BORAL CEMENTBuild something great™

Cement manufacturing at

Portland cement dates from its

discovery by an English mason,

Joseph Aspdin in 1824 who

obtained the patent and gave

the product its name ‘Portland

cement’ because the mortar

colour it produced resembled a

natural building stone obtained

from the Isle of Portland off the

English coast.

Portland cement significantly

improved on earlier cement

developments by preparing a

synthetic mixture of lime and

clay without depending on raw

materials found in nature which

might contain such elements in

desirable proportions.

In 1877 the first rotary kiln was

patented in England. In 1885

Englishman Frederick Ransome

patented the first rotary cement

kiln. Since that time rotary kilns

have developed in size,

capacity, output quality and

operational economy. Now

with modern materials handling

equipment, more efficient

combustion techniques and

computerized processing and

control, kilns are capable of

producing over four thousand

five hundred tonnes of cement

clinker per day.

BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523

VICTORIA1800 673 570

TASMANIA(03) 6427 0133

PRODUCT SUPPORT: 1800 721 258

www.boral.com.au/cement

BCC_10301_08/12

The Berrima cement works

are the longest in Australia. The

130km integrated manufacturing

process begins at Marulan – where

limestone is quarried, then railed to

Berrima where clinker is produced.

The clinker is then transported by

rail to Maldon for cement milling,

where it is bagged and distributed.

Berrima’s plant capacity is

1.4 million tones of clinker per

annum. Twenty five percent of

this output is transported to the

grinding plant at Maldon where it is

converted to cement. The remaining

clinker is ground at Berrima and

dispatched in large quantities to

Canberra, the NSW south coast

and other NSW markets.

The Berrima kilns are equal to

the most modern in the world with

continuous development upgrades

featuring the latest technology

and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known.

Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings.

Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.

Berrima

Berrim

a

Marulan-Berrima-Maldon production line

Portland Cement

BORAL CEMENTBuild something great™

Cement manufacturing at

Portland cement dates from its

discovery by an English mason,

Joseph Aspdin in 1824 who

obtained the patent and gave

the product its name ‘Portland

cement’ because the mortar

colour it produced resembled a

natural building stone obtained

from the Isle of Portland off the

English coast.

Portland cement significantly

improved on earlier cement

developments by preparing a

synthetic mixture of lime and

clay without depending on raw

materials found in nature which

might contain such elements in

desirable proportions.

In 1877 the first rotary kiln was

patented in England. In 1885

Englishman Frederick Ransome

patented the first rotary cement

kiln. Since that time rotary kilns

have developed in size,

capacity, output quality and

operational economy. Now

with modern materials handling

equipment, more efficient

combustion techniques and

computerized processing and

control, kilns are capable of

producing over four thousand

five hundred tonnes of cement

clinker per day.

BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523

VICTORIA1800 673 570

TASMANIA(03) 6427 0133

PRODUCT SUPPORT: 1800 721 258

www.boral.com.au/cement

BCC_10301_08/12

The Berrima cement works

are the longest in Australia. The

130km integrated manufacturing

process begins at Marulan – where

limestone is quarried, then railed to

Berrima where clinker is produced.

The clinker is then transported by

rail to Maldon for cement milling,

where it is bagged and distributed.

Berrima’s plant capacity is

1.4 million tones of clinker per

annum. Twenty five percent of

this output is transported to the

grinding plant at Maldon where it is

converted to cement. The remaining

clinker is ground at Berrima and

dispatched in large quantities to

Canberra, the NSW south coast

and other NSW markets.

The Berrima kilns are equal to

the most modern in the world with

continuous development upgrades

featuring the latest technology

and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known.

Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings.

Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.

Berrima

Berrim

a

Marulan-Berrima-Maldon production line

Portland Cement

BORAL CEMENTBuild something great™

Cement manufacturing at

Portland cement dates from its

discovery by an English mason,

Joseph Aspdin in 1824 who

obtained the patent and gave

the product its name ‘Portland

cement’ because the mortar

colour it produced resembled a

natural building stone obtained

from the Isle of Portland off the

English coast.

Portland cement significantly

improved on earlier cement

developments by preparing a

synthetic mixture of lime and

clay without depending on raw

materials found in nature which

might contain such elements in

desirable proportions.

In 1877 the first rotary kiln was

patented in England. In 1885

Englishman Frederick Ransome

patented the first rotary cement

kiln. Since that time rotary kilns

have developed in size,

capacity, output quality and

operational economy. Now

with modern materials handling

equipment, more efficient

combustion techniques and

computerized processing and

control, kilns are capable of

producing over four thousand

five hundred tonnes of cement

clinker per day.

BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523

VICTORIA1800 673 570

TASMANIA(03) 6427 0133

PRODUCT SUPPORT: 1800 721 258

www.boral.com.au/cement

BCC_10301_08/12

The Berrima cement works

are the longest in Australia. The

130km integrated manufacturing

process begins at Marulan – where

limestone is quarried, then railed to

Berrima where clinker is produced.

The clinker is then transported by

rail to Maldon for cement milling,

where it is bagged and distributed.

Berrima’s plant capacity is

1.4 million tones of clinker per

annum. Twenty five percent of

this output is transported to the

grinding plant at Maldon where it is

converted to cement. The remaining

clinker is ground at Berrima and

dispatched in large quantities to

Canberra, the NSW south coast

and other NSW markets.

The Berrima kilns are equal to

the most modern in the world with

continuous development upgrades

featuring the latest technology

and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known.

Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings.

Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.

Berrima

Berrim

a

Marulan-Berrima-Maldon production line

Portland Cement

BLAST FURNACESLAG STOCKPILE

SLAG DRYER

Marulan Limestone Quarry

DRY SLAGSTORAGE

SHALE

COAL BLENDING& STORAGE

CRUSHERSHALE

LOCALSHALE QUARRY

LOCALIRON ORE

LIMESTONE

LOCALSAND

LABORATORY & CENTRAL CONTROL ROOM

DRY PROCESS

KILN

COAL MILL

ELECTROSTATIC

DUST COLLECTOR

DUST

RETURN

COND

ITIO

NING

TOW

ER

RAW MEALCO

NDIT

IONI

NGTO

WER

STACK

PREHEATERTOWER N02 RAWMEAL

BLENDING SILO

RAW

MAT

ERIA

L BL

ENDI

NGAN

D ST

ORAG

E

RAW

MAT

ERIA

LSAD

DITI

VE B

UILD

ING

BULK CEMENT STORAGE SILOS

BAGGED CEMENT

BULK CEMENT

BULK CEMENT & SLAG

CEMENT MILLS

GRATE COOLER

GYPSUMCLINKER STORAGE

BUILDING

CLINKER STORAGE

BUILDING

BULK CEMENT

BULK CEMENT STORAGE SILOS

BULK CEMENT

CEMENT MILLS

No.6 RAW MILL

KILN EXHAUST

GASES

No.7 RAW MILL

WASTE GASES

(TO STACK)

KILN EXHAUST

GASES

DUST

RETURNRAW MEAL

BULK LIME

BAGGED LIME

ROTARY LIME KILN

LIMESTONE

PRIMARY DRILL& BLASTING

SECONDARYPRIMARYCRUSHER CRUSHER

TO BERRIMA

GYPSUM

TO MALDON

CLINKERSTORAGE SILO

TROMMEL SCREEN

WAS

TE G

ASES

(TO

STAC

K)PREHEATERTOWER No1

Berrima Clinker and Cement Works

Maldon Cement Works

Berrima Colliery

Cement making is a simple

process in which carefully

measured quantities of limestone,

shale, iron ore and occasionally

sand are blended together,

ground to a fine powder and

fused at a very high temperature

in a rotary kiln. The fused material

or ‘clinker’ is cooled and then

ground with a small amount of

gypsum in a ball mill to produce

the finished cement powder.

Limestone is the primary raw

material in cement with a high level

of calcium carbonate. Chalk or

coral can also be used. At Berrima

limestone is used which comes

from Boral’s limestone quarry at

Marulan (70kms south of Berrima).

Limestone is a high grade stone

won by blasting, then crushed

before being transported by rail

to the cement works. Shale is

quarried on the cement works site.

