cent of production in 2012–13. This technology has been replaced in
long dry kilns
Australia by ‘long dry’ kilns that represent a dramatic improvement over earlier
wet process plants.
Water use has
continued to Figure 11 shows that, in total, CIF member companies used 59761 ML of
water in 2012–13, compared with 6877 ML in 2011–12 and 7067 ML in
decrease
2010–11. This usage equates to 670 L per tonne of cementitious production
in Australia, 13 per cent lower than that recorded for 2011–12 and 17 per cent
lower than 2010–11.

Figure 11: CIF integrated cement plants total water usage

8

0
2007–08 2008–09 2009–10 2010–11 2011–12 2012–13
Raw Potable Recycled

1 Cement industry water

usage numbers have been
updated to include all water
sources — including bore water.

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).

industry report 2013 17

www.cement.org.au