Sustainable Development Report 2016 · 2017-04-05 · 2 mpa cement Mineral Products Association MPA...

2

Mineral Products Associationmpa cement

MPA CementSustainable Development Report 2016cement in the circular economy

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

Recycling: 1.6Mt of waste and by-products from other sectors recycled

Fossil fuel replaced: 42% of the thermal input replaced by waste derived fuels

Building a Better Britain: every £1.00 invested in construction generates nearly £3.00 in economic activity

Health and safety: lost time injuries 84% lower than in 2005 in pursuit of zero harm

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

Cement market: Domestic cement sales improved 30% since 2012 but sales still 15% lower than 2007

Decarbonisation: CO2 emissions reduced by 23% compared with a 1998 baseline

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

Waste diverted: zero process waste sent to landfill

2015 provided further evidence of the sector’s slow and steady recovery from the 2008 economic recession. Domestic production of cement increased to 9.2 million tonnes and there is evidence that cement sales in the South-East of England (including London) are growing faster than the rest of the UK.

Further structural changes took place

in the cement sector, with Aggregate Industries taking ownership of two kiln sites, CRH taking ownership of Tarmac and, more recently in 2016, Breedon took ownership of Hope Construction Materials (now trading as Hope Cement). This results in five Portland cement manufacturing companies in the UK: Aggregate Industries operating

as Lafarge Cement, CEMEX, Hanson, Hope Cement and Tarmac (a CRH company).

With increasing interest in progressive sustainable development themes, such as the ‘circular economy’, our new style sustainable development report highlights the contribution of domestic cement production to the environment and the economy.

Reflecting on 2015

1

Material flow in the UK cement industry

Fossil fuels: 0.63

Waste derived fuels: 0.63

Natural raw materials: 12.13

Kiln dust recovered on-site: 0.01

Waste raw materials: 0.64

Water: 1.74

Natural raw materials interground: 0.91

Waste raw materials interground: 0.34

Clinker: 7.80

Cement: 9.06

Kiln dust sent to land�ll: 0.00

Water evaporated for cooling: 0.73

Fossil fuel CO2: 1.59

Waste derived fossil CO2: 0.56

Biomass CO2: 0.47

Process CO2: 4.51

Figure 1: Shows the material flow in cement manufacture in 2015 (in million tonnes).

Coarsepowder

Finepowder

Transport

Cementsilo

Gas �owRaw material �ow

Alternative and waste derived material reception

Raw grinding mill

Limestone

Clay

Preheater

Waste tyres

Refuse derived fuelMeat and bone meal Paper sludges

Clinkersilo

Gypsum from desulphurisationGypsum from recovered plasterboardGypsum

Kiln dustReject cementFly ash from power generationGround granulated blastfurnace slag

Separator BlenderRaw materialsstorage

Quarry washingsLime dust/waste & other calcium wasteHydrated limeFiltercakeWaste iron oxide

MillscaleAlumina catalystFly ash from power generationSodium carbonatePaper industry ash

Rotary kiln

Cooler (clinker cooler) Cement grinding mill (�nish mill)

Pre-grindingsystem

Refuse derived fuelWaste oilWaste solventsWaste wood chipsWaste tyres

Clinker

CoalPetcoke

Portlandcement

Blendedcement

Figure 2: The cement manufacturing process highlighting the different input points of waste as fuel and raw material (images adapted from the Japan Cement Association (http://www.jcassoc.or.jp/cement/2eng/e_01a.html).

2015 provided further evidence of the sector’s slow and steady recovery from the 2008 economic recession. Domestic production of cement increased to 9.2 million tonnes and there is evidence that cement sales in the South-East of England (including London) are growing faster than the rest of the UK.

Further structural changes took place

in the cement sector, with Aggregate Industries taking ownership of two kiln sites, CRH taking ownership of Tarmac and, more recently in 2016, Breedon took ownership of Hope Construction Materials (now trading as Hope Cement). This results in five Portland cement manufacturing companies in the UK: Aggregate Industries operating

as Lafarge Cement, CEMEX, Hanson, Hope Cement and Tarmac (a CRH company).

With increasing interest in progressive sustainable development themes, such as the ‘circular economy’, our new style sustainable development report highlights the contribution of domestic cement production to the environment and the economy.

Reflecting on 2015

1

2

Cement in the circular economy

The material flow diagram (Figure 1) shows where cement already contributes to the circular economy. In particular cement manufacturing:

■ recycles mineral and metal content as well as recovering energy from fuels

■ takes wastes at the end of their valuable life

■ adds value via a quality product

■ restarts the value chain and

■ is mainly used in durable and 100% recyclable concrete products.

The recycling of mineral and metal content in UK cement production is not counted towards UK and EU recycling statistics. The evidence in Figure 3 shows that the UK cement sector makes a valuable contribution to recycling and MPA believe this should be formally recognised.

Figure 3: The total recycled content of UK produced cement. This illustrates that there is an aspect of recycling that is not counted towards UK and EU recycling statistics. An anomaly that MPA believes has been created by a rigid interpretation of the EU’s Waste Framework Directive.

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

RECYCLING: 1.6MT OF WASTE AND BY-PRODUCTS FROM OTHER SECTORS RECYCLED

0

3

6

9

12

15

0

50,000

100,000

150,000

200,000 Waste derived fuel ash

Fossil fuel ash

Not currently counted as recycling

2015

2015

Perc

enta

ge re

cycl

ed c

onte

nt in

cem

ent (

t rec

ycle

d m

ater

ial/t

cem

ent p

rodu

ced)

Ash

recy

cled

(ton

nes)

100,485

60,838

Kiln dust recovered on-site

Fuel ash recycled as mineral content

Alternative raw materials interground

Alternative raw materials in kiln feed

0.12%

1.75%

3.70%

6.98%

Limestone & aggregatesAbundant in nature

+Material recycling

Alternative for limestone

Material recyclingAlternative for aggregates:Recycled aggregates from

demolition waste

Energy recovery

Alternative fuels for coal & petcoke

+

Material recycling

Alternative raw material

Durability

=

Resource e�cient

Mat

eria

l rec

yclin

g

Clinke

r sub

stitu

tion:

by-p

rodu

cts o

r was

te fr

om

other

indu

stries

Concr

ete

=10

0% re

cycl

able

Cement Concrete

Circular Economy

Co-processing

Build

ings + Infrastructure

CON

CRETE IN USECONCRETE PRODUCTION

CEMENT P

ROD

UCT

ION

CLINKER PROD

UCTIO

N

RAW MATERIALS

END

-OF-

LIFE?

RECYCLED IN

OTHER APPLIC

ATIONS

REC

YC

LED

IN C

ON

CRET

E

RECYCLED AGGREGATES

Figure 4: The circular economy of cement and concrete. Graphic courtesy of CEMBUREAU.


3

4

0

10

20

30

40

50

%

Year

1998 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 (industry base year)

Figure 5: Waste derived fuel use in the base year 1998 and from 2005 – 2015.

The cement sector is a significant contributor to the circular economy, by:

■ Using 7.4% alternative raw materials including quarry washings, lime dust, hydrated lime, filtercake, millscale and iron oxide. This has almost doubled from a contribution of 4.0% in 1998.

■ Recovering all (46kt) process waste back into the product or into off-site uses. No process waste has been sent to landfill in the last four years.

■ Making 342kt cementitious additions at the cement plant including kiln dust, incinerator bottom ash, recovered plasterboard, fly ash from power generation and ground granulated

blastfurnace slag. Further additions are made by concrete producers at concrete plants.

■ Replacing 42% of thermal input with waste derived fuels including waste oils, solvents and tyres, refuse derived fuel, and waste sludges, meat and bone meal, and wood. This is a significant increase from 5.7% in 1998 but there has been a levelling off in recent years. MPA is concerned that policy drivers such as those incentivising the use of biomass in other sectors is increasing the competition for limited biomass resource, resulting in a market distortion with the potential to drive cement manufacture back towards coal use.


PROPORTION OF FUEL COMPRISING WASTE MATERIAL

FOSSIL FUEL REPLACED: 42% OF THE THERMAL INPUT REPLACED BY WASTE DERIVED FUELS1.6

Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

WASTE DIVERTED: ZERO PROCESS WASTE SENT TO LANDFILL

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

Building Britain

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

BUILDING A BETTER BRITAIN: EVERY £1.00 INVESTED IN CONSTRUCTION GENERATES NEARLY £3.00 IN ECONOMIC ACTIVITY

Key infrastructure projects like Hinkley Point C nuclear power station will depend upon UK cement.

Imag

e: E

DF

Ener

gy

5

6

■ Cement is the key component in producing ready-mixed concrete, precast concrete and mortar.

■ Following a stable market in the early and mid-2000s, the economic recession saw domestic cement sales drop by 30% between 2007 and 2009. Since 2012, markets have improved by 30%, but sales are still 15% lower than in 2007.

■ One of the greatest threats to the UK cement industry currently and in the near future is the considerable cumulative cost burden from the implementation of climate change policies.

■ Cement manufacture is energy and electro-intensive. Energy costs are 40% of sector GVA and electricity costs alone are 25% of sector GVA.

■ In 2015, direct plus indirect climate change policy cost in the cement sector was £3.24 per tonne of cement. MPA estimates that this will rise to £4 per tonne of cement in 2020 and could reach as much as £17 per tonne of cement by 2030.

■ If action is not taken to protect the UK cement sector from these rising costs, imports will increase, jobs will be lost and security of supply will be threatened.

Year2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

0

20

40

60

80

100

120

0

0.50

1.00

1.50

2.00

2.50

3.00

3.50

Renewable obligation

Small scale feed in tari�s

Carbon price support tax on fossil fuel use in power generation

EU ETS CO2 in electricity

CCL cost to cement with mineralogical process exemption

EU ETS

Indirect cost of renewable energy policies

Direct cost of carbon policies

Indirect cost of carbon policies

Cost

(£ p

er to

nne

cem

ent)

2015

Combustion of waste derived fuels (excluding biomass)

Combustion of fossil fuels

Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015

Figure 6: The cumulative burden of direct and indirect cost of climate change policies on the cement sector (per tonne of cement).

Economic sustainability1.6

Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

CEMENT MARKET: DOMESTIC CEMENT SALES IMPROVED 30% SINCE 2012 BUT SALES STILL 15% LOWER THAN 2007

7

0

0.50

1.00

1.50

2.00

2.50

3.00

3.50






EU ETS




Cost

(£ p

er to

nne

cem

ent)

2015



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015

Year2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

0

20

40

60

80

100

120

0

20

40

60

80

100

120

Local communities

■ Cement plants, mainly located in rural areas, are important to the communities in which they operate. They provide jobs and make a major contribution to the local economy.

■ Local liaison: Recognising that their operations have the potential to impact on their neighbours, cement companies take the need for local liaison very seriously. Liaison meetings are attended by local councillors, local residents, site representatives, and the Environment Agency. The meetings allow local communities to raise any concerns and allow the site to communicate any changes taking place. Newsletters are also produced by many sites and circulated to local residents.

Health and safety

■ ‘Zero Harm’ is the overriding health and safety priority for MPA Cement. Our safety targets are to:

■ Reduce the 2013 rate of lost time injuries by 65% by the end of 2018 for employees and;

■ Reduce the 2013 number of lost time injuries by 65% by the end of 2018 for contractors.

■ MPA Cement members meet regularly to share information on their health and safety initiatives and to share details of any incidents that have occurred. MPA Cement shares details of its programmes with the glass, ceramic and concrete industries through the CHARGE network and participates with the rail, nuclear,

chemical and petrochemical industries in the Process Safety Forum. An example of a topic discussed in 2015 is the relining of cement mills which poses a number of challenges, particularly the repetitive handling of steel relining plates, some as heavy as 55kg. Good practice was shared on opening up mill access e.g. by increasing the mill door size, the use of roller conveyors to get the plates up to mill and the sourcing/use of lighter plates.

Social sustainability

Contractors

Employees

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2

HEALTH AND SAFETY: LOST TIME INJURIES 84% LOWER THAN IN 2005 IN PURSUIT OF ZERO HARM

Figure 7: MPA Cement lost time injuries 2003 – 2015.

0

0.50

1.00

1.50

2.00

2.50

3.00

3.50






EU ETS




Cost

(£ p

er to

nne

cem

ent)

2015



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015

Year2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

0

20

40

60

80

100

120

0

20

40

60

80

100

120

9

Non-CO2 emissions

■ Measured against a 1998 baseline and on a per-tonne of Portland cement equivalent (PCe)* basis, non-CO2 emissions in 2015 were:

■ Dust emissions: 82% reduction on 1998

■ Oxides of nitrogen emissions: 69% reduction on 1998

■ Sulphur dioxide emissions: 88% reduction on 1998

Responsible sourcing

■ 100% of cement produced in the UK is certified to very good or excellent level under the BES 6001 responsible sourcing scheme. Certification to BES 6001 requires companies to demonstrate (and have verified by an independent third party) that organisational governance, supply chain management and environmental and social responsibilities have been responsibly managed.

Water consumption

■ Climate change is expected to result in significant impacts on water availability whilst population growth

will place increased demand on water supplies. Both of these factors have serious implications for the long term management of water availability for industry and public use.

■ Therefore, in 2012, MPA initiated to gather detailed information on water inputs, consumption and outputs. Measurement of water consumption in the production of cement is complex due to the number of different water input, losses/consumption and discharge points:

■ Inputs – abstracted from groundwater and surface water, potable water, harvested rainfall and external waste water

■ Losses/consumption – evaporation for cooling equipment, evaporation from water storage, water used directly

■ Discharges – surface water, to water treatment and to sewer or ocean

■ The measuring system is still in its infancy, however MPA is able to report on the use of potable water (Figure 8) and a considerable decrease of 24% has been measured between 2012 and 2015.

Figure 8: Potable water consumption showing a 24% reduction in 2015 compared with 2012.

Environmental sustainability

2012

400,000m3

2015

305,000m3

Groundwater

Surface water

Potable water

Harvested rainfall

External waste water

Evaporation for cooling equipment

Evaporation from water storage

Water used directly

To surface water

To water treatment

To sewer or ocean

INPU

TS

DIS

CHA

RGES

LOSSES/CONSUMPTION

2012

400,000m3

2015

305,000m3

Groundwater

Surface water

Potable water

Harvested rainfall

External waste water

Evaporation for cooling equipment

Evaporation from water storage

Water used directly

To surface water

To water treatment

To sewer or ocean

INPU

TS

DIS

CHA

RGES

LOSSES/CONSUMPTION

WATER CONSUMPTION IN CEMENT PRODUCTION

*Portland cement equivalent (PCe) is a normalising factor related to cement output, which enables a comparison of impacts, such as environmental impacts, between sites whilst taking into consideration differing production methods, cement product types and movement of intermediate products.

10

Decarbonisation

■ Emissions of CO2 directly from cement plants per tonne of Portland cement equivalent (PCe): 23% reduction on 1998.

■ In 2013, MPA was the first national cement sector association to publish a decarbonisation strategy. This set out how the UK cement sector could reduce emissions of CO2 to 2050 with industry investment and help from Government policy and funding.

■ The roadmap has two scenarios, showing what is possible with and without carbon capture and storage/use.

■ In 2015, MPA worked with Government to produce an industrial decarbonisation and energy efficiency roadmap to 2050 for the cement sector.

■ In 2017, the aim is to publish a plan detailing the actions required by industry, Government, research institutions and investors to deeply decarbonise the cement sector.

■ Key issues for the action plan are costing the work required as well as sourcing and funding decarbonisation technologies. The actions of most significance for decarbonisation are around the use of biomass fuels, clinker substitutes and carbon capture and storage/use.

■ Government support is needed to fund and help implement the actions identified.

Figure 10: Reduction in direct emissions of CO2 in 1998 (base year) and 2005 – 2015.

1990

-81%

-62%1990 to 2050 reductionunder two scenarios

2050

1 2

Figure 9: MPA scenarios for greenhouse gas reduction to 2050.