The small quantity of iron

ore required to make cement

is obtained from outside resources.

Sand is supplied locally when

required for fine correction of

the mix.

Berrima employs a dry process

for cement manufacturing in which

raw materials are ground to a fine

powder in a vertical raw mill, then;

1. The dry ground meal is stored

in a large blending silo.

2. From the silo it is conveyed

by elevator to the top of the

pre-heater tower with four

cyclone stages.

3. The raw meal falls by

gravity through each

interconnected cyclone

during which the hot gases

from the kiln pass through the

cyclones and heat the raw

meal to approx. 1000ºC.

4. From the bottom cyclone the hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.

5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage.

The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and lime-bearing cement for buildings,

roads, bridges and aqueducts.

The word ‘cement’ was

derived from the early Roman

‘Caementum’, a rough, unhewn

stone or chips of marble from

which a kind of ‘mortar’ was

made. The term ‘Concrete’

came from ‘Concretus’- meaning

‘growing together’. The Romans

used cement to make loose

stones ‘grow together’ into a

single rock-like mass to build

concrete structures such as

the Roman baths (27BC), the

Colosseum and the Basilica

of Constantine. The ruins still

survive today.

It is believed the Romans also

developed the first known

hydraulic cement – cement

capable of hardening under

water. Created by mixing slaked

lime with a volcanic rock or sand

called ‘Pozzolana’, the cement

was named after the place where

it was first found - Possuoli near

Mount Vesuvius and is commonly

known as Pozzolanic cement.

The Marulan-Berrima-Maldon Production Line 2012

BerrimaCement manufacturing at

The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed.

GEELONGMELBOURNE

MARULAN

MALDONSYDNEY

NEWCASTLE

BERRIMA

How Portland Cement is made at Berrima

BLAST FURNACESLAG STOCKPILE

SLAG DRYER

Marulan Limestone Quarry

DRY SLAGSTORAGE

SHALE

COAL BLENDING& STORAGE

CRUSHERSHALE

LOCALSHALE QUARRY

LOCALIRON ORE

LIMESTONE

LOCALSAND

LABORATORY & CENTRAL CONTROL ROOM

DRY PROCESS

KILN

COAL MILL

ELECTROSTATIC

DUST COLLECTOR

DUST

RETURN

COND

ITIO

NING

TOW

ER

RAW MEAL

COND

ITIO

NING

TOW

ER

STACK

PREHEATERTOWER N02 RAWMEAL

BLENDING SILO

RAW

MAT

ERIA

L BL

ENDI

NGAN

D ST

ORAG

E

RAW

MAT

ERIA

LSAD

DITI

VE B

UILD

ING

BULK CEMENT STORAGE SILOS

BAGGED CEMENT

BULK CEMENT

BULK CEMENT & SLAG

CEMENT MILLS

GRATE COOLER

GYPSUMCLINKER STORAGE

BUILDING

CLINKER STORAGE

BUILDING

BULK CEMENT

BULK CEMENT STORAGE SILOS

BULK CEMENT

CEMENT MILLS

No.6 RAW MILL

KILN EXHAUST

GASES

No.7 RAW MILL

WASTE GASES

(TO STACK)

KILN EXHAUST

GASES

DUST

RETURNRAW MEAL

BULK LIME

BAGGED LIME

ROTARY LIME KILN

LIMESTONE

PRIMARY DRILL& BLASTING

SECONDARYPRIMARYCRUSHER CRUSHER

TO BERRIMA

GYPSUM

TO MALDON

CLINKERSTORAGE SILO

TROMMEL SCREEN

WAS

TE G

ASES

(TO

STAC

K)

PREHEATERTOWER No1

Berrima Clinker and Cement Works

Maldon Cement Works

Berrima Colliery

Cement making is a simple

process in which carefully

measured quantities of limestone,

shale, iron ore and occasionally

sand are blended together,

ground to a fine powder and

fused at a very high temperature

in a rotary kiln. The fused material

or ‘clinker’ is cooled and then

ground with a small amount of

gypsum in a ball mill to produce

the finished cement powder.

