Boral secure Federal funding for Berrima cement kiln adaptations
Project will reduce CO2 process emissions from cement clinker manufacturing by up to 100,000 tonnes
BORAL Ltd have successfully secured A$24.5 million in Federal Government funding for a new cement kiln infrastructure project that will allow the company to significantly reduce its CO2 emissions arising from cement manufacturing by up to 100,000 tonnes per annum, based on predicted production rates.
The kiln-feed optimization project at Berrima cement works will play a key role in Boral’s broader decarbonization pathway by reducing process emissions – the largest and most difficult-to-abate emissions source in cement manufacturing.
The funding announcement was made by Minister for Climate Change and Energy the Hon Chris Bowen MP at Berrima cement works, in the Southern Highlands of New South Wales (NSW) – a strategically significant site for Boral and for Australia’s manufacturing capability, responsible for supplying up to 40% of cement in NSW and the Australian Capital Territory (ACT). The grant from the Federal Government’s Powering the Regions Fund is aimed at supporting projects that will enable the decarbonization of existing industries and contribute to Australia’s emission reduction targets.
The funding will supplement Boral’s significant capital investment into the integration of a new specialized grinding circuit and supporting infrastructure at Berrima, which will allow the company to substantially increase the proportion of alternative raw materials (ARMs) in kiln feed to up to 23%, up from its current 9% capability, and subsequently lower the amount of limestone used.
The key benefit of utilizing ARMs over limestone, is that limestone, when heated, releases CO2 as it is converted into clinker through calcination. Around 55% of the CO2 emissions from the Australian cement and concrete sector originate from the calcination of limestone. As an additional benefit, ARMs also require lower heating temperatures compared with limestone, and therefore, lower energy intensity.
Boral plan to use ARMs derived from a range of by-products from the steel manufacturing process and industrial waste rejections, including granulated blast-furnace slag, steel slag, cement fibre-board, fly ash, and fine aggregates from recycled concrete.
The funding will enable the company to progress to the next phase of detailed process designs for front-end engineering, followed by procurement, construction, installation, and commissioning. It is expected to be fully operational in 2028.
Boral chief executive officer Vik Bansal said: ‘We believe that today’s grant signifies a vote of confidence from the Federal Government on Boral’s decarbonization and innovation efforts, amidst our immense progress in an industry that is highly carbon intensive and operates in a hard-to-abate sector.
‘At Boral, we have clearly set out the range of measures we intend to implement to meet the challenge set for us on reducing carbon emissions. This is just one investment we have made at Berrima, building on our previous innovations around use of alternative fuels. As a result, Boral are on track to remain below the baseline safeguard mechanism requirements.’
Dr Ali Nezhad, head of innovation and sustainability at Boral, said: ‘Along with the entire cement and concrete industry in Australia, Boral have been seeking pathways to lower their CO2 emissions and contribute to Australia’s ambition to reach net zero by 2050. This project plays a key role in Boral’s broader decarbonization pathway by reducing process emissions which are the largest and most difficult-to-abate emissions source in cement manufacturing.
‘By increasing the proportion of ARMs in the kiln feed, less limestone and shale is added to the kiln, lowering process emissions and lowering the carbon intensity of the resulting clinker. In terms of the resulting emissions intensity of the manufactured clinker, the project will result in up to 11% reduction in clinker emission intensity, 9% attributable to a reduction in calcination emissions and 2% attributable to thermal efficiency gains.’
Last year, Boral upgraded their carbon-reduction technology at Berrima cement works, a key part of which – a Chlorine Bypass which reduces the build-up of chlorides and other alternative fuel by-product – is a key enabler to increase the site’s alternative fuel usage to 60% over the next three years.
The new kiln-feed optimization project is in addition to a concurrent project focusing on alternative fuels to reduce fuel-based emissions. Boral say that, together, these projects will result in significant and meaningful reductions to both process and fuel-based emissions at Berrima.
