Rüdersdorf Cement Plant

Transcription

Environmental Statement 2016
Contents
Contents
Foreword
2
4
Sustainability
6
Product range and its application
8
Manufacturing process
10
Our environmental policy
14
Our Environmental Management System
16
Input-output analysis 2014
18
Environmental aspects:
ppExtraction of raw materials and nature conservation 20
ppEmission control
28
ppWater protection 34
ppResource conservation through secondary materials
36
ppWaste management 39
ppFrom climate protection to energy efficiency 40
ppIndirect environmental aspects 42
Core Indicators
43
Environmental Program
44
Certificates of Validity
46
Glossary
47
1
Foreword
Foreword
Dear Reader
This Environmental Statement strives to provide an insight into our plant,
production processes and activities to protect the environment. It is part of
our voluntary commitment to the Eco-Audit Regulation of the European
Union (EMAS).
EMAS stands for Eco-Management and Audit Scheme and involves a commitment
to a continuous improvement process that includes regular audits by approved
external experts.
15 years ago, we decided to participate in this system and have used it since then
in our efforts to fully meet the demanding German environmental standards, ensuring
that our Rüdersdorf cement plant can boast a high level of environmental protection.
By dealing with issues such as air pollution control, energy efficiency, conservation
of resources, careful handling of water or biodiversity, we find ourselves at the very
epicentre of current discussions. We contribute to this debate through our understanding of sustainable development, i.e. securing a domestic raw material industry
that must be economically viable and at the same time committed to corporate
social responsibility and environmental sustainability.
In autumn 2015, in the presence of Mayor André Schaller, we proudly accepted
the EMAS certificate of Honour for 15 years EMAS at the Rüdersdorf Cement Plant
from the hands of the President of the Chamber of Commerce East Brandenburg
Dr. Ulrich Müller, and the Environment Minister of Land Brandenburg Jörg Vogelsänger.
We see this award as both recognition and incentive to continue along the chosen
path.
This path is already lined with specific projects that we would like to share with
you in this Environmental Statement. But you will also learn a lot about our current
environmental performance, the most important environmental aspects and figures,
as well as recent improvements to our facilities.
We hope this brochure meets your expectations and that you will enjoy reading it,
and look forward to any feedback and discussions.
Henning Weber
Managing Director
CEMEX Zement GmbH
Peter Scur
Head of Environmental Protection
CEMEX Deutschland AG
Environmental protection is a major issue in the
interim Sustainability Report recently published
by CEMEX Germany. It informs about the
company‘s efforts in the area of sustainability,
the new sustainability strategy and updated
performance indicators including practical
examples for each sustainability objective.
The Interim Sustainability Report is available for
download: www.cemex.de (in German)
2|3
The development of the village of
Rüdersdorf is closely linked to its local
limestone deposits – the only such
deposits in northeastern Germany.
These have been exploited for the
production of building materials for
more than 750 years, leading to a
strong mining tradition at the location
over the centuries. This history is
preserved in a mining association
and a museum park showcasing the
building materials industry, which
also brings active mining operations
closer to the public.
As from 2016, the headquarters of CEMEX Deutschland AG will be located at Rüdersdorf.
In the year 1885, cement began to be
manufactured in Rüdersdorf. Since then
cement supplies have been delivered to
Berlin and its surroundings, but also to
further away regions.
The mining
tradition is kept
alive in
Rüdersdorf.
Petershagen
Torfhaus
Zinndorf
Fredersdorf-Vogelsdorf
B1/5
CEMENT
PLANT
ZEMENTWERK
OPEN-PIT
MINING
TAGEBAU
Herzfelde
Lichtenow
Rüdersdorf
Kagel
Erkner
A variety of cement plants and the
associated high level of dust emissions
have shaped the face and reputation of
the location in these years.
The amount of output produced by
11 kilns in 3 plants in 1987 is supplied
today by a single, extremely effective
kiln. It was put into operation in 1995 in
the course of an overhaul of the entire
plant that concentrated production into
a single area. The plants were upgraded
to incorporate the latest process and
environmental technology for the manufacture of cement. Thanks to ongoing
process and cost analysis and according investments, this state of the art
has been maintained to this day.
With a headcount of more than 300
employees and extensive service requirements, the cement plant is a major
A10
Grünheide
(Mark)
employer in the region of Rüdersdorf
and a major industrial location in Brandenburg, Germany. The company also
manages a much acclaimed training
centre, which was restructured in 2015
and adapted to the modern requirements of vocational training. Currently
around 80 apprentices are training as
professional drivers, electronic technicians, industrial mechanics, building materials testers, clerks for office management, clerks for forwarding and logistics
services, and automotive mechatronics
technicians. In the future, there will be
also the option of training as a process
mechanic.
The limestone pit is located on the
eastern outskirts of Berlin, in the
municipality of Rüdersdorf, between the
villages of Rüdersdorf and Herzfeld. It has
a length of 4 km and a width of 1 km.
www.castamap.com
Woltersdorf
The limestone storage is secured for
the next 50 years and will be extracted
in this time almost exclusively from the
deep areas. The cement plant is located at the northeastern edge of the
open pit mine and is separated from it
by the Federal Highway B1/5. The site
covers an area of 60 hectares, and is
part of a major industrial area.
The village of Herzfelde lies at the eastern boundary of the plant, with the first
houses standing immediately behind a
small agricultural area. At a slighly larger
distance to the north lies the Rüdersdorf
district of Hennickendorf.
4|5
Sustainability
Our new sustainability strategy –
Environmental protection remains at the heart
Changes are coming at an ever faster pace: the challenges of a globalised world,
our stakeholders‘ expectations for a sustainable company and its significance
for our business. Therefore, it was high time to adjust the objective formulated
by our sustainability strategy in 2010. The result is a set of precision instruments
for our company and its sustainable development in the future.
The new strategy is based on the results
of a world-wide survey among our stakeholders, from which the issues considered material were elicited.
The derived priorities and targets for the
German organisation are currently being
defined with the aim of describing the
individual initiatives in a more concrete,
tangible and measurable way.
With the introduction of the new sustainable development strategy, some significant changes have been made: The
new section ‚Corporate Governance‘
has been added. Since past developments have shown that the traditional
three-pillar model is not reflecting the
complexity of today´s challenges adequately anymore. The existing circle of
goals has been replaced by a triangle
with Corporate Governance as its core
element.
However, it is not only the individual
measures which are significant, but also
how the path to the desired change
can be structured and controlled. This
enables a holistic view of the enterprise
and its development processes.
A careful environmental management
that aims at minimizing our impact
continues to be the basis of our
business operations. The following
pages show how we implement our
strategies.
In particular, the new strategy focuses
on greater transparency and a clearer
link between global and national challenges and business goals.
The existing circle of objectives has
evolved into a triangle with
„Corporate Governance“
as its centerpiece.
LD
HO
EN
GA
G E M EN T O F
S
O UR
TA
KE
e
g
conomic
overnance
ERS
Sustainability
at CEMEX
T
NT
ONME
VIR
EN
HE
ION OF VALUES
EAT
CR
SIBLE ATTITU
PON
DE
RES
TO
e
nvironmental
s
ocial
Our
sustainability
circle
NATIONAL
Social challenges
Sustainability
e
conomic
nvironmental
s
ocial
overnance
Climate Change,
Resource Scarcity
and Biodiversity
Loss
Social Poverty,
Income Inequality,
Aging Population
and Unemployment
Increasing
Expectations for
Private Sector to
Act Responsibly
and Be Proactive
Provide Resilient
Infrastructure and
Energy-Efficient
Building Solutions
Enable a
Low-Carbon and
Resource-Efficient
Industry
Implement a
High-Impact
Social Strategy
to Empower
Communities
Embed Our
Core Values
into
Every Action
1
2
Delivering solutions
for affordable &
resource/energyefficient buildings
3
Implementing
resilient and
low-impact
infrastructure
4
Infrastructure
for optimization
of our CO2 footprint
by using alternative
fuels and raw
materials, renewable
energies and high
energy efficiency
5
Minimizing air
emissions and
enhancing our
environmental
management
7
Actively
participating in
the development
of sustainable
communities
8
Promoting
empowerment,
diversity and
community
capacity-building
Growth opportunities
in new markets
Enhanced profitability
of commercial
business model
Increased value of
the natural capital
in our land and
quarrying assets
Reduced and
predictable energy
and water costs
Enhanced license
to operate due to a
strong environmental
performance
10
Ensuring
satisfied customers
and responsible
suppliers
11
Engaging
and retaining
our talent
12
6
Increased
competitiveness and
a differentiated portfolio
of products, services
and solutions with
sustainability attributes
9
Placing health
& safety first
Strengthening
business ethics,
compliance and
transparency
Conserving land,
biodiversity and water
Creating value
for shareholders and
stakeholder groups
g
Relentless
Population Growth,
Ailing infrastructure
and Urbanization
Providing sustainable
products and services
Our 12
sustainability priorities
e
Considered the
best neighbor and
private sector
contributor to
community
development
Social License
to operate
Improved reputation
as a company with
superior sustainability
performance
Satisfied customers that
enhance
profitability and
responsible suppliers
that reduce
operational risks
Diverse workforce and
increased employee
engagement
6|7
Product range
and its application
Cement – the building
material for building, design
and safekeeping
As a universal, worldwide available
building material for the production of
concrete, reinforced concrete and
prestressed concrete, cement has
proved its worth for more than 150
years in building structures of all kinds.
But the story of cement is much more
ancient and begins with „opus caementitium“ – a new construction technology
developed by the Romans more than
2000 years ago. The properties of
cement however influenced not only
building construction, but also and
especially construction technology, from
the first stamped concrete up to the
modern high-performance concretes.
Building with cement – based on essential characteristics stipulated in standards
and standards series – is today a matter
of course, but it increases the options of
civil engineering significantly.
Foto: Frank Eritt
CEMEX Germany produced for the Mercedes Benz Arena in Berlin high-strength concretes of the
compressive strength class C100/115 for the supports of the roof made in visual quality.
„Three shovels of sand and one of cement“: Almost everyone is familiar with
this „concrete recipe“. However, the
majority of our customers have much
more sophisticated processing technologies and requirements for the fresh
and hardened concrete properties. In
particular for large-scale projects, the
importance of site-related, fresh concrete properties has increased.
CEMEX supplied more than 10,000 m3
of ready-mixed concrete for the construction of
the Steigenberger Hotel at the Chancellery.
For the construction of the city-tunnel Leipzig CEMEX Germany provided
approximately 350,000 m3 of concrete
Product range and its application
the usage cycle of construction works
and components with a high degree of
responsibility for securing the planned
durability and the sustainability of the
structure.
In recent decades, moreover, concrete
construction has been subjected to
additional environmental requirements.
The cement industry has responded
among other things with the new and
further development of Portland composite and blast furnace cements. These
modern cements form the basis for new
concretes with special properties and at
the same time have led to a significant
reduction of CO2 emissions in their
manufacture.
Transport infrastructure, residential, commercial: CEMEX supplies construction materials for buildings
of lasting value, here for the highway-triangle Barnim by the Berlin motorway ring.
Based on the analysis of technological
procedures used in cement processing
by our customers, we have defined the
application groups Ready-Mix Concrete,
Precast Concrete Products, Civil Engineering / Environmental Engineering,
Traffic Areas and Construction Products.
Our products are distinguished not only
by the „standard characteristics“ of the
construction material, but often also
through additional proven performance
characteristics or application-related
services.
In this way, the respective product
requirements can be better analysed
and appropriate product offerings
developed.
Product ecology
The use of recycled aggregates obtained
from crushed concrete is a current
challenge to maximise the closure of
material cycles and conserve our natural
aggregate resources.
In a recent construction project, the
new research and laboratory building
for life sciences of Humboldt University
of Berlin, has been almost exclusively
built from resource-saving concrete with
recycled aggregate. According to the
Berlin Senate, the undertaking is a lighthouse project for future public works.
As part of the concrete construction value
chain, our products are an integral part of
For this purpose, a large cement assortment is available in which granulated slag and limestone flour increasingly
play a role as main cement constituents
alongside cement clinker. Examples are
CEM II/B-M cements for the specific
needs of ready-mix concrete industry,
CEM III/A 52.5 N-SR/NA with increased
acid resistance for supply and waste
pipes of water management or CEM II/
BS 52.5 N (st) or CEM III/A 42.5 N (st)
for the construction of concrete road
pavements.
Here, our product range is defined
as the sum of:
Building material
+ t ested additional performance
characteristics
+ service
CEMEX provided a concrete made with recycled aggregate for the new research and laboratory
building of Life Sciences at the Humboldt University.
8|9
1. Extraction of raw materials
4. Cement grinding
2. Raw grinding
3. Clinker production
Extraction of the raw material
The main raw material component in the
production of cement is limestone. This
is mainly produced in our own opencast
mine by blasting. However, up to 20%
of the limestone can also be extracted
with a modern hydraulic excavator by
breaking. This possibility is used in
areas close to settlements.
No blasting needed: Hydraulic excavator loads
dissolved limestone on to heavy duty trucks.
Transport of the raw material
Large wheel loaders and hydraulic excavators load heavy-duty trucks, which
transport the extracted raw material to
the crushing plant. The interventions in
nature associated with limestone extraction are compensated by intensive
recultivation measures.
Vertical roller mill for raw meal production.
5. Packing/shipping
materials such as ashes are used
alongside primary raw materials (sand,
bauxite and ores).
Raw meal production
The raw meal components are dried in
a grinding and drying plant (roller mill)
that uses the residual heat of the kiln
exhaust gases and at the same time
crushed. Using modern laboratory
systems, the composition of the raw
meal is continuously analysed and any
necessary adjustments to the component mixture is triggered.
Raw meal homogenisation
The raw meal is stored in 3 large raw
meal silos and simultaneously homogenized. Permanent automated quality
controls also ensure a high and, above
all, uniform product quality.
Limestone crusher
The still differently sized limestone fragments are processed in the stationary
crushing plant into smaller rocks with a
maximum size of 110 mm.
Limestone blending bed
The crushed limestone enters the
blending bed via a belt conveyor, where
it is stored (provisioning) and simultaneously homogenized (homogenization).
A constant composition of the limestone
mixture is decisive for the quality and
uniformity of the subsequent cement.
2. Raw grinding
Corrective substances
In addition to the limestone, silicon, iron
and aluminium substrates are required
as so-called corrective components to
compose the total raw material mixture.
For this purpose, secondary raw
Limestone, sand and granulated
blast furnace slag production
Several ball mills generate meal from
limestone, sand or blast furnace slag
(granulated blast furnace slag – a byproduct of pig iron production), which
are used as raw meal in the clinker
production, or, in the form of limestone
or granulated blast furnace slag meal,
as main ingredients in the subsequent
production of cement.
10 | 11
Clinker production
The homogenized raw meal is first
heated in the upstream floating gas heat
exchanger (cyclone with integrated calciner) to about 900 °C and then fired in the
actual rotary kiln to a peak temperature
of 1,450 °C. This produces so-called
clinker. This semi-finished product is
then rapidly cooled in a grate cooler
and transported via conveyors to the
clinker storage.
Fuels
In addition to coal dust, appropriately
treated and quality-assured secondary
fuels provide the necessary heat energy.
Some of these secondary fuels are not
supplied directly to the cement kiln, but
first pass a circulating fluidized bed (CFB),
from which a gas is generated.
Race change on rotary kiln – the centrepiece of the cement plant.
Quality of combustion in the main burner is
continuously monitored with a thermal imaging
camera and by special computer programs.
Corrective
substances
Open pit
Cyclone preheater
Secondary
fuels and raw Circulating
materials
fluidized bed
Raw
meal
Vertical
roller mill
Limestone
crusher
Limestone circular
blending bed
Calciner
Hot ashes
Classifier
Sand/blast
furnace slag
Ball mill
Granulated
blast
furnace
slag
Lean gas
Rotary kiln
Lime
stone
meal
Sand
meal
Limestone
2. Raw grinding
The process of cement production at the Rüdersdorf Cement Plant.
5. Packing and shipping
Alongside filled and palletized 25 kg
bags, cement is mainly shipped as a
bulk product. The bulk goods are loaded
in approximately equal amounts into
railcars for environmentally friendly rail
transport or alternatively in silo trucks.
4. Cement grinding
Cement types
In order to control the processing properties of the cement, the clinker is always ground with the addition of sulfate
carrier, usually gypsum and anhydrite.
Depending on the cement types to be
produced, further ground components
such as granulated blast furnace slag or
limestone meal are added and adjusted
to the appropriate level of fineness of
the finished cement.
Cement mills
After pre-grinding in so-called high
pressure grinding rolls (roller presses),
the post-refining is performed by ball
mills. The different types of cement
are stored in separate silos for cement
shipping.
Railcar loading for cement shipment
was expanded in 2014.
Classifier
Grate cooler
Cement
Clinker
Secondary
fuels
Coal dust
Roller press
Shipping options of cement: in sacks or as
bulk product over road, rail and waterway.
Plaster/
anhydrite
Ball mill
4. Cement grinding
5. Packing/shipping
12 | 13
CEMEX is involved in many environmental protection projects worldwide.
Our product, cement, is one of the most important building materials and, as
an integral part of concrete, has made an essential contribution to the development of civilization.
he production of cement is however
resource-intensive and generates
emissions; it therefore has an impact
on the environment. Our goal is to keep
this environmental impact as low as
possible and to ensure environmental
compatibility of our processes and
products at all times.
Modern environmental protection
makes this possible. We have therefore
adopted the guiding principle of sustainable development and, alongside the
economic success of our company, are
committed to social responsibility and
environmental protection.
We can rely on the environmental and
sustainability policies of our internationally
operating parent company CEMEX.
Environmental protection
We consider compliance with environmental legislation a minimum requirement. Taking into account profitability,
we examine further ways of reducing
environmental pollution. We evaluate
our environmental performance and
environmental impact in a verifiable way
and work amongst other things with
process performance parameters.
Resource conservation, air pollution
and the reduction in specific CO2
emissions play an essential role in our
environmental protection activities. From
this perspective, lowering the proportion
of clinker in cement has a great significance for us. What‘s more, we strive
to replace natural raw materials and
fuels by secondary resources if possible
without compromising product quality
and emission situation. Evidence of the
environmental impact is given particular
weight.
We value the cleanliness of our facilities
and attractive appearance of our plants.
Environmental considerations are taken
into account in the process management in order to make maximum use of
the opportunities of production-integrated environmental protection. Effective
and energy saving processes are important criteria for us.
We minimize the impact on the natural
environment caused by mining operations through preventive measures,
targeted reclamation and promotion
of biodiversity to ensure a high level of
attractiveness of the sites after mining
completion.
We use water and soil with utmost care,
set up closed circuits if possible and
take the necessary measures to avoid
damaging surface water, ground water
and soil.
We avoid waste as far as possible, for
example, by closed loop circulation or
recycling. We ensure re-utilization of
unavoidable waste, and only if this does
not make sense, transfer waste to
disposal sites.
Planning and communication
We embrace state of the art technology
when making investments, system
modifications or product developments.
Potential environmental impacts are
thereby already considered in the
project phase and appropriate precautions are included in the planning if
necessary. When selecting suppliers,
we consider ecological aspects in the
evaluation.
We work closely with authorities, associations, etc. and inform the interested
public and our business partners about
the company and its environmental
performance. We are ready to support
educational institutions in disseminating
environmental knowledge and we train
our employees so that they can fulfil
their environmental responsibilities.
Commitment
To meet the demands of quality and
important goal of joint responsibility for
the environment, we have developed
and documented our relevant major
organizational measures and policies in
an Integrated Quality and Environmental Management System. We regularly
check our self-defined rules and practices, compare the same with the actual
development of our company and
derive therefrom corrective and preventive actions to continuously improve our
processes.
Through this Environmental Statement,
the management and all employees are
committed to carry out their activities in
accordance with the descriptions of the
Integrated Quality and Environmental
Management System Manual.
The company management sees it as
its permanent responsibility to promote
at all levels quality and environmental
awareness, as well as flexibility and motivation, through staff training measures.
This environmental policy enters into
force through the signature provided
below. It is mandatory for all cement
plants of CEMEX Deutschland AG and
shall be made known to all employees
by means of the notice board and on
the staff meetings.
Rüdersdorf, 03.09.2015
Henning Weber
Managing Director
CEMEX Zement GmbH
14 | 15
Our Environmental
Management System
Handbuch
Integriertes Management
Änd.-Index: 1
CEMEX Zement GmbH
CEMEX Zement GmbH
Eisenhüttenstadt
Werke Rüdersdorf und
ch
M agement - Handbu
Integriertes Man
(IM- Handbuch)
gemäß
tätsmanagementsystem
DIN EN ISO 9 001 Quali
eltmanagementsystem
DIN EN ISO 14 001 Umw
iemanagementsystem
DIN EN ISO 50 001 Energ
Adresse:
CEMEX Zement GmbH
Postfach 13/14
15558 Rüdersdorf
/54
Tel.: 033638/54-0
/54
Fax: 033638/54-222
ar 2015
Ausgabedatum: Febru
Datum und Unterschrift:
nt
Freigabe durch Vice Preside
Henning Weber
Operations: Henni
Seite 1 von 1
Datei: IM-HB Deckblatt
Datum: Febr. 2015
Our integrated management manual.