Limestone is the primary raw

material in cement with a high level

of calcium carbonate. Chalk or

coral can also be used. At Berrima

limestone is used which comes

from Boral’s limestone quarry at

Marulan (70kms south of Berrima).

Limestone is a high grade stone

won by blasting, then crushed

before being transported by rail

to the cement works. Shale is

quarried on the cement works site.

The small quantity of iron

ore required to make cement

is obtained from outside resources.

Sand is supplied locally when

required for fine correction of

the mix.

Berrima employs a dry process

for cement manufacturing in which

raw materials are ground to a fine

powder in a vertical raw mill, then;

1. The dry ground meal is stored

in a large blending silo.

2. From the silo it is conveyed

by elevator to the top of the

pre-heater tower with four

cyclone stages.

3. The raw meal falls by

gravity through each

interconnected cyclone

during which the hot gases

from the kiln pass through the

cyclones and heat the raw

meal to approx. 1000ºC.

4. From the bottom cyclone the hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.

5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage.

The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and lime-bearing cement for buildings,

roads, bridges and aqueducts.

The word ‘cement’ was

derived from the early Roman

‘Caementum’, a rough, unhewn

stone or chips of marble from

which a kind of ‘mortar’ was

made. The term ‘Concrete’

came from ‘Concretus’- meaning

‘growing together’. The Romans

used cement to make loose

stones ‘grow together’ into a

single rock-like mass to build

concrete structures such as

the Roman baths (27BC), the

Colosseum and the Basilica

of Constantine. The ruins still

survive today.

It is believed the Romans also

developed the first known

hydraulic cement – cement

capable of hardening under

water. Created by mixing slaked

lime with a volcanic rock or sand

called ‘Pozzolana’, the cement

was named after the place where

it was first found - Possuoli near

Mount Vesuvius and is commonly

known as Pozzolanic cement.

The Marulan-Berrima-Maldon Production Line 2012

BerrimaCement manufacturing at

The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed.

GEELONGMELBOURNE

MARULAN

MALDONSYDNEY

NEWCASTLE

BERRIMA

How Portland Cement is made at Berrima

BLAST FURNACESLAG STOCKPILE

SLAG DRYER

Marulan Limestone Quarry

DRY SLAGSTORAGE

SHALE

COAL BLENDING& STORAGE

CRUSHERSHALE

LOCALSHALE QUARRY

LOCALIRON ORE

LIMESTONE

LOCALSAND

LABORATORY & CENTRAL CONTROL ROOM

DRY PROCESS

KILN

COAL MILL

ELECTROSTATIC

DUST COLLECTOR

DUST

RETURN

COND

ITIO

NING

TOW

ER

RAW MEAL

COND

ITIO

NING

TOW

ER

STACK

PREHEATERTOWER N02 RAWMEAL

BLENDING SILO

RAW

MAT

ERIA

L BL

ENDI

NGAN

D ST

ORAG

E

RAW

MAT

ERIA

LSAD

DITI

VE B

UILD

ING

BULK CEMENT STORAGE SILOS

BAGGED CEMENT

BULK CEMENT

BULK CEMENT & SLAG

CEMENT MILLS

GRATE COOLER

GYPSUMCLINKER STORAGE

BUILDING

CLINKER STORAGE

BUILDING

BULK CEMENT

BULK CEMENT STORAGE SILOS

BULK CEMENT

CEMENT MILLS

No.6 RAW MILL

KILN EXHAUST

GASES

No.7 RAW MILL

WASTE GASES

(TO STACK)

KILN EXHAUST

GASES

DUST

RETURNRAW MEAL

BULK LIME

BAGGED LIME

ROTARY LIME KILN

LIMESTONE

PRIMARY DRILL& BLASTING

SECONDARYPRIMARYCRUSHER CRUSHER

TO BERRIMA

GYPSUM

TO MALDON

CLINKERSTORAGE SILO

TROMMEL SCREEN

WAS

TE G

ASES

(TO

STAC

K)

PREHEATERTOWER No1

Berrima Clinker and Cement Works

Maldon Cement Works

Berrima Colliery

Cement making is a simple

process in which carefully

measured quantities of limestone,

shale, iron ore and occasionally

sand are blended together,

ground to a fine powder and

fused at a very high temperature

in a rotary kiln. The fused material

or ‘clinker’ is cooled and then

ground with a small amount of

gypsum in a ball mill to produce

the finished cement powder.

Limestone is the primary raw

material in cement with a high level

of calcium carbonate. Chalk or

coral can also be used. At Berrima

limestone is used which comes

from Boral’s limestone quarry at

Marulan (70kms south of Berrima).

Limestone is a high grade stone

won by blasting, then crushed

before being transported by rail

to the cement works. Shale is

quarried on the cement works site.

The small quantity of iron

ore required to make cement

is obtained from outside resources.

Sand is supplied locally when

required for fine correction of

the mix.

Berrima employs a dry process

for cement manufacturing in which

raw materials are ground to a fine

powder in a vertical raw mill, then;

1. The dry ground meal is stored

in a large blending silo.

2. From the silo it is conveyed

by elevator to the top of the

pre-heater tower with four

cyclone stages.

3. The raw meal falls by

gravity through each

interconnected cyclone

during which the hot gases

from the kiln pass through the

cyclones and heat the raw

meal to approx. 1000ºC.

4. From the bottom cyclone the hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.

5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage.

The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and lime-bearing cement for buildings,

roads, bridges and aqueducts.

The word ‘cement’ was

derived from the early Roman

‘Caementum’, a rough, unhewn

stone or chips of marble from

which a kind of ‘mortar’ was

made. The term ‘Concrete’

came from ‘Concretus’- meaning

‘growing together’. The Romans

used cement to make loose

stones ‘grow together’ into a

single rock-like mass to build

concrete structures such as

the Roman baths (27BC), the

Colosseum and the Basilica

of Constantine. The ruins still

survive today.

It is believed the Romans also

developed the first known

hydraulic cement – cement

capable of hardening under

water. Created by mixing slaked

lime with a volcanic rock or sand

called ‘Pozzolana’, the cement

was named after the place where

it was first found - Possuoli near

Mount Vesuvius and is commonly

known as Pozzolanic cement.

The Marulan-Berrima-Maldon Production Line 2012

BerrimaCement manufacturing at

The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed.

GEELONGMELBOURNE

MARULAN

MALDONSYDNEY

NEWCASTLE

BERRIMA

How Portland Cement is made at Berrima

BORAL CEMENTBuild something great™

Cement manufacturing at

Portland cement dates from its

discovery by an English mason,

Joseph Aspdin in 1824 who

obtained the patent and gave

the product its name ‘Portland

cement’ because the mortar

colour it produced resembled a

natural building stone obtained

from the Isle of Portland off the

English coast.

Portland cement significantly

improved on earlier cement

developments by preparing a

synthetic mixture of lime and

clay without depending on raw

materials found in nature which

might contain such elements in

desirable proportions.

In 1877 the first rotary kiln was

patented in England. In 1885

Englishman Frederick Ransome

patented the first rotary cement

kiln. Since that time rotary kilns

have developed in size,

capacity, output quality and

operational economy. Now

with modern materials handling

equipment, more efficient

combustion techniques and

computerized processing and

control, kilns are capable of

producing over four thousand

five hundred tonnes of cement

clinker per day.

BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523

VICTORIA1800 673 570

TASMANIA(03) 6427 0133

PRODUCT SUPPORT: 1800 721 258

www.boral.com.au/cement

BCC_10301_08/12

The Berrima cement works

are the longest in Australia. The

130km integrated manufacturing

process begins at Marulan – where

limestone is quarried, then railed to

Berrima where clinker is produced.

The clinker is then transported by

rail to Maldon for cement milling,

where it is bagged and distributed.

Berrima’s plant capacity is

1.4 million tones of clinker per

annum. Twenty five percent of

this output is transported to the

grinding plant at Maldon where it is

converted to cement. The remaining

clinker is ground at Berrima and

dispatched in large quantities to

Canberra, the NSW south coast

and other NSW markets.

The Berrima kilns are equal to

the most modern in the world with

continuous development upgrades

featuring the latest technology

and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known.

Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings.

Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.

BerrimaBerrim

aMarulan-Berrima-Maldon production line

Portland Cement