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BORAL CEMENT Build something great™ Cement manufacturing at Portland Cement Portland cement dates from its discovery by an English mason, Joseph Aspdin in 1824 who obtained the patent and gave the product its name ‘Portland cement’ because the mortar colour it produced resembled a natural building stone obtained from the Isle of Portland off the English coast. Portland cement significantly improved on earlier cement developments by preparing a synthetic mixture of lime and clay without depending on raw materials found in nature which might contain such elements in desirable proportions. In 1877 the first rotary kiln was patented in England. In 1885 Englishman Frederick Ransome patented the first rotary cement kiln. Since that time rotary kilns have developed in size, capacity, output quality and operational economy. Now with modern materials handling equipment, more efficient combustion techniques and computerized processing and control, kilns are capable of producing over four thousand five hundred tonnes of cement clinker per day. Berrima A.C.N. 008 528 523 A.B.N. 62 008 528 523 VICTORIA 1800 673 570 TASMANIA (03) 6427 0133 PRODUCT SUPPORT: 1800 721 258 www.boral.com.au/cement BCC_10301_08/12 Berrima Berrima Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year. Marulan-Berrima-Maldon production line The Berrima cement works are the longest in Australia. The 130km integrated manufacturing process begins at Marulan – where limestone is quarried, then railed to Berrima where clinker is produced. The clinker is then transported by rail to Maldon for cement milling, where it is bagged and distributed. Berrima’s plant capacity is 1.4 million tones of clinker per annum. Twenty five percent of this output is transported to the grinding plant at Maldon where it is converted to cement. The remaining clinker is ground at Berrima and dispatched in large quantities to Canberra, the NSW south coast and other NSW markets. The Berrima kilns are equal to the most modern in the world with continuous development upgrades featuring the latest technology and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known. Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings. BORAL CEMENT Build something great™ Cement manufacturing at Portland Cement Portland cement dates from its discovery by an English mason, Joseph Aspdin in 1824 who obtained the patent and gave the product its name ‘Portland cement’ because the mortar colour it produced resembled a natural building stone obtained from the Isle of Portland off the English coast. Portland cement significantly improved on earlier cement developments by preparing a synthetic mixture of lime and clay without depending on raw materials found in nature which might contain such elements in desirable proportions. In 1877 the first rotary kiln was patented in England. In 1885 Englishman Frederick Ransome patented the first rotary cement kiln. Since that time rotary kilns have developed in size, capacity, output quality and operational economy. Now with modern materials handling equipment, more efficient combustion techniques and computerized processing and control, kilns are capable of producing over four thousand five hundred tonnes of cement clinker per day. Berrima A.C.N. 008 528 523 A.B.N. 62 008 528 523 VICTORIA 1800 673 570 TASMANIA (03) 6427 0133 PRODUCT SUPPORT: 1800 721 258 www.boral.com.au/cement BCC_10301_08/12 Berrima Berrima Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year. Marulan-Berrima-Maldon production line The Berrima cement works are the longest in Australia. The 130km integrated manufacturing process begins at Marulan – where limestone is quarried, then railed to Berrima where clinker is produced. The clinker is then transported by rail to Maldon for cement milling, where it is bagged and distributed. Berrima’s plant capacity is 1.4 million tones of clinker per annum. Twenty five percent of this output is transported to the grinding plant at Maldon where it is converted to cement. The remaining clinker is ground at Berrima and dispatched in large quantities to Canberra, the NSW south coast and other NