2012 CEMENT ENVIRONMENTAL STATEMENT - Tarmac · 2015-07-31 · 2012 Environmental Statement - Cement Update 2 2012 ENVIRONMENTAL STATEMENT Lafarge Tarmac is the newly formed UK construction

2012 Environmental Statement - Cement Update 1

2012 CEMENT ENVIRONMENTAL STATEMENTCement update

Cement & Lime


2012 ENVIRONMENTAL STATEMENT

Lafarge Tarmac is the newly formed UK construction materials supplier.

The merger of Lafarge’s UK operations and those of Tarmac took place on 7 January 2013 following clearance from the Competition Commission.

As part of the approval process, some assets within the former organisations were divested. One of these assets was the Hope Cement Plant and its associated depots at Dewsbury and Theale.

This statement is an update to the full-verifi ed statement issued in 2012 and focuses on the performance of the operations that were under the direct control and registration held by Lafarge Cement UK at the time and so details pertaining to the former Tarmac Tunstead Cement and Lime operations and their associated facilities are not included in this statement. Therefore, the scope of the report and EMAS registration is limited to the following:

Aberthaw Cement Plant Cauldon Cement Plant

Barnstone Cement Plant Dunbar Cement Plant

Cookstown Cement Plant Hope Cement Plant*

Belfast Depot West Thurrock Depot

Carlisle Depot Manchester Depot

Liskeard Depot Uddingston Depot

Aberdeen Depot Inverness Depot

Westbury Depot Seaham Depot

Dewsbury Depot Theale Depot

Sapphire operations ScotAsh

EMASThe environmental management system implemented at Lafarge Cement has been verifi ed. Certain information within this statement has been validated to the Eco-Management and Audit Scheme regulation (EC) No. 1221/2009 on 8 May, 2013 by Lloyd’s Register Quality Assurance, EMAS accreditation number UKV- 005.

* Please note, this data is indicative and as reported to the regulatory authorities in 2012, no external site validation has been formally undertaken but data has been compared to historic and is shown to be representative of expected performance levels.

In 2012, Lafarge’s UK

cement operations performed

very well against our

stated objectives and core

performance indications with

almost 95% of indicators

meeting or exceeding the

stated target. In support of

this, an extensive campaign

was delivered around

stakeholder engagement

and in December our

environmental statement

won the EMAS 2012 award

in the Private Sector Large

Organisations category.

2012 SUMMARY

REG NO. UKV-005REG. NO. UKV-005


In May, the Environment Agency, Scottish Environment Protection Agency (SEPA) and the Mineral Products Association (MPA) attended our bespoke PCM course at Hope Cement Plant.


turn hopefully achieve better and more effi cient regulation across the industry.

The course also highlighted the innovations we have introduced to reduce the environmental impact of our operations as well as the high technical skills and passion our employees have in their work.

Feedback from those who attended the course was very positive. Mark Haslam, environment manager for the Environment Agency’s East area commented:

“With a more sector-specifi c approach, our inspectors and advisors require a deeper level of understanding of individual industries than before in order to make informed decisions to protect the environment. Lafarge’s PCM course has been invaluable in that respect and our team who attended learned a great deal.”

Dr Richard Leese, a director of Energy and Climate Change at the Mineral Products Association, who attended the course said:

“Understanding the technical challenges of cement manufacturing is an important aspect of the MPA’s role. The presentation of the course struck the right balance between technical content and practical delivery. Putting the theory in real-life manufacturing situations will assist MPA in its role to demonstrate how vital cement making is to the UK economy.”

In May the Environment Agency, Scottish Environment Protection Agency and the Mineral Products Association attended our bespoke PCM course at Hope Cement Plant.

The three-day course was designed from internal Lafarge programme traditionally aimed at staff. The objective of the course was to help environmental inspectors and advisors to get to grips with cement making and gain a real understanding of the technologies employed as well as the chemical and physical limitations placed on the process.

Throughout the course the 17 attendees were shown various aspects of the cement making process from the quarrying of raw materials to cement milling and blending as well as clinker chemistry which included operating a cement kiln via a simulator to give a hands-on experience. The attendees were also given a full tour of the plant and a walk through the quarry to give them a holistic understanding of the complex manufacturing process.

The course was offered to the regulators as the changing structure of the regulatory bodies into a more specifi c sector approach will lead to ‘new’ inspectors and advisors from the UK’s regulatory bodies. These individuals will need to understand the complex processes involved in cement-manufacturing and this will in

Lafarge’s PCM course has been invaluable...and our team who attended learned a great deal.

Stakeholder engagementIn 2012 several projects were undertaken to further develop our stakeholder relationships specifi cally, improving our understanding of each other’s needs. The projects undertaken were diverse in their approach as well as the range of stakeholders included.

The programme began in May where a bespoke course called the ‘Principles of Cement Manufacture’ was held over three days for UK cement industry regulators and trade association members. This was followed in the summer with the commissioning of an independent community survey around four of our cement plants. We also engaged in a highly successful partnership project with the Environment Agency and industry representatives (both operators and regulators) from a number of East African countries. The year closed with a series of ‘innovation focus’ documents for our customers regarding some of the initiatives we use with regard to environmental performance and stakeholder relations.

Mark HaslamEnvironment Manager, East Area The Environment Agency

The presentation of the course struck the right balance between technical content and practical delivery.

Dr Richard LeeseDirector of Energy and Climate Change Mineral Products Association

Principles of Cement Manufacture (PCM) course

ENGAGEMENT

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� +� +2� +3+� The vast majority of people do not think we have a negative impact on their health.

Understanding our local community is very important to us. During the summer months we actively sought the views of our neighbours through an independent survey.

This survey was carried out at the Aberthaw, Cauldon, Cookstown and Dunbar cement plants. In total, the combined sample of 800 households, equivalent to just over 1500 adults, were interviewed using a bespoke questionnaire which sought their views of our plants, the way in which they operate and the impact we have upon them. The survey looked at four key themes:

Do we add value to the community?

What are the key issues for the community?

Is the community concerned about health impacts associated with the operation?

How effective are our communications?

Community survey

COMMUNITY

The plant does notaffect my health

Agree Mixed views Disagree

Survey results

In general terms the results were very good, as seen in the charts below. Importantly to us, the survey results show that a clear majority of the respondents believe that we add value to their community, we do not have an impact on their health and they support our use of waste materials as fuels and raw materials. In 2013 we will assign actions and each plant will be developing plans to further improve our relationships and community engagement.

85%

The plant does notaffect the health of

the community

89%

Support the use of waste-derived fuels as a source

of energy at the plant

91% 91% 91%

The vast majority of people do not think we affect the health of the community as a whole.

A large proportion of people are supportive with only a small number against the use of waste as a fuel. 30% of the population would like to know more or have no view.

65%

� +� +3� +� +2� +1+9Communities recognise the contribution we make to their local economy.

Plant is good for the local economy

90%

Plant is good for the local community

82%

Good that the plant is here

The community value us as a neighbour and we add value to our communities.

The community values the plant.

81%

ComplianceAll of the cement works are permitted by Part A Environmental Permits issued by the Environment Agency, Scottish Environment Protection Agency and the Northern Ireland Environment Agency. The grinding stations and some Depots are regulated by Part B Environmental Permits issued by Local Authorities, and the planning permission’s associated with our quarries also regulate how they must operate.

In 2012 all our operations were compliant with the permits they hold and the associated reporting requirements.

� +8+389%

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In December 2012 we were awarded the annual Eco-Management and Audit Scheme (EMAS) Award for our water management solutions.


In April we were asked by the Environment Agency to take part in its Commonwealth Fellowship scheme to promote best practice and improve compliance across its network.

Held over four weeks, six Fellows from Commonwealth countries of Tanzania, Kenya and Uganda (representing their respective country’s environmental regulator and cement industry) were invited by the Environment Agency to spend time with them learning about how it works with the cement industry in the UK. The Fellows then spent some time with us learning about our environmental and sustainability initiatives as well as our operational management processes.

A further aim of the scheme was to showcase how environmental performance can be improved by developing constructive working

Partnership project

relationships between industry, regulators and local communities.

The Fellows were split into groups of two and hosted at different plants within our network (Aberthaw, Cauldon and Dunbar) by a specialist to discuss the business’s stakeholder tools and policies, management systems, community engagement activities and biodiversity restoration projects.

The programme culminated in a tour of the Imperial College carbon capture pilot plant in central London. The only facility of its kind in any academic institution in the world, the pilot plant contains the latest in process control and instrumentation technology, provided by the engineering company, ABB.

The pilot plant aims both to equip students with the practical skills needed for a career in industry and demonstrates best practice of capturing and storing harmful carbon dioxide before it can be released into the atmosphere.

The Commonwealth Fellowship Programme provided us with an opportunity to share our experience in managing our environmental impact whilst bringing together regulators and industry which we hope will deliver tangible business and environmental benefi ts to the countries where these fellows live. It also strengthened relationships here in the UK between all parties.

The carbon capture pilot plant demonstrates the investments being made by industry leaders and academia here in the UK which could potentially be replicated around the globe to the benefi t of those in both the engineering and construction industries.

PARTNERSHIP

Innovation focusWe published a series of documents to help our customers understand the innovations we have made to our processes and products. Three of these documents focused specifi cally on our environmental aspects in relation to plastic packaging, water footprinting and community survey. These one-page documents supply customers and other stakeholders with simple reviews of the innovations and are available on our web site.

INNOVATION

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Each of the 27 entries from 14 European countries were judged by an expert panel chaired by executive director of the European Environment Agency, professor Jacqueline McGlade.

Launched in 2005, the EMAS Awards have been designed by the European Commission to reward the efforts of registered organisations which are striving to improve their environmental and fi nancial performance while also showcasing their latest sustainability initiatives.

Martin Baxter, executive director for Policy at the Institute of Environmental Management and Assessment (IEMA), said:

“Lafarge Cement UK has shown real leadership in improving its environmental performance. Winning the European EMAS award is recognition of its achievement in reducing its environmental footprint.”

Following on from the original water footprint work we set a corporate target to achieve a 5% improvement in water usage based on 2009. Through improved management and behaviour practices we have achieved a 8% improvement in water by abstracting less from natural sources and reusing both existing water and harvested rainfall.

Lafarge Cement UK has shown real leadership in improving its environmental performance.

Martin BaxterExecutive Director for Policy Institute of Environmental Management and Assessment (IEMA)

2012 EMAS Award

In December, Dave Shenton, National Environment Manager and Paul Firth, Emission Monitoring Technician, attended the EMAS Awards ceremony in Brussels.

At this event, we were awarded the annual Eco-Management and Audit Scheme (EMAS) Award in the Private Sector Large Organisations category for our water management solutions. These were originally developed at the Cauldon Cement Plant and then rolled-out across our network of sites. The solutions show excellence in respecting and safeguarding the environment by applying a pioneering water management system - water footprinting and water effi ciency improvements.

The water footprinting scheme identifi es where the greatest volume of water is used during the whole lifecycle in the manufacturing process of cement at a specifi c site and implements new management methods and decisions. The initiative addresses water consumed at the site itself as well as the entire supply chain and end user.

The knowledge gained through the scheme has allowed choices to be made to reduce the water intensity of the cement-making process including a reduction of coal use with more sustainable waste fuels, which reduce both the embedded water and carbon content as well as making the process increasingly sustainable.

Our objectives for 2013

Reduce CO2 compared to 2012

Increase the use of waste raw materials and product extenders used in the cement making process. Target 5% increase on 2012

Increase the use of waste derived fuel. Target 8% above 2011

Achieve certifi cation to ISO 50001 (energy management systems) at all key cement related operations in 2013

Establish new cement and lime related operations within the existing IMS frameworks and ISO certifi cation

Engage in business exchange with the Environment Agency

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Performance against 2012 objectives

Energy

Electricity Consumption target 5% reduction in kWh/tPCE against 2005 performance. We signifi cantly exceeded this target with a 12% reduction in electricity consumption over the period.

Waste-derived fuelsWe targeted an increase of 8% for the use of waste derived fuels, however we only achieved a 4% increase. This was partially due to delays in commencing new fuel evaluations.

Our target of securing a PSP permit at Dunbar and an SRF Permit at Hope was achieved. Both permits were received in 2012 from the regulators following consultation and application for trials.

OBJECTIVE TARGET ACHIEVED/ACTUAL

Reduce CO2 compared to 2011 Less than 704kg/tPCE 678kg/tPCE

Increase the use of waste raw materials and product extenders used in the cement making process

10% increase on 2011 6% increase on cement plant usage in 2011

Improve water effi ciency at sites At least 5% improvement over 2010 levels 8% reduction in use on 2009

Contribute to the Lafarge WWF partnership projects

In 2012 all cement plants developed existing biodiversity management plans in line with WWF criteria

Less than a total of 10 Notifi cations within Lafarge Cement against ELV’s Less than 10 6

Increase community engagement around our cement plants Community survey Community survey undertaken

Waste

Reduce waste sent off for recovery. Our target was to achieve less than 1kg/tPCE in 2012, which we achieved for normal waste generated. Total waste generated in 2012 was 1.7kg/tPCE. However this includes exceptional waste from activities such as construction and demolition.

EMISSIONS UNITS 2011 2012

Particulates kg/tPCE 0.04 0.04

SO2 kg/tPCE 0.74 0.73

NOx † kg/tPCE 1.43 1.38

CO kg/tPCE 2.65 2.51

CO2 kg/tPCE 704 678

In addition to these main objectives we also set the following targets for 2012:

Land Use

Dunbar North West Quarry : Work with operational team and RSPB to develop proposals for a bird reserve. We signed a memorandum of understanding with RSPB Scotland to develop the area as a bird reserve.

Holborough Marshes : Work with Kent Wildlife Trust to achieve the Enhanced and widened marsh reserve (SSSI). We continue to work with them on this site.

Medway Woodlands : Achieve FSC status. Achieved in May 2012.

Magheramorne : Complete INTERREG* funding process for recreation. We were unable to secure funding for this project.

Northfl eet : Work with Crossrail and its contractors to ensure barge facilities exist at the site. Facilities were set up ready to export materials from Northfl eet, including winning the rail freight award in September.

Weardale : Formalise managed access to Fairy Hole Caves SSSI. Managed access to the Fairy Hole Cave SSSI was agreed.

SPECIES UNITS 2005 2012%

CHANGE

Particulates kg/tPCE 0.13 0.04 –67%

SO2 kg/tPCE 2.15 0.73 –66%

NOx † kg/tPCE 3.50 1.38 –61%

kg/tPCE 1990 2012%

CHANGE

CO2 kg/tPCE 902 678 –25%

*The INTERREG initiative is designed to stimulate cooperation between member states of the European Union on many levels

† The value reported in the 2011 statement of 1.1 was a typographical error and should have been 1.43

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Glossary ARM Alternative Raw Material

BAT Best Available Technique

BREF Best Available Technology Reference

CEM Continuous Emissions Monitors

CKD Cement Kiln Dust

CO2 Carbon dioxide

EA Environment Agency

ELV Emission Limit Value

EMAS Eco Management and Audit Scheme

JV Joint venture

KEPI Key Environmental Performance Indicator

Kg/tPCE Kilogramme per tonne of Portland Cement Equivalent (a standard measure in the cement industry)

Products and services

Targets:

• 49% of grey cements sales to be CEM II, III or IV, we signifi cantly exceeded this target achieving a 63% sale of lower CO2 cements.

• 10% of pallets recycled, this target was achieved, 10% of pallets recycled in 2012.

• 10% of timber and paper to be derived from FSC or PEFC certifi ed sources - Not Verifi ed.

Corporate Social Responsibility

Targets:

• Establish Community Liaison Committee at Cauldon Works

Achieved: 2 meetings held

• Continue to hold regular Liaison Committee meetings at all works.

Cookstown did not hold a meeting.

• Issue a minimum of one Spotlight newsletter for each works.

Cookstown did not produce a newsletter.

• Carry out community perception surveys around our cement works.

Completed.

Logistics and supply planning

Data for these targets in 2012 is not available for reporting.

MBM Meat and Bone Meal

MPA Mineral Products Association

NIEA Northern Ireland Environment Agency

NOX Oxides of nitrogen

PSP Processed Sewage Pellets

RFO Recovered Fuel Oil

SEPA Scottish Environment Protection Agency

SO2 Sulphur dioxide

SRF Solid Recovered Fuel

SSSI Site of Special Scientifi c Interest

WDF Waste Derived Fuel

WDLF Waste Derived Liquid Fuel

WID Waste Incineration Directive

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Unit Aberthaw Cauldon Cookstown Dunbar Hope Total Kg/tPCE

Production Clinker PCE Tonnes 446,541 910,855 274,681 637,285 1,289,957 3,559,317

Cement Tonnes 453,697 820,000 275,628 618,059 1,285,182 3,452,566

Raw Materials Limestone / Chalk

Tonnes 497,523 1,080,959 366,300 774,402 1,419,075 4,138,259 1,163 kg/tPCE

Shale / Clay Tonnes 0 190,109 22,031 48,524 221,634 482,298 136 kg/tPCE

Sand Tonnes 0 24,789 0 41,799 0 66,588 19 kg/tPCE

Gypsum Tonnes 23,664 39,321 16,002 21,498 62,142 162,627 46 kg/tPCE

Other Tonnes 114,545 82,300 429 72,747 119,996 390,017 110 kg/tPCE

Total Tonnes 635,732 1,417,478 404,762 958,970 1,822,847 5,239,789 1,472 kg/tPCE

Emissions to Air Particulates Tonnes 13 30 29 43 35 149 0.04 kg/tPCE

SO2 Tonnes 367 111 428 420 1,285 2,611 0.73 kg/tPCE

NOx Tonnes 562 1,249 595 637 1,864 4,907 1.38 kg/tPCE

CO Tonnes 322 2,203 323 2,579 3,500 8,927 2.51 kg/tPCE

CO2 Tonnes 281,269 575,830 202,814 461,481 892,021 2,413,415 678 kg/tPCE

Energy Fossil fuel Coal / Pet coke Tonnes 38,641 44,042 31,281 53,274 88,103 255,341 72 kg/tPCE

Waste Derived Fuel

Tyres + Tyre fl uff Tonnes 2,133 28,953 0 14,539 29,487 75,112 21 kg/tPCE

RLF Tonnes 0 6,866 18 4,615 0 11,499 3 kg/tPCE

PSP Tonnes 0 27,594 0 2,535 1,986 32,115 9 kg/tPCE

MBM Tonnes 3,866 0 0 0 19,273 23,138 7 kg/tPCE

Packaging Tonnes 0 0 0 0 0 0 0 kg/tPCE

RDF Tonnes 0 0 0 0 0 0 0 kg/tPCE

Total WDF 5,999 63,413 18 21,689 50,745 141,864 40 kg/tPCE

% WDF Substitution 10.9 53.1 1.6 29.8 33.0 32.4

Electricity KWh 52,315,070 106,803,561 33,335,168 55,462,809 151,571,582 399,488,189 116 KWh/t

Green electricity KWh 36,756,660 36,756,660 11 KWh/t

Total Energy GJ 174,433 384,493 120,007 331,990 545,658 1,556,581 0.5 GJ/t

Waste On site CKD Tonnes 0 0 0 0 0 0 0 kg/tPCE

Hazardous Tonnes 0 0 0 0 0 0 0 kg/tPCE

General Tonnes 0 0 0 0 0 0 0 kg/tPCE

Off site CKD Tonnes 0 0 0 0 0 0 0 kg/tPCE

Hazardous Tonnes 78 96 0 66 112 353 0.10 kg/tPCE

General Tonnes 3,447 869 173 271 935 5,695 1.60 kg/tPCE

Water Mains m3 75,621 14,405 10,536 48,085 70,609 219,256 0.06 m3/tPCE

Process m3 59,748 153,526 50,735 216,914 130,699 611,622 0.17 m3/tPCE

Compliance Notifi cations Number 0 0 2 1 3 6 0.002 No./tPCE

Complaints Number 12 11 0 3 1 27 0.008 No./tPCE

Biodiversity1 Area m2 8,166,182 2.3 m2/tPCE

EMAS data 2012

Notes

CO2 The CO2/per tPCE in the 2009-2011 EMAS Summary table in the 2011 ES (page 30) was reported in kgCO2/tPCE and not as indicated in tCO2/tPCE

Water process Water consumption quantifi cation method has been redefi ned from abstracted to evaporated hence Cauldon works has gone from zero m3 process water in 2011 to 153,526m3 in 2012.

NOx 2011 Works EMAS data in the 2011 ES (page 29) for NOx was reported incorrectly for Cauldon works. The table shows a fi gure of 1.1 kg/tPCE which should have been 1.6 with a mass tonnage of 133t which should have been 1,326t, consequently the totals should have reported 1.43kg/tPCE and 5,400t respectively.

1 Total area of Scope: Aberthaw, Cauldon, Cookstown, Dunbar, Hope, Medway, Northfl eet, Weardale & Westbury disturbed land

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Unit PCE

Unit Aberthaw Cauldon Cookstown Dunbar Hope Kg/tPCE

Emissions to Air Particulates kg/tPCE 0.03 0.03 0.10 0.07 0.03 0.04

SO2 kg/tPCE 0.82 0.12 1.56 0.66 1.00 0.73

NOx kg/tPCE 1.26 1.37 2.17 1.00 1.44 1.38

CO kg/tPCE 0.72 2.42 1.18 4.05 2.71 2.51

CO2 kg/tPCE 630 632 738 724 692 678

Energy Fossil Fuel Coal / Pet coke Gj/tPCE 2.40 1.31 2.98 2.04 2.21 2.03

Electricity GJh/tcement 0.38 0.47 0.44 0.75 0.42 0.45

Waste Total waste kg/tPCE 7.90 1.06 0.63 0.53 0.81 1.70

Water Mains m3/tPCE 0.17 0.02 0.04 0.08 0.05 0.06

Process m3/tPCE 0.13 0.17 0.18 0.34 0.1 0.17

Value Unit

Production Cement 195,847 Tonnes

Raw Materials Sand 128,347 Tonnes

Gypsum 486 Tonnes

Ferrosulphate 51 Tonnes

Fuel Oil 1,321,317 Litres

Electricity 8,428,700 KWh

Energy Oil 49,421 GJ

Electricity 30,343 GJ

Emissions to Air Particulates 4 Tonnes

Water Mains 4,952 m3

Waste Hazardous 0 Tonnes

Non-Hazardous 193 Tonnes

Compliance Notifi cations 0 Number

Complaints 0 Number

EMAS data 2012

Barnstone 1

Dunbar Manchester Oldbury West Thurrock

Total

Production Tyres received 12,369 10,147 12,025 15,613 50,153

Waste Tyre waste 1,179 152 28 169 1,528

Hazardous waste 0 114 11 0 125

Non-hazardous waste 4 11 6 25 46

EMAS data 2012

Sapphire 1

1 Data has been verifi ed but not included in EMAS core indicators.

1 Data has been verifi ed but not included in EMAS core indicators.

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3038

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3Lafarge Tarmac Portland House Bickenhill Lane Solihull Birmingham West Midlands B37 7BQ

T 0845 812 6400 www.lafargetarmac.com

Report authors

David ShentonNational Environment ManagerLafarge Cement UK

Paul Firth Emissions Monitoring TechnicianLafarge Cement UK

Documents

2012 CEMENT ENVIRONMENTAL STATEMENT - Tarmac · 2015-07-31 · 2012 Environmental Statement - Cement Update 2 2012 ENVIRONMENTAL STATEMENT Lafarge Tarmac is the newly formed UK construction