Cement Kilns: Difference between revisions

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'''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>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability report 2019]</ref>.
'''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>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability report 2019]</ref>.


'''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 Fuels]].  
'''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]].  


'''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>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability report 2019]</ref>.
'''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>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability report 2019]</ref>.
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==Use of Waste - Current Context==
==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 is summarized as follows:
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 accounts for 753,783.67 tonnes out of the 1,414,195 tonnes reported by the <ref>[https://cement.mineralproducts.org/documents/MPA_Cement_SD_Report_2019.pdf MPA Cement Sustainability report 2019]</ref>. The difference can be accounted for via several factors:
* There are no returns for cement kilns
* The material may not be captured by the waste reports <ref> As Blast Furnace Slag is considered a primary input for this type of cement, it is not defined as waste 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:
 
{| class="wikitable"
|-
! EWC Code !! Waste Description !! Tonnes (2018)
|-
| [[01 04 08]]||  || 795
|-
| [[02 02 02]] || Example || 1,639
|-
| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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| Example || Example || Example
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As Blast Furnace Slag is considered a primary input for this type of cement, it is not defined as waste and therefore is not normally captured in [[UK Waste Tonnage]] figures or waste permit returns.


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