Our EMS is designed according to the
specifications of DIN EN ISO 14001
and part of an integrated management system (IMS) for environmental
protection, quality and energy. It is
therefore tightly integrated into the
structures of CEMEX Zement GmbH.
A corporate IMS Manual sets down
the general principles and practices.
The Environmental Management System
(EMS) is based on the environmental
policy adopted by the company‘s top
management, the process descriptions
and an analysis of the potential environmental impact from the company‘s individual activities (environmental aspects).
Concrete, detailed descriptions and
guidelines for environmentally compatible behaviour and the associated
responsibilities are set down in environmental guidelines and work instructions.
The responsibility for the entire system
lies with the Vice President Cement
Production & Technology. He is supported and advised by the Integrated
Management System Officer and the
Head of Environmental Protection, who
reports directly to the Vice President
Law & Sustainability.
Organigram CEMEX Zement GmbH
Vice-President
Sales
Application
Technology
Cement
Sale
Plant Manager
Eisenhüttenstadt
The Management System Officer
constantly assesses the effectiveness,
appropriateness and timeliness of the
EMS, its requirements and objectives.
He or she analyses weaknesses and
need for action and reports to the Vice
President Cement Production on an
annual basis. An important tool here are
internal and external audits. In 2015, a
total of 15 internal audits and an external
recertification audit by the TÜV (Technical Control Board) were performed.
3.
Environmental
Program
4.
Environmental
Management
System
5.
Environmental
Operating Test
6.
Environmental
Statement
2.
Environmental
Policy
1.
Environmental
Assessment
7.
Examination
by an auditor
8.
Registration
The EMS is subject to regular cycles aiming
at level increases if possible.
President
CEMEX Germany
Vice-President
Supply Chain
& Logistics
Supply Chain &
Logistics Cement
Plant Manager
Rüdersdorf
Vice-President
Cement Production
& Technology
Vice-President
Law &
Sustainability
Processes &
Technology
Environmental
protection
Fuels &
Energy
Quality &
Environmental
Management System
Maintenance
Quality Control
Sustainability
Energy Tax
& Energy
Management
Vice-President
HR
Vice-President
Strategic
Planning
Workplace
Safety
Purchasing
Company
Controlling
Our Environmental Management System
Another important tool is process
performance parameters, which
illustrate general trends and enable an
assessment of performance.
An annual management review carries
out a summary assessment of the EMS
and environmental performance,
compares it with current legal environmental legislation, takes stock of the
last Environmental Program and defines
measures to address weaknesses and
ensure a continuous improvement
process. This is communicated to all
company areas and aims at ensuring
that all employees identify with the issue
of environmental protection and integrate
it into their work. This internal communication process uses a wide range of
other options, such as the employee
newsletter, staff meetings, service
consultation and team meetings.
1
Dialogue with business partners
and the general public
3
Images: [1] Blasting show at the Bergfest,
[2] open house day, [3] Gewerbemeile („Trade
Mile“), [4] state premier visit to apprentices,
[5] factory tour.
bauwerk
Forum für Kunden
und Partner der
Die Stadt gestalten –
Lebensraum bauen
Nr. 21 | 2015
We are involved in community projects
and are for example the largest sponsor
of the Construction Industry Museum
Park or the Bergfest („Miner’s Festival“).
We also provide the opportunity to visit
the plant itself and periodically open our
factory gates for public plant tours or as
part of larger public projects, such as
our participation in the Brandenburg
„Long Night of Industry“ in the years
2013 and 2014 or the Rüdersdorf
Gewerbemeile („Trade Mile“) in 2015.
2
Nr. 22 | 2015
We strive to communicate our understanding of the environment to the outside world, to our neighbours, customers,
service providers and public representatives. In addition to our environmental
statements, we provide information on
our website, in the local press, in scientific journals or at conferences. Environmental protection is an integral part of
our conditions of purchase and inductions for external companies as well as
information for our customers.
bauwerk
bauwerk | Ausgabe 22 | 2015
Customer
magazine
„bauwerk“.
4
1
Forum für Kunden
und Partner der
Wege in
die Zukunft
Innovationen für die Baubranche
bauwerk | Ausgabe 21 | 2015
1
5
16 | 17
Input
Output
1. Feedstocks
1. Product
Limestone
t
2,448,000
Sand
t
129,000
Cement
t
2,029,000
Clinker
t
Ashes
t
139,000
81,000
Rock meal
t
Mineral residuals
69,000
t
17,500
Coal dust
t
1,500
Calcium fluoride
t
6,300
Iron ore + bauxite
t
9,000
Sulphate carrier
t
92,000
Blast furnace slag
t
265,000
Share of renew
able energies
2. Energy
2. Emissions
Coal
GJ
1,942,000
0 %
Dust
t
106
Fluff
GJ
3,828,000
39 %
CO2 raw material
t
880,000
Animal meal
GJ
326,000
100 %
GJ
125,000
100 %
CO2 fuel, fossil
(of which secondary fuel)
t
Sewage sludge
407,000
212,000
Gas + oil
GJ
35,700
0 %
SO2
t
1,130
Electric power
MWh
211,000
n. b.
NOx
t
1,640
Surface water
m3
315,000
Drinking water
m3
11,600
3. Water
3. Water
Water discharge
m3
Wastewater
m3
11,100
Open pit dewatering
m3
12,300,000
60,600
4. Waste
4. Raw materials and supplies
Grinding aids
t
160
Hazardous
t
860
Explosive material
t
280
Non-hazardous
t
5,100
Hydrated lime
t
17,000
NOx reducing agents
t
470
Activated carbon
t
14
Oxygen
t
930
Chromate reducer
t
3,700
Diesel
t
1,300
n. k. = not known
Of which from construction and demolition work:
Hazardous
t
810
Non-hazardous
t
2,600
18 | 19
Extraction of raw materials
and nature conservation
The wheatear, here a male in front of a breeding cave at -35 m NN, has a comparatively high population density
with at least 12 breeding pairs in the open-pit mine; it lives on all beds.
Extraction of raw materials and nature conservation
Limestone mining – the
basis for cement production
in Rüdersdorf
The shell limestone extracted from
the open pit mine in Rüdersdorf is
the basic, natural raw material for our
cement production; the carbonaterich portions are mainly delivered to
the neighbouring lime plant for the
production of quicklime.
From the perspective of nature protection law, limestone mining is a significant
intervention in nature and landscape. It
requires the lowering of ground water
and is connected to blasting vibration
and other emissions (secondary dust
and noise by mobile device technology,
etc.). These environmental impacts
cannot be avoided or relocated due to
the local nature of the raw material.
However, their impact must be evaluated and minimized so as to be environmentally acceptable as well as compensated through targeted measures.
Limestone extraction
near the village
The limestone mining in areas near the
village is carried out exclusively with a
320-ton hydraulic excavator, which was
designed and built specifically for this
application. It is equipped with a special
noise protection package, which reduces acoustic emissions by 50%.
Explosives were not used in order to
avoid shocks and hazards. Dust development (especially on the train paths) was
largely prevented through the use of a
water truck with a capacity of 48,000 l.
The Rüdersdorf mining project has a
tradition spanning over 760 years and
has already been approved by the
competent authority until the year 2062.
But in order to ensure limestone extraction and thus cement production for the
next 45 years on site, the local conditions required that open-pit mining operations be conducted in a vicinity of up
to 70 m from the residential area of
Rüdersdorf.
The years 2012-14 saw mining operation
come closest to the village – so this is
meanwhile „history“.
View of open pit and cement plant from the Museum Park.
However, more than 11 hectares of
forests (a large part of the so-called
„green throat“ of Rüdersdorf) had to be
cut down.
Of the approximately 35 hectares of
compensatory planting (afforestation
and forest conversion activities) outside
the mining surfaces, 24 hectares have
been implemented – although the corresponding forest conversion process
has not yet been completed.
No additional intervention in the groundwater was required.
The necessary green noise barriers (with view point into the open pit)
can be integrated into the network of hiking trails.
20 | 21
intervals that are hardly noticeable for
the observer. Noise and vibration can
thus be reduced to a minimum.
But despite all countermeasures, the
residents of Rüdersdorf and Herzfelde
can still perceive the explosions today.
– Why is that?
To avoid dust emissions, the driveways are kept
moist with a water tanker in dry weather.
About 15% of the required limestone can be
extracted without explosives in the area near the
village by using this hydraulic excavator.
To minimize further noise developments,
e.g. by bulldozers and lorry traffic, three
noise barriers have been built with a
total length of 360 m and additional
greenery.
Blasting vibration
Blasting operations have been carried
out in our open pit for over 200 years.
During this time, blasting technology
has constantly developed. Today holes
are drilled along the quarry walls and
filled with explosives. Not all holes are
detonated at once, but in millisecond
By blasting a large amount of energy is
released, which is necessary to loosen
the solid rock from the mountain face.
However, a part of this energy passes
as a seismic wave through the mountains, thereby causing vibrations.
It is not technically possible to prevent
the emergence of these seismic wave,
i.e. the formation of blast vibrations.
Blasting can therefore never be carried
out without shocks. However, it is
possible to influence the strength of the
vibrations. The vibration strength mainly
depends on the amount of explosives
ignited at once (charge amount per
ignition time stage) and on the distance
from the blast site. But geological and
hydrological conditions also have an
impact on the damping of the shock
wave.
The GPS-equipped rock drilling machine
drills the blast holes.
Only selected, representative blasting operations
Monitoring of all quarry blasting
Development of blasting vibration monitoring. As early as 1980, individual detonations were monitored by measurement.
Today‘s devices allow all detonations to be measured around the clock.
Dec. 14
Nov. 14
Oct. 14
Sept. 14
Aug. 14
July 14
June 14
May 14
Apr. 14
Mar. 14
Table showing the vibration values measured in 2014 in relation to the permissible values of DIN 4150 Part 3
It can be clearly seen that the explosions are below permissible values.