Environmental sustainability

DECARBONISATION: CO2 EMISSIONS REDUCED BY 23% COMPARED WITH A 1998 BASELINE

1.6Mt

0processwaste

to land�ll

42%waste

derivedfuels

23%reduced

30%higher

84%

low

er

CO2



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015



Calcination

Emis

sion

s of

CO

2 (kg/

tonn

e PC

e)

200

400

600

800

1000

0

Year1998

(baseline)2010 2011 2012 2013 2014 2015

Combustion of waste derived fuels (excluding biomass) Combustion of fossil fuels Calcination (process emissions)

12

CIRCULAR ECONOMY

Data tables

Units 1998 2010 2011 2012 2013 2014 2015

Total waste and by-products used as fuel and raw materials

tonnes 446,511 1,528,315 2,481,106 1,811,200 1,452,553 1,612,584 1,619,766

Proportion of fuel thermal input comprising waste material

% thermal input

5.7 38.2 39.7 40.4 44.0 43.0 41.6

Proportion of fuel thermal input comprising biomass

% thermal input

Not available

10.2 11.3 11.5 13.5 13.6 12.9

Proportion of raw material mass comprising waste and by-products

% 4.0

7.2 7.6 7.6 7.0 7.7 7.4

Process waste recovered on-site

tonnes Not available

11,379 9,195 2,819 10,390 1,513 11,009

Process waste recovered off-site

tonnes nil 36,945 47,796 57,471 47,238 33,988 35,103

Process waste sent to landfill

tonnes 289,207

14,021 4,631 nil nil nil nil

13

Data tables

ENVIRONMENTAL

DECARBONISATION

Units 1998 2010 2011 2012 2013 2014 2015

CO2 emissions from calcination (process emissions)

kgCO2/tPCe 520 471 468 459 468 462 476

CO2 emissions from combustion of fossil fuels

kgCO2/tPCe 387 187 177 169 164 158 172

Indirect CO2 emissions from electricity use

kgCO2/tPCe Not available

55 61 56 44 58 57

Units 1998 2010 2011 2012 2013 2014 2015

Emissions of NOx kgNOx/tPCe 3.34 1.35 1.31 1.31 1.25 1.27 1.04

Emissions of SO2 kgSO2/tPCe 2.56 0.33 0.40 0.48 0.48 0.41 0.31

Emissions of dust kgdust/tPCe 0.33 0.06 0.06 0.06 0.05 0.06 0.06

Potable water use m3/tPCe Not available

0.05 0.05 0.05 0.04 0.04 0.03

Licensed abstraction

m3/tPCe Not available

Not available

Not available

0.04 0.04 0.05 0.07

1

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

The Mineral Products Association is the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and silica sand industries.

MPA CementGillingham House 38-44 Gillingham StreetLondon SW1V 1HU

Tel +44 (0)20 7963 8000 Fax +44 (0)20 7963 [email protected] www.cement.mineralproducts.org

© MPA February 2017

RugbySouth FerribyTilburyKettonPadeswoodRibblesdaleHopeDagenhamDewsburyThealeWalsallCauldonCookstownBelfastAberthawDunbarTunsteadBarnstoneCeltic AshNorthfleetSeahamScotashWest ThurrockPurfleet

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

MPA Cement site locations

Key

Kiln sites

Grinding and blending sites

Grinding only sites

Blending only sites

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

1

4

12

7

9

14

22

21

6

5

2

10 315

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

4

5

6

1

2

3

18

8

11

16

17

18

2019

2324

13

mpa cement members

CEMEX UK Hanson Hope CementKerneos* Lafarge Cement Tarmac (a CRH company)

This report has been titled as 2016 to follow the general MPA nomenclature to use the year of data collection rather than the year of performance.

*Kerneos are members of MPA but data from their operations has not been included in this report because they produce calcium aluminate cements rather than Portland cement.

Sustainable Development Report 2016 · 2017-04-05 · 2 mpa cement Mineral Products Association MPA...

Documents

Transcript of Sustainable Development Report 2016 · 2017-04-05 · 2 mpa cement Mineral Products Association MPA...