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Reducing raw material and fossil fuel use: Castle Cement
Castle has substantially reduced its use of virgin raw materials and fossil fuels over recent years. In the years 2003-4, Castle used over 195,000 tons of alternative fuels to replace approximately 160,000 tons of coal in its kilns. Energy has been recovered from scrap tires, Cemfuel (processed from the residues of recycled waste solvents) and Profuel (paper and plastic wastes not viably recycled in other ways). Now uniquely in the UK, Castle has introduced a biomass fuel, Agricultural Waste Derived Fuel (AWDF), which is meat and bone meal, produced by sterilizing and grinding abattoir waste. The company has permission to trial at its Ribblesdale site and received permission to do so at Ketton. Markets in north Wales and north west of England are principally supplied from Castle’s Padeswood works. Projects have included the Conwy and Mersey tunnels and the Deeside Crossing. Castle continues to use alternative raw materials prolonging the life of the company’s quarries. Pulverized fuel ash has been widely used, while other recycled materials include waste plaster moulds from the ceramics industry. Castle Cement’s kiln 4 at Padeswood works in north Wales is operational. The new kiln is the most modern in Europe and will bring enormous benefits to the company and local community. It also underlines Castle’s position as an indigenous UK cement producer and Castle’s commitment to the north Wales and north west English market. Not only will Castle increase production at the works from 500,000 to over 800,000 tonnes of cement per year, but the kiln will operate to the very highest levels of environmental control and performance. Central to the greatly improved performance is the use of alternative fuels, in which Castle has been a pioneer. Alternative fuels to be used at Padeswood include Cemfuel, which is processed from the residue of recycled waste solvents and Profuel, which comprises paper and plastic wastes. In the future, vehicle tires will also be used as an alternative fuel. The new kiln also ensures an increased supply in the marketplace of particularly light-colored cement. The light color is especially attractive to precast concrete manufacturers as it can allow a brighter finished product and when used, less pigment may be necessary to arrive at a specified shade. Precast concrete paving slab and reconstructed walling stone manufacturer, Fred Blackburn, of Wyresdale Concrete Products says: “We have used many cement suppliers in the past but as the competition and the market gets tighter, we need to look round for ways to improve our products. What we have found is that we can get sharper colors for our range by using Padeswood cement.” Technical director of Hanson Building Products, Trevor Poole, confirms the importance of cement color: “We make a yellow-cream facing block used, for example, on large industrial buildings where any variation in color is crucial as any inconsistencies could lead to costly, site-based remedial work. All cements tend to have a color shift over a year of production and we have found that basically gray cements do tend to become darker. Because color is so important to our block we could be faced with having to stop a production run if shades change as we prefer not to use pigments but to let the natural color of the aggregates we are using come through. With Padeswood cement we have found that if there is a slight shift in color then it tends to be more to a yellowish tinge which suits our production.” The opening of the new kiln has resulted in the closure of three existing kilns at Padeswood and two wet kilns at the company’s Ribblesdale works in Lancashire. This will reduce the company’s carbon dioxide emissions by 17.5 per cent per ton of cement produced against 2004 performance. Acid rain gases at Padeswood will be reduced by a staggering 75 per cent. Peter Weller, managing director of Castle Cement said: “Kiln 4 will lead to major improvements in the local environment. It will also help reduce Wales’ dependence on landfill sites while using waste both for cleaner production and lower energy consumption.” “Castle Cement’s Kiln 4 maintains the company’s position as a world class cement producer and places Wales at the forefront in the drive for sustainable development.” Key figures
Key facts
Project Milestones
Castle Cement is a member of the Business Council for Sustainable Development – United Kingdom. The Business Council for Sustainable Development – United Kingdom is the UK’s only affiliated branch of the World Business Council for Sustainable Development. The BCSD-UK is committed to the promotion of sustainable development and to explore the practical implications of implementation. It is an independent multi-sectored business group with a keen focus on action and projects. The Midlands Environmental Business Company is a not-for-profit company and custodian of the Midlands Environmental Business Club formed in 1991. It is a regional multi-sectored network and the strategic partner of Advantage West Midlands in the Regional Economic Strategy for the development of the environmental technology sector. It too is very action focused. Further information
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Castle
Cement is the UK cement arm of 