Feb. 14
100 %
90 %
80 %
70 %
60 %
50 %
40 %
30 %
20 %
10 %
0%
Jan. 14
Relation to DIN standard
Relation of vibration to DIN standard for residential buildings
Metrologically, blast vibrations can be
measured in mm/s by recording the
vibration velocity. To assess the vibration
impacts on building works, the recorded
values have to be compared with the
permissible values in the DIN standards.
The values given in the DIN standard
are set so low that the risk of damage
to buildings is excluded. However,
overshooting these values does not
necessarily lead to building damage.
The vibrations are nevertheless perceptible, and the aim is therefore to
keep them at a low level.
Extensive blasting vibration monitoring
has been carried out at the site since
1995. A measurement system monitors
the vibrations caused by the blasting
operations at critical points at the village
outskirts. To date, over 13,000 vibration
measurements were recorded and
stored for extensive analyses and evaluations in a database. A new ignition
process was successfully tested and
measured. Through the use of nonelectric ignition, emissions (explosive
bangs and shocks) could continue to
be kept at a low level despite the fact
that operations steadily came closer to
the village. There are current attempts
to further optimize the vibration values
using an electronic ignition. Freely
programmable delay times from hole to
hole aim at stopping the increase of
vibrations, or even decreasing them, in
geologically induced vibration-sensitive
areas along the limestone pit and in the
center of Rüdersdorf.
The natural dynamics in embankment
areas create new ecological niches.
Nature is resourceful – it always finds a way:
Bayonet growth of a birch.
22 | 23
The heat-loving lizards find good living conditions
in the peripheral areas of the mine, also due to the
good feeding sources.
The open pit mine established through
several quarries, including its direct
environment (mining waste and dumps,
partial village displacements in the
area of Heinitz or Redenstraße) can be
virtually seen as a mining landscape.
Nevertheless, the exposed limestone
covering an area of 300 hectares left to
natural (only slightly controlled) succession in its most diverse stages forms
the quasi-natural geogenic basis of the
current – for Brandenburg extremely
valuable – ecological situation.
The laburnum, actually a „garden plant“,
has taken over the porous limestone cliffs
of the mining area Heinitz-Nord.
Biodiversity and limestone
extraction at the Rüdersdorf site
The preservation and promotion of
biodiversity are an integral part of the
sustainability strategy of CEMEX – and
not just since the international year of
biodiversity of 2010.
What does that mean in concrete terms
for the extraction of raw materials at the
Rüdersdorf site? And how is conservation of biodiversity in the active limestone
quarry ensured?
The basis for considerations and
assessments in this regard is the status
quo that has emerged through mining
operations over the centuries.
For example, more than 460 species of
ferns and flowering plants have made
their habitat within boundaries of the
open pit recently (within the past 20
years), including Red List species such
as maple and elm (in the past 20 years
more than 2,000 specimens of each
were planted), the Great Anemone
(partial relocations from active mining
areas), the Nettle-Leaved Bellflower, the
Fragile Bladder Fern and the Upright
Ziest.
In addition, more than 50 moss and 53
lichen species have been recorded in
special geological mappings, including
species that thrive better here than
anywhere else or others which were
considered lost for Brandenburg.
If the limestone deposits of Rüdersdorf
had not been mined and used, we
would now have at the same place a
subsidy-based agricultural landscape
with stony fields and significantly less
biodiversity.
A Yellowhammer has made its home in
scrubby areas of upper mining embankments.
The same holds true for the supraregionally important hibernation site for bats
in the mining cavities or industrial structures at the open pit boundary, which
would not exist without the limestone
exploitation.
The open pit also is also significant as
an extensive habitat that offers refuge to
other animal groups.
Mention may be made here of interesting Red List species such as eagle owl
or peregrine falcon; but also less spectacular breeding birds, such as Kestrels,
Wheatear, Yellowhammer, Whitethroat
or Woodlark, which are rare in the open
countryside. The many, also temporary,
damp patches in the open pit have an
immense importance for the reproduction of special amphibians (e.g. natterjack toad).
Not least, a selection of Red List insect
species should be mentioned, for
example, Mourning Cloak, Swallowtail,
Small Pearl-Bordered Fritillary or Blue
Winged Grasshopper, which find optimal
living conditions under the microclimatic
conditions and specific location factors.
But how can biodiversity be ensured
despite progressive mining on several
beds?
Of the total open pit area, less than 10%
are actively used and this does not
change (only the workshop area and the
crusher forecourt are sealed). The rest,
including the extensive, inaccessible
embankment system is defined as a
quiet zone where the animals have
become accustomed to the processes
of open pit operation.
The mining fronts of the different beds
„migrate“ annually about 50 m to the
west. The habitats, or succession
stages, migrate accordingly with them
(migrational biotope). All habitat types
(10 different secondary habitat types
have been detected in the open pit)
therefore exist: from nearly barren open
spaces with dry and very humid areas
for primary settlers (lichen / moss ...,
As a bird typical of half-open landscapes with
sufficient supply of large insects (as nutritional and
reproductive basis), the red-backed shrike feels at
home in the southern end slopes of the opencast
mine.
24 | 25
A former limestone bunker was
rehabilitated to accommodate bats.
Natterjack Toad) through to fresh
meadows (insects, etc.) and finally scrub
encroachment with pioneer vegetation
(willow, birch, pine, sea buckthorn) for
Spiny Dogfish Warbler, Yellowhammer
and Red-Backed Shrike. On the other
hand, the protection of the species is
also actively considered, for example in
the selection of plants for reclamation,
through establishment and maintenance
of wetland sites (waterholes, ditches) as
oases in the limestone quarry, through
In coordination with the Environment
Ministry, the Inspectorate and the Wildlife
Protection Society, measures to secure
bat winter roosts were developed and
implemented in conformity with the
mining activity:
the relocation of specific herbs and
flowering plants from the immediate
vicinity, including measures such as the
blasting ban on potential bat winter
lodgings from October to April.
Due to the fact that the number of
winter roosts within the pit will diminish
in the long term, old industrial buildings
(basements of limestone bunkers and
old belt tunnels) have been converted
into alternative roosts which provide a
lasting solution.
Winter roosts for bats
Thanks in particular to their special
characteristics derived from mining
exploitation, open pit areas provide an
excellent haven for bats. The limestone
cavities created by mining (tunnels, tracks
and wells) have provided one of the few
Central European mass wintering roosts
for bats for more than 70 years. The
method of bat ringing was developed in
Rüdersdorf in the 1930s.
Back then, more than 3,000 animals
were registered during the winter months.
Since the early 90s, an animal popula
tion of 1,000 to 1,500 has been recorded, although a large part of the headings
can no longer be checked for safety
reasons.
•No mining of headings
from October to April
•Bat-friendly closure of all shafts
(mouth holes)
•Securing of control surveys
•Cleaning and removal of fixtures
• Frost-proof covers and gratings
•Installation of slot walls and hollow
block ceilings
In this way the bat roost Ruedersdorf
could be declared as FFH area with
5 specific locations by the Brandenburg
Ministry of Environment.
Reclamation – renaturation
The open pit mine provides good
conditions for ecologically diverse areas
and spaces for the public to experience
nature, which can be designed already
during mining activities with a well thoughtout restoration concept.
The special ecological value of the area
around Rüdersdorf is therefore directly
connected to the overground limestone
deposits as well as their excavation
and use, making the area unique for
Brandenburg.
The reclamation program of the
Rüdersdorf mining plant takes this into
account and pursues a range of targets
according to the location and type of
use of the respective area:
•Promotion of natural succession
(e.g. modelling of flat, structured
embankments)
•Site-specific cultivation care
(conservation of floriferous shrubs:
laburnum, lilac)
•Initial plantings of site-specific trees
or shrubs (buckthorn, brooms, etc.)
Initial planting (even without further care) can „bear fruit“ even on sandy, dry embankments:
Broom in the second year.
•Greening of flat slopes (above the
limestone and later lake level)
•Partial plantings (primarily of open
spaces: biotope networking and
pollution control)
•Biodiverse plantings for insects
(e.g. as bee pasture)
•Development of areas for local
recreation and education (hiking trails,
geological and mining peculiarities
along the open pit rim, observation
decks)
•Integration of historical relics in
the restoration measures (old wine
terraces)
•Creation of park-like structures
(green areas, parkways)
Since the beginning of systematic reclamation in 1993, a total of approximately
82,000 plants of more than 80 species
have been planted and maintained in
the border areas of the open pit and
outdoor heaps.
Anemone silvestris grow on a residue embankment conceived as a barrier.
Over the past 5 years, these have
included 6,000 primarily native plants
with a high percentage of ecologically
valuable tree species, such as mountain ash, wild service tree, field maple,
buckthorn, dogwood, elderberry,
honeysuckle, buckthorn and hazel.
Natural succession is promoted by structuring the
Pleistocene boundary slopes, with an inclination of
approx. 18 degrees: here mainly Norway maple.
26 | 27
Immission
control
The 121-meter-high kiln exhaust stack with measuring platform. In front is the electrostatic precipitator, which was converted into a bag filter in early 2016.
Immission control
Keeping the air clean
Cement production requires the handling of large amounts of pulverized or
dust-prone materials. Dust emission
was therefore perceived for many
decades as the main environmental
issue caused by cement plants.
This problem can now be managed very
well thanks to the development of high
performance fabric filters and the encapsulation of conveyors and warehouses,
in conjunction with a systematic installation of modern filtering systems. In the
Rüdersdorf Cement Plant, about 250
bag filters in different sizes with a fabric
surface totalling approximately 20,000
m2 have been installed for this purpose.
The functioning of the filter is checked
and recorded on a daily basis by the
responsible employees and examined
by experts at regular intervals. The last
dust content measurements behind bag
filters of grinding and ancillary facilities
have brought the following results (see
Table 1).
Heavy metals emission concentrations
were additionally checked on a cement
mill (see Table 2).
Here the measured values are very low,
in areas well below the limit value,
usually even below the detection limit.
Table 2: Results of heavy metal measurements on cement mill 2 in 2013
Measurements
Max. value
mg/N.m³
Hg
Tl
Pb
Co
Ni
Se
Te
Sb
Cr
Cu
Mu
V
Su
< 0.00001
< 0.00003
< 0.0003
< 0.0003
0.0006
< 0.0003
< 0.0003
< 0.0003
0.0003
< 0.0003
0.0004
< 0.0003
< 0.0003
According to TA Luft („Technical Guidelines on Air Quality Control“), limit values
here lie between 20 and 30 mg/m3 and
can be reliably observed.
Table 1: Results of control measurements
of dust emission 2013/14
Plant
Screening plant, open pit
Raw mill 4
Raw mill 5
Raw mill 6
Raw mill 7
Clinker silo 1
Clinker silo 1
Clinker silo 2
Clinker silo 2
Cement mill 1
Cement mill 2
Cement mill 3
Cement mill 4
Cement mill 5
Roller press 3
Roller press 2
Coal mill 1
Coal mill 2
Limestone silos
Material feed RMA
Readings
mg/m³
1
1
13
16
3
2
2
7
3
1
2
2
8
2
5
3
7
17
1
1
Staff members of an external measurement institute during the calibration of continuous dust measurement by the flue of the cooler exhaust air.
28 | 29
Renewal of refractory lining in the kiln
during the winter repairs.
Kiln exhaust gas /
Combustion conditions
Combustion conditions of the kiln
°C
The plant‘s main emission source is
the exhaust gas stack with an outlet
height of 121 m. It is subject to the
17th German Federal Pollution Control
Ordinance (BimSchV), which regulates
the incineration and co-incineration of
waste.
2,000
2,000
1,500
1,450
1,050
1,000
880
850
500
350
0
Preheater
10
1
Calc.
Rotary kiln
Grate cooler
5
8
1
Dwell time, gas [s]
30
0,1
20
Dwell time, material [min]
Combustion conditions of calciner
Pyrotop
T
Combustion chamber of calciner
from inlet of lean gas
• 43 m until entry pyrotop (2.1 s)
• 79 m until entry cyclone 5 (4.2 s)
CFB
Switch-on and failure lock for the SBS:
T before Pyrotop > = 850 °C;
This temperature level is also maintained
at the measuring point before cyclone 5
T
Entry of fuels into calciner
Rotary kiln burner
Cyclone 5
T
Temperature
Up to 85% of the heat required by the
kiln can be provided by secondary
fuels. The cement kiln provides almost
ideal conditions for the combustion of
these substances. This applies both to
the fuels, which are fed to the kiln via
the main burner in the rotary kiln and
here generate a temperature of approx.
2,000 °C (see diagram: Combustion
conditions of the kiln), as well as the
fuels supplied to the calciner (see diagram: Combustion conditions of calciner)
which ensure the deacidification of
limestone at temperatures of about
900–1,000 °C.
The combustion conditions stipulated
in Section 7 of the 17th BImSchV
Dwell time ≥ 2 sec
temperature ≥ 850 °C
are strictly observed in all cases.
If the temperature in the calciner falls
below 850 °C, the feed of secondary
fuels is automatically interrupted.
Immission control
Emission control and monitoring
of kiln exhaust gas
The exhaust is subjected to several
cleaning stages before the emission via
the stack:
– production-integrated primary flue
gas cleaning by the raw meal running
through the gases in counterflow;
– SNCR system for non-catalytic
reduction by NOx;
– dry adsorptive flue gas cleaning
with hydrated lime to reduce SO2
emissions;
– active coal injection for reduction
of mercury;
– dust collection in the electrostatic
precipitator.
This multi-stage flue gas cleaning process is required for compliance with the
highly demanding German emission limit
values. The table on the right shows
the evolution of these limits and a comparison with European norms. Despite
uniform framework legislation in Europe,
the German limits are significantly lower
in almost all cases.
The current results of our extensive
emission control can be found on the
following table (Table: Emission results
of kiln). Further improvement can be
detected here for the dust and mercury
emission. The cooler filter of the bypass
gas was relieved to reduce dust and
thus enable us to comply with the limit
of 10 mg/m3 in the future.
As a further measure to reduce dust
emissions, the electrostatic precipitators
for dedusting kiln exhaust gases will be
converted into a bag filter in 2016.
Attempts to inject activated carbon for
mercury emission compliance were
started 2014. A system that can be
used in normal production operation is
meanwhile available.
Table: Development of kiln exhaust gas emission limits
Components
Rüdersdorf
Europe
1990
2005
New limit in 2014
Dust
50
20
10 3)
30
NOx
800
500
200 4)
500
SO2
400
350
HCl
30
10
NH3
—
—
Hg
0,2
0,03
Heavy metals
2012
50 (4001)
10
30 3)
—
0,05
5
0,38
0,5
TOC
150
30
101)
CO
—
—
800 3)
2)
1)
Exemption, if the emission is raw material-related
2) Must be determined by the approval authority
3) Valid from 2016
4) Valid from 2019
Table: Emission results of kiln
Parameter
Limit
value 1)
Type of
monitoring
Measured values
2015 4)
Daily values
> limit value
Jan.–Oct.
(of which from
March)
Dust
20
Cont. measurem.
SO2
12
14 (2)
350
Cont. measurem.
314
6
NOx
500
Cont. measurem.
330
0
HCl
10
Single measurem.
1.2–3.3
—
HF
1
Single measurem.
< 0.04–0.2
—
Hg
0.03
Cont. measurem.
0.008
7
Cd + TI
0.03
Single measurem.
0.00005–0.0004
—
∑ Heavy metals 2)
0.38
Single measurem.
0.001–0.008
—
30
Cont. measurem.
12
0
0.03 3)
Single measurem.
All values < 7* 10-6
—
0.1
Single measurem.
0.001–0.002
—
Single measurem.
0.3/31–43
—
Kiln exhaust gas
∑ Corg.
Benzo(a) pyrene (BaP)
Dioxins I Furans
NH3 (VB/ DB) 5)
Cooler exhaust air
Dust
20
Cont. measurem.
10
14 (7)
Cd + Tl
0.5
Single measurem.
0.00005–0.00006
—
5
Single measurem.
0.003–0.005
—
∑ Heavy metals 2)
Values in mg/m3, except for dioxins/furans in ng/m3
1) Limit value (as daily average value)
2) Sb, As, Pb, Cr, Co, Cu, Mn, Ni, V, Sn
3) Limit value as a checksum value BaP + As + Cd + Co + Cr
4) W ith cont. measurement Annual average (up to and including Oct.)
with single measurement: lowest and highest measured value
5) CO = composite operation (with raw mill),
DO = direct operation (without raw mill - approximately 15% of kiln run time)
30 | 31
Development of the NOX emissions and measures for reduction
mg/Nm3
1,000
900
873
1996: Optimization of the fuel and burning process, staged combustion
2008: Installation of a SNCR system
2014: 1st successful optimization step of the SNCR
2017/18: 2nd optimization step of the SNCR (in planning)
800
700
600
500
391
400
397
330
300
Target < 200
200
100
0
1996
2000
2010
2015
2019
Emissions
Emissions forecast, concentrations of air quality
Parameter
Particulate matter
SO2
NO2
Cadmium
Lead
HCl
Mercury
Arsenic
Thallium
Chrome
Cobalt
Copper
Vanadium
Manganese
Antimony
Tin
PCDD/F
Unit
Maximum
additional load
Benchmark
Source
µg/m³
µg/m³
µg/m³
ng/m³
ng/m³
µg/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
ng/m³
fg/m³
0.18
1.21
0.25
0.10
0.56
0.03
0.10
0.097
0.206
0.453
0.117
0.599
0.324
1.980
0.142
0.148
0.34
40
50
40
20
500
30
50
6
100
17
100
10,000
20
150
80
1,000
150
TA Luft (JMW)
TA Luft (JMW)
TA Luft (JMW)
TA Luft (JMW)
TA Luft (JMW)
AGW/100
LAI (1996)
39. BImSchV
Kühling/Peters
LAI (2004)
MAK/100
MAK/100
LAI (1997)
WHO
Eikmann
MAK/100
LAI (2004)
Unit
Maximum
additional load
Benchmark
Source
g/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m2*d)
µg/(m²*d)
µg/(m2*d)
µg/(m2*d)
pg/(m2*d)
0.00008
0.045
0.045
0.260
0.042
0.097
0.212
0.055
0.281
0.152
0.928
0.066
0.069
0.03
0.35
4
2
100
1
2
82
16
99
7
60
10
15
4
TA Luft
TA Luft
TA Luft
TA Luft
TA Luft
TA Luft
BBodSchV
Kühling/Peters
BBodSchV
Kühling/Peters
LUA Bbg
MLUR
Kühling/Peters
LAI (2004)
Emission forecast, deposition on soil
Parameter
Dust precipitation
Arsenic
Cadmium
Lead
Mercury
Thallium
Chrome
Cobalt
Copper
Vanadium
Manganese
Antimony
Tin
PCDD/F
As a further measure to reduce
emissions, the SNCR system will be
upgraded in 2017/18 with the option of
targeted injection of ammonia-water as
reduction agent. As the accompanying
chart shows, after the 1st optimization
phase of the SNCR in early 2015, the
NOX emissions could already be safely
kept under the 350 mg/m3 limit. After
completing this process, a reduction
of about 80% compared with the level
of 1996 is likely to be achieved.
Prerequisite for further optimization is
the installation of a continuous NH3
measurement system in early 2016.
Measuring instruments
for continuous emission
measurement.
An emission forecast, i.e. the impact of
emissions on air and soil in the vicinity
of the plant, was created for our plant in
2014 as part of an approval process.
The area which suffers the highest
environmental impact lies at the east of
the plant at the exit of the village of
Herzfelde. The maximum values for the
concentrations and the deposition of
the individual substances detected show
the low impact on air quality caused by
the cement plant. The values are well
below comparable reference values for
the protection of human health cited by
literature – in general, the impact is even
under the irrelevance threshold of 3%.
Immission control
Noise protection
Numerous production units such as
mills, fans, drives or conveyors can
cause significant noise exposure for
workers and neighbourhood unless
appropriate protective measures are in
place. An analysis of each source is
required to implement a targeted and
successful noise protection.
For this purpose, a comprehensive
examination was completed, which
resulted in a noise map of the plant that
showed the impact of over 50 individual
noise sources at defined check locations in the plant surroundings. A newly
developed acoustic camera consisting
of 48 microphones also proved very
helpful. With the help of a computer,
acoustic images were created that
facilitated a more detailed analysis of
noise sources.
Fan for cooling the kiln shell with noise dampers in front of the enclosed kiln drive.
In this way, a wide range of mitigation
measures have been carried out,
ran-ging from smaller interventions
such as the relocation of units away
from exposed areas to widely visible
measures such as the encapsulation
of the kiln‘s main drive in 2012.
Sound insulation wall at the edge of the open pit mine before the village of Rüdersdorf.
Recent test results confirm the good
progress as well as adherence to emission benchmarks at points specified by
the authorities (residential buildings in
the vicinity of the plant). The noise that
can be attributed to cement plant operations, after factoring out extraneous
sound, was between 41 and 43 DB (a)
in 2014, the reference value is 45 dB(A).
Noise measurements at the enclosure of the bypass ventilator.
Noise protection measures
•
•
•
•
•
•
Consistent observance of noise protection in planning
Noise management, teaching staff to comply with protective measures
Regular measurements, identification of noise sources
Silencer on inlet and outlet openings
Protected installation of facilities, enclosures
Soundproof gates
Conformance measurements in Herzfelde – noise values measured at night in dB(A)
Benchmark
night
Hauptstraße 85
Hauptstraße 70c
Ziegelstraße 6
45
45
45
Equivalent sound level
without traffic
Operating noise
of cement plant
1997
2012
2014
2012
2014
52
50
47
45,3
45,7
46,2
44,5
44,5
43,8
42
45
45
41
43
41
32 | 33
Water protection
Water requirements
The water requirements for cement
plant operation usually include the
following three areas:
•Cooling water for the
machinery and equipment
•Water for the production process
•Drinking water supply and
sanitation areas
Cooling and process water
requirement 2014
Rüdersdorf
Values
in 103 m3
Required cooling and
process water
Withdrawal from water
Discharge into water bodies
5,860
315
61
Circulating amounts of cooling and process water (values in 103 m3/a)
Cooling circuit
kiln line 5
Cooling circuit
cement cooler
Evaporation
147
7
3385
Evaporation
precipitation
2
105
11
3
3
5
Bypass
Gravel filter
315
252
131
Rainwater retention basins
Lake withdrawal
61
Lake discharge
Today, only a very small part of the
required process and cooling water
needs to be taken from the lake.
In particular, cooling water requirements
are not negligible. To achieve an efficient
use of natural resources, recirculation of
cooling water is used to allow multiple
use of water. For this purpose, two
cooling towers are operated in Rüdersdorf which, in combination with a rainwater retention basin, were able to
reduce the specific needs for fresh water
from the lake from more than 2 m3/t
cement in the early 90s to now approximately 0.15 m3/t cement. To supply
these circuits, existing resources are
used as far as possible – in Rüdersdorf
this is rainwater (graph left).
Water pollutant substances
2328
VDK
Resource conservation through
cooling circuits and rain water use
Cooler filter
15
1
In cement plants, liquid substances
hazardous to water are, as a rule, used
as additives. These include diesel,
heating oil, grinding aids, ammonia
water (to reduce NOx emissions),
lubricating oils. These substances are
stored in double-walled tanks or via
collecting trays. In compliance with the
statutory requirements, these tanks and
trays are regularly checked by TÜV
(Technical Control Board).
Water protection
Investigation of soil and
groundwater
strongly so that still available oil accumulates on the surface. From there, it can
be collected by means of an absorbent
or a pumping vehicle and disposed of.
Additionally, the part of the water discharged into Lake Stienitz is channeled
via an oil and coalescence separator.
So, not only oil, but also settleable
particles are retained and the contamination of the lake is reduced further.
The discharged water is analyzed on a
monthly basis. A summary of the results
is shown in the table below.
As part of an approval procedure, a
so-called initial state report was created
in the year 2014, which investigates
whether the use of corresponding waterpolluting substances on our premises
have led to soil or groundwater damage
and whether adequate precautions have
been taken. No cause for complaints
were found.
Protection of Stienitzsee
In the port area, a new cleaning bay
was built in 2014 that allows vehicles
from the open pit and port to be cleaned prior to entering the main road.
For use of rainwater and for multiple use
of cooling water, a 2,000 m3 large rainwater retention basin was built prior to
the discharge into the Großen Stienitzsee (Great Stienitz Lake). Beyond this
technical function, this reservoir has
another important safety role in case of
an oil accident in the plant. An oil
detector at the reservoir inlet detects
even small oil quantities and triggers an
alarm. The water in the 2,000 m3
rainwater reservoir is calmed down
Monitoring of cooling and rainwater discharged into the Stienitzsee
Rüdersdorf
Suspended solids
Chemical oxygen demand
Hydrocarbons total
Phosphorus
mg/l
mg/l
mg/l
mg/l
Monitoring
value
Ø 2012
Ø 2013
Ø 2014
—
6.9
< 10
< 0.1
0.37
5.8
< 34
< 0.1
0.26
4.2
< 16
< 0.1
0.59
40
5
—
Drainage station at the nearby Stienitzsee.
The rainwater reservoir is regularly cleaned
by specialists in order to ensure proper
functioning of the system.
34 | 35
Using secondary materials
to preserve resources
In recent years, a paradigm shift has taken place in waste management, away
from a disposal economy to a recycling economy. The selective separation
and recovery of waste enables the utilization of their material and energetic
properties with the aim of replacing natural resources in the production
process.
Around 80% of Germany‘s waste is now
brought to waste recycling centres –
the need for landfill sites has correspondingly declined sharply. The cement
industry has made a significant contribution here as Germany‘s cement plants
cover more than 60% of their fuel demands by alternative fuels in the national
average. This approach also ensures
very high quality waste recycling as the
process has a thermal efficiency of more
than 80%, so that primary fuels are replaced almost in the ratio 1:1 and, what‘s
more, internal waste components are
integrated into the product – meaning
that material recovery takes place alongside thermal utilization. In the reference
document of the European Commission
for Best Available Techniques (BAT),
alternative fuels were included as BAT
in cement production.
BREF document frontpage.
Secondary fuels
Building on a long tradition of use of
secondary raw materials, the Rüdersdorf
Cement Plant addressed the issue of
alternative fuels when planning the new
Kiln Line 5. In 1997 we began with the
substitution of coal by alternative fuels
and continued to pursue this path in the
following years. In the last years, a level
of 71–74% has been achieved (see chart
below). This allows annual savings of
about 225,000 tons of coal.
Fuel mix, Kiln 5
Mineral residuals
and bottom ash
0.3%
Lignite 5.2%
Natural gas 0.5%
Hard coal
21.9%
Fluff 64.3%
Animal meal
5.7%
Development of heat utilization of secondary materials (Kiln 5, Rüdersdorf plant)
%
80
72
69.4
64
56
48
44
40
32
32
24
16
8
0
48
51 52
55
56
59.5
73.7
73.8
Sewage sludge pellets 2.1%
71.1 74 72.4
The main share of secondary fuels is
derived from treated municipal and
commercial waste (briefly referred to as
fluff). In addition, animal meal, dried
sewage sludge and mineral residuals
with organic adhesions (e.g. foundry
sand or road construction waste) are
used.
63.7
36
19
9
1997
1999
2001
2003
2005
2007
2009
2011
2013
Using secondary materials to preserve resources
Share of secondary fuels from Brandenburg and Berlin
(without meat and bone meal and sewage sludge granules)
Ma-%
100
Until September 2015
80
60
40
20
0
2000
2002
2004
2006
Improved material flow management
processes have been able to significantly reduce transport distances for
the delivery of alternative fuels. In 2015,
for example, more than 80% of the
alternative fuels prepared from industrial
and household waste were produced
in the states of Brandenburg and Berlin
and were transported via short distances to the cement plant. The cement
plant has therefore become an important element in local regional waste
management concepts.
Quality assurance
To ensure trouble-free, stable combustion processes and the desired clinker
quality, but also to implement operational licenses by the regulatory authority,
very high demands are placed on the
physical and chemical properties of
secondary materials.
Delivery of treated fluff material.
2008
2010
2012
2014
A comprehensive quality assurance
system has been developed to monitor
these requirements. This system sets
down that waste treaters may only use
predetermined types of waste and must
prepare on a regular basis a declaration
analysis of the finished recycled material
that demonstrates compliance with the
acceptance limits of our plant. This is
the prerequisite for the release of the
delivery.
A visual inspection is carried out and
samples are taken before acceptance
of the material at the cement plant. To
carry out the examinations, a cuttingedge, powerful environmental laboratory
was installed at the plant. The standard
scope of examination includes the content of all major heavy metals, chlorine
and sulphur as well as calorific value
and ash content. The analysis portfolio
of the laboratory also includes organic
ingredients.
As part of our self-monitoring process, about
1,500 raw material and fuel samples are analysed
every year. Very elaborate analytical methods and
equipment are used for the process, including
an inductively coupled plasma atomic emission
spectrometer, an ion chromatograph, a mercury
analyser and a gas chromatograph with mass
spectrometer.
36 | 37
The self-monitoring process in the
cement plant is supported by independent laboratories. These laboratories
select reference samples, compare
them with analysis results from the
self-monitoring process and report the
results to the competent authority.
Process optimisation
A good example of a facility that was
designed directly for the recovery of
secondary materials and offers best
combustion conditions in combination
with the cement kiln, is the circulating
fluidized bed. Such a system is part
of Kiln Line 5 and absorbs here the
greatest amounts of fluff and mineral
residues.
Heavy metal contents in secondary fuels
Data base are the analyses of supplier sampling upon delivery, in mg/kg
Heavy metals
Arsenic
Lead
Cadmium
Chrome
Cobalt
Copper
Nickel
Mercury
Thallium
Fluff
492 analyses
Required
Analysis results 2011
80th perc.
Median
80th perc.
20
2.3
3.9
350
89
140
10
1.8
4
200
68
100
20
6
8.7
750
200
610
100
32
47
1.5
0.32
0.50
3
< 0.5
< 0.5
The most recent alternative fuel project,
a new feeding point for roofing felt, was
commissioned in 2014.
directly to the kiln. The circulating fluidized bed provides hereby additional
opportunities for separation of the substances into their mineral and energy
components.
Secondary raw materials
Both the material properties (sulphate
carriers) and hydraulic properties (granulated blast furnace slag, ash), i.e. the
ability to harden upon contact with
water, of secondary raw materials for
cement grinding are sought after.
Secondary raw materials are used both
as a raw material for clinker production
in the form of ash, slag, used sands or
above-mentioned mineral residues, as
well as as main ingredient in final cement
grinding in the form of FGD gypsum as
sulphate carrier or blast furnace slag.
Discharge of sewage sludge
into closed systems.
In recent years, secondary fuel use has
become increasingly diverse and flexible,
for example through the construction of
a receiving station with sliding floor, the
construction of silos and closed conveyor systems for very fine or powdery
substances (animal meal, dried sewage
sludge, finely processed fluff), or the
use of a multi-channel burner for the
simultaneous use of different fuels by
the main burner.
Sewage sludge
32 analyses
Required
Analysis results 2014
80th perc.
Median
80% perc.
20
2.75
3.76
350
24
38.4
10
1.7
2.48
350
23
33
20
6.95
9.36
1500
860
956
100
19
21.8
2.5
0.62
0.73
3
< 0.5
< 0.5
Overall, the proportion of secondary raw
materials used the Rüdersdorf plant in
2014 was 14.3% of the overall raw materials. It has remained fairly constant in
the last years and is divided into about
1/3 for clinker production and 2/3 for
cement grinding.
The materials for clinker production are
ingredients for the main components of
the cement, i.e. CaO, SiO2, Fe2O3 or
Al2O3. Depending on whether they are
inert or have combustible components,
they are used via the raw mill or fed
Ternary diagram: suitable raw materials for cement production
(brown: natural, green: secondary)
0
100
Sand
20
80
in
Slag
Marl
80
Cement clinker
100
0
Withdrawal from the storage bin for
shredded roof felt.
Wet ash
%
Fluff ash
60
60
in
Ca
O
Mineral
residues
SK filter ash
2
SiO
%
Clay
40
Sludge
40
BK filter ash
Bauxite
20
Paper ash
Iron ore
Limestone
0
20
40
60
AI2O3 + Fe2O3 in %
80
100
Using secondary materials to preserve resources | Waste management
Waste management
Cement production, while being a lowwaste process, obviously generates
waste, for example through process
ancillary work such as maintenance
work. These are primarily:
•Contaminated oil resources,
such as rags, oil filters
• Waste oil and waste grease
• Used filter bags
• Conveyor belts
• Packaging made of paper and plastic
• Scrap
• Furnace linings
•Used electrical appliances, e.g.
fluorescent tubes, computers ...
• Paper
• Domestic-type commercial waste
These different wastes are sorted as well
as possible in order to enable efficient
and environmentally friendly recycling.
Meanwhile, about 98% of all waste is
recycled. The very small percentage
that needs to be eliminated relates
almost exclusively to hazardous waste,
such as cleaning rags or waste grease,
which may not be recycled due to its
properties. We generally hire certified
specialist companies for waste
disposal.
In Rüdersdorf, approx. 1.14 kg of waste
was generated per ton of product in the
year 2014. Not included in this figure is
waste from demolition work, which was
quite sizable in 2014 due to the dismantling of an old kiln (see input-output
analysis).
Collection of fluorescent tubes.
Ready-for-pickup concrete cubes
from cement testing.
Development of production-specific waste quantities
t
3,500
3,000
2,500
2,000
1,500
1,000
500
0
2009
2010
2011
2012
2013
2014
38 | 39
From climate protection
to energy efficiency
Approximately half of the total electric energy is
needed for cement grinding. By combining a ball
mill (right) with a roller press (left), about 30% of
the required energy can be saved. View into the
interior of the two main plants.
The energy turnaround has been a dominant issue in Germany affecting
all aspects of life. The Federal Government has formulated very ambitious
targets in this regard. An overarching goal is the reduction of greenhouse
gases by 40% in 2020 compared to 1990 levels.
To achieve this, the share of renewable
energies in power generation must
expand to 35% by 2020 while primary
energy consumption must fall by 20%
and electricity consumption by 10%
compared to 2008 levels. This reduction in consumption must primarily be
achieved through an increase in energy
efficiency.
As a result, the manufacturing sector in
Germany has committed to improve its
energy efficiency by 1.3% yearly and by
1.35% from 2016 onwards.
The chart illustrates the increasing
demand for cements with high final
strengths, coupled with a higher
electric power demand.
In the Rüdersdorf Cement Plant, basic
modernisation measures were carried
out in the 90s and the obsolete production facilities were upgraded to state-ofthe-art technology. The conditions were
therefore met to achieve a very good
BAT level in the area of the heating and
electric energy consumption, and the
potential for process improvements has
since been more or less exhausted.
Development of cement product ranges according to strength classes
%
80
70
52.5
42.5
1998
2000
32.5
60
50
40
30
20
10
0
2003
2006
2009
The cement industry is especially
affected by this development as it
belongs to the group of energy-inten
sive basic industries with relatively high
CO2 emissions. Energy costs can
account for up to 50% of production
costs, which is also a major reason why
German plants have exploited potential
energy savings in the past and reduction potentials are accordingly extremely
limited. In addition, increasing environmental requirements and the need for
more powerful or specialised products
often lead to an escalation of energy
consumption.
2012
2014
From climate protection to energy efficiency
CO2-emissions
from 1990
Impact of individual measures on the reduction
of direct CO2 emissions
kJ/kg clinker
kg CO2/t Cement
1,000
Einsparung
Savings through
durch
heat efficiency
Wärmeeffizienz
843
108
1,100
Einsparung
Savings through
durch
clinker
Klinkersubstitution
substitution
Einsparung
Savings through
durch
Brennstoffsubstitution
fuel substitution
53
1,000
102
Limit acc. to emissions
trading: 766
900
500
580
800
700
0
600
1990
2014
Heat consumption
5,000
2012
2013
2014
2015
YTD
%
The BAT area acc. to BREF refers to a kiln
for production of 5,000 t/d clinker with SBS
incl. start-up and shut-down processes and
lies between 3280–3620 kJ/kg
5,500
2008
Kiln efficiency
kJ/kg clinker
6,000
1990
100
85 %
83 %
81%
84 %
2012
2013
2014
2015
YTD
80
4,500
60
4,000
3,500
40
BVT
3,000
20
2,500
2,000
1990
2008
2012
2013
However, it is clear that the BAT level
can only be achieved with trouble-free
operation and optimal operating parameters. To tap into hidden potentials and
ensure systematic work, the existing
Quality and Environmental Management
System was extended by the area Energy
in 2010. In energy efficiency teams both
larger and smaller improvement potentials
are now put to the test, and strategic
and operative energy objectives are
defined and measures pursued until their
final evaluation. Newer process performance parameters such as faults per
unit time, operating time between 2 faults
(MTBS) or system efficiency as the product of availability and productivity. Even
after 2000, genuine room for improvement remained for CO2 emissions
through the use of alternative fuels with
a higher content of biogenic, i.e. CO2
neutral carbon when compared to coal.
The European Emissions Trading Scheme
only monitors the intermediate product
clinker. In relation to the final product
cement (assuming a medium-sized
2014
0
2015
YTD
clinker content across the entire product
range) a specific CO2 emission of 580 kg
CO2/t cement results for 2014, i.e. 33%
less than 1990 with 843 kg CO2/t.
The CO2 reduction can be attributed to
measures for lower fuel consumption,
biogenic carbon in secondary fuel and
substitution of clinker in the cement
(see chart above left).
If fuel-related CO2 emissions are exclusively considered, a reduction of over
50% has even been achieved. Per year
now compared to 1990, CO2 savings
of more than 500 thousand t have been
achieved.
Specific electric energy consumption
kWh/t Cement
150
140
130
120
110
100
90
80
70
60
Benchmark for efficient
electric power consumption in
cement production 100–110 kWh/t
1990
2008
2012
2013
2014
2015
YTD
40 | 41
Indirect environmental
aspects
2
Footprint
Supply chain
The main raw material component,
limestone, is delivered from the nearby
open pit mine on belt conveyors. All
other raw materials and fuels must be
transported to the premises. For this, a
railway and waterway connection is
available alongside the road network.
When selecting suppliers, the means of
transport are also included in the
assessment.
Indirect environmental aspects are
those which are related to the manufacture of our product, but which are
carried out and have an impact at a
different location and can therefore not
be fully controlled by our company.
In our case, two aspects are at the
focus here:
•Emissions from the provision of
electric power
•Supply chains for raw and auxiliary
materials.
Provision of electric power
The efforts to reduce the electric energy
consumption have been described in
the previous chapter.
From all emissions caused by electricity
generation, CO2 emissions are of particular interest. We take as a basis the
emission factor for Germany‘s electricity
mix to calculate the contribution from
our activities.
For 2014 this 508 g CO2/KWh and results for our electricity needs to indirect
CO2 emissions of 107,000 t.
For the CO2 footprint, this leads to additional specific CO2 emissions per ton of
produced products, in accordance with
the input-output model, of 57.4 kg CO2/t.
For example, today anhydrite and coal
are delivered by rail, calcium fluoride,
bauxite, iron ore and wet ashes partially
by ship. Transport route and type are
reflected also in CO2 footprint of the
product.
CO2-footprint
A program has been developed at
CEMEX which allows calculation of the
entire CO2 emissions generated by the
manufacture of each product, from the
provision of raw and auxiliary materials
to readiness for shipment of the finished
product. It thus includes direct and
indirect CO2 emissions.
The result ranges from about 300 kg
CO2/t cement for a CEM III / B 42.4
N-HS up to 850 kg CO2/t cement for
a CEM I 42.5 N(re). The average value
for our entire cement portfolio is 650 kg
CO2/t cement.
Indirect environmental aspects | Core Indicators
Core indicators
The core indicators are used for standardized illustration of a company‘s
environmental performance and its
development/improvement.
The indicators give particular weight to
the direct environmental aspects which
have been identified as being essential.
The following core indicators always refer
to the sum of all products specified in
the input-output analysis.
Core Indicators
2013
2014
kg/t
kg/t
kg/t
kg/t
0.03
0.74
0.55
581
0.05
0.73
0.50
575
Waste
Non-hazardous
Hazardous
kg/t
kg/t
0.95
0.03
1.12
0.02
Biological diversity
Sealed area
m²/t
0.07
0.07
Water
Total consumption
m³/t
0.14
0.15
Energy
Fuels
Share of renewable
Electric power
Share of renewable
Total energy consumption
MWh/t
MWh/t
MWh/t
MWh/t
MWh/t
0.78
0.24
0.09
Not known
0.87
0.78
0.24
0.09
Not known
0.87
Raw material efficiency
Input quantities/products
t/t
1.38
1.32
Direct emissions
Dust
NOx
SO2
CO2
(Other greenhouse gases are
metrologically undetectable or
negligible)
42 | 43
Statement of Environmental Program 2014/2015 as of 24.08.2015
Objectives
Specific objectives/actions
Implementation
of legal claims
Preparation of initial state report for soil and
Was successfully completed in the context of an
groundwater by IED (Industrial Emissions Directive) authorization procedure
Process engineering
Emissions reduction
Energy efficiency
Comments
Status
4
Implementation of the new Regulation for systems
handling water-polluting substances
Unexpected delays have occurred in the legislative
process. Currently, only a draft is available. Since
the requirement has not been issued, operational
implementation could not be carried out
6
Promoting recycling and secondary raw materials
by separating metals from CFB ash
After the starting phase, there were initial difficulties
with regard to the temperature level that impede
reliable evaluation. An evaluation by mid-2016 is
planned
l
Detailed planning for the recirculation of
the tertiary air elbow dust into the kiln process
The planning has been completed and submitted
for further decision-making
4
Decrease in the sound level of cooling air blowers
by modification of the suction nozzle, 7th floor WT
Successfully completed
Installation of a washing area for vehicles from
the open pit and the port
Conversion of bypass line incl. improvement of
cooler exhaust air dedusting system
Completion of planning for replacement
investment for conversion of kiln filters
The contract was concluded in February 2015.
Corresponding preparations and planning are
ongoing, so that realization/IBN can take place in
January 2016
l
Increasing the efficiency of Hg separation
The replacement of the provisional activated
carbon dosage by an improved stationary system
is in the implementation phase and should lead to
results in 2016
l
4
4
4
Studies on the selection of filter elements for safe
compliance with a future threshold of 10 mg/Nm3
on the grinding plants
Use of tire pressure monitoring devices on all
construction equipment
The project continues until the end of 2015
with a new technical approach
Optimization of natural gas consumption
(kiln main burner)
Optimization of specific electric energy
consumption (kWh/t) by modification of the
circulating fan RM6 (replacement of inlet
guide vane control by frequency converter)
Reduction of the specific energy consumption
of ZM2 and ZM3 at Mono mode by increasing
the throughput at the pre-cement belt scales
4
l
4
4
Already done 4
4
Ongoing l
Processing stopped 6
New Environmental Program 2015/2016 as of 26.08.2015
Objectives
Specific objectives/actions
Person responsible
Date
Implementation
of legal claims
Adaptation of the reporting requirements under the amended
German Federal Immission Control Act
Environmental Protection
Mid-2016
Review of the implementation status of BAT (best available technology)
Mid-2016
Promoting recycling and secondary raw materials by
enhanced separation of metals from CFB ash
New construction,
Production Manager
Mid-2016
Trial use of meat and bone meal over ring gap on main burner for
optimisation of combustion conditions
Technology Director
End of 2015
Test of a separator for improved ejection of impurities in
secondary fuels
New construction
1st quarter
2016
Realization and commissioning of measure for conversion of
furnace filter
New construction,
1st quarter
2016
Improved efficiency of mercury separation
Production Manager
End of 2015
Evaluation of the new filter bag quality for safe compliance with a
future threshold of 10 mg/Nm3 on the grinding plants 4–7
Environmental Protection,
Head of Grinding
End of 2016
Continuous ammonia measuring technology in the exhaust gas stack
of kiln line 5
Environmental Protection,
Maintenance
1st quarter
2016
Evaluation of the separation efficiency of the radiator filter based on
a future dust threshold (daily average value) of <10 mg/Nm3
End of 2015
Preparation for the optimisation of the SNCR system to the NOx
reduction by modification of the ammonia injection point
Technology Director
End of 2016
Check of the use of electronic ignition for the reduction of blasting
vibration
Open pit
Mid-2016
Use of tire pressure monitoring devices (new technology) on all
construction equipment
Open pit
End of 2015
Reduction of electric power consumption by conversion of the
furnace exhaust gas filter
New construction,
Mid-2016
Reduction of the specific power consumption by 0.5 kWh/t cement
(including infrastructure) compared to previous year at unchanging
Production Manager
1st quarter
2016
Process Engineering
Emissions reduction
Energy efficiency
44 | 45
Certificates of Validity
The next consolidated environmental statement will be published
in January 2019. In addition, we
create yearly updated environmental
statements.
Proof of passed environmental review.
Certificates of Validity | Glossary
Glossary
Audit: Systematic, independent and documented
process to assess/verify the company‘s environmental performance.
Autochthonous: Rocks belonging to a location
on which site-related vegetation can develop.
B[a]P: Benzo[a]pyrene is a polycyclic aromatic
hydrocarbon, which is often taken as reference
substance for the group.
Ball mill: Tubular, armoured assembly in which
milling balls move by rotation by which the mill
feed is crushed.
Biogenous fuels: Fuels based on renewable raw
materials; their combustion is considered CO2
neutral.
Bowl mill crusher (also roller mill): Here, drying,
grinding and classifying take place in one unit
where the mill feed is crushed under grinding rollers
by means of a rotating milling disc.
BREF (BAT reference document): A document
of the European Commission that describes the
best available techniques (BAT) for the prevention
and reduction of environmental impacts caused
by industry (here cement manufacture).
Bypass: A bypass is used to withdraw volatile compounds from the kiln. The dust is added again to the
process in the next stage, the cement grinding.
Calciner: Entrained flow reactor which is arranged
between rotary kiln and cyclone pre-heater and
which facilitates de-acidification of the kiln run under
the best reaction conditions already before the
rotary kiln. To achieve this, up to 60% of the fuel is
shifted from the rotary kiln burner to the calciner.
Cement: HydrauIic bonding agent which, after
the addition of water, is malleable when fresh.
Subsequently, it sets both in the air and under
water and attains a high strength durability. Basic
component for building material concrete.
Clinker: Gray, granuIar intermediate product in
cement production produced in the rotary kiln by
heating the raw material up to the sintering tem
perature of about 1,450 °C.
Life cycle analysis: Method to assess the impacts
of a product to its surroundings, from the extraction of raw materials, the production and use up to
its final disposal.
CO2: Gas generated in particular during the burning of carbon fuels, but also the de-acidification
of limestone (CaCO3).
Marl: Sediment rock from a mix of clay and carbonates. When favourably mixed, it is an ideal raw
material for the cement production. As a rule, the
precise raw material formula must be set by adding
clay or limestone.
Concrete: Artificial stone that is produced by mixing
and subsequent hardening of cement with water
and aggregates (sand, gravel, crushed stone).
Cyclone preheater: Fuel-saving technology in
cement production in which the raw meal is
transported through various cyclone stages
arranged over one another and, by means of the
hot exhaust gases from the kiln is preheated up
to about 850 °C.
Dry sorption technique (also dry additive method): Method to purify exhaust gas in which a substance (sorbent) is charged into an exhaust gas
stream in the form of powder, where it absorbs
hazardous components; subsequently, it is separated from the gas stream together with the hazardous components. In this case, separation of SO2
with the help of lime hydrate.
EMAS: Europe-wide system for eco-management
and audit according to which organisations under
take to voluntarily review and improve their environmental performance.
Emission: Discharge of solid, liquid or gaseous
substances into the environment. Noise and
odours are also considered emissions.
Emissions trading: Market tool of climate politics
under which the pollution emitters must have respective emission certificates and the overall emission is limited by a restricted issue of certificates.
Certificates can be acquired or sold on the basis
of need and availability. So far, the system includes
about 12,000 plants in 30 European countries.
Cements containing blastfurnace slag: In addition to Portland linker, => granulated slag is one main
component; the result is Portland slag cement
with a granulated slag content of 35% and blast
furnace cement with a higher share of granulated
slag. Granulated slag facilitates the production of
cement with specific properties.
Fluff: Fraction of light and high-calorific parts from
commercial and municipal solid waste (e.g. paper,
cardboard, textiles, wood, plastics) for the generation of alternative fuels.
Chromate reduction: Reduction of water-solvent
chromate (VI) content in the dermatologically
sensitizing ready-mix concrete in cement to less
than 2 mg/kg by adding a reducing agent (Iran
sulfate or tin sulfate).
High-pressure grinding roll: Also rreferred to as
roller press. For a short while, the mill feed is exposed to high pressure between two rollers rotating
in opposite directions; the grinding takes place in
the so-called milling bed.
Classifier mill: Also closed circuit mills with bucket
elevator. Grinding mill in which the mill feed is
channelled into a classifier and classified into
coarse and fine material with the coarse material
being charged into the mill again.
Hydration: Reaction of substance with water which
leads to the inclusion or adsorption of water. In
building materials chemistry, hydration is the process in which a bonding agent (e.g. cement) cures
with the addition of water.
Granulated slag: Blast furnace slag which is
shock-cooled in a special granulation plant which
leads to latent-hydraulic properties.
Immission: Impact of emissions to the environment (people, animals, plants, buildings ...)
NOx: Total of nitrogen oxides. It mainly develops
in high-temperature combustion processes, and
mostly comes as NO2 under atmospheric conditions. In case of strong insolation, it is an ozoneprecursor chemical and thus considered a cause
of summer smog.
Oil and coalescence separator: Device for the
separation of oil and other light liquids from water
on the basis of different densities.
Raw mill: After the resources have been extracted
in the quarries, crushed in the bucket and transported to the cement plant, all raw materiaIs are
ground in the raw mill and, at the same time,
dried. Subsequently, the resulting raw meal is
transported to the rotary kiln via a conveyor belt.
Secondary materials: Processed wastes which
replace natural materials and thus help to conserve naturaI resources (secondary raw materials
in case of primary use of their material properties
and alternative fuels in case of primary use of
their heating value).
SNCR: Selective Non Catalytic Reduction. Process to reduce NOX emissions in a waste gas
stream by the addition of an agent containing
ammonia and urea in a temperature range of about
850–1,050 °C. The reaction products are N2 and
H2O.
SO2: Colourless gas, which largely develops as
an undesired by-product in the combustion of
sulphurous fossil energy sources (coal, oil) and is
released in various industrial processes. Causes
acid rain.
Sustainable development: „Sustainability means
to equally consider environmental aspects, social
and economic aspects. Thus, future-oriented management means: We must leave our children and
grandchildren children an intact ecological, social
and economic fabric. The one cannot be achieved
without the other.“ (www.initiative-nachhaltigkeit.de)
Waste: All movable items the owner wishes or is
obliged to dispose of. This can be assumed when
the items accumulate without this being the purpose of the respective action, or the original function of the items is no longer relevant and no new
purpose can replace the previous one.
46 | 47
Publisher
CEMEX Zement GmbH
Contact persons
Evelin Veit
Manager Communication & Public Affairs
Phone +49 (0)30 33009238
Peter Scur
Senior Manager Environmental Protection
Phone +49 (0)33638-54457
Fax
+49 (0)33638-54462
Dieter Spiller
Commissioner for Integrated Management
Phone +49 (0)33638-54453
Fax
+49 (0)33638-54462
www.cemex.de
Version 12/2015
Picture credits
CEMEX, unless otherwise stated
48
www.cemex.de

Rüdersdorf Cement Plant

Transcription

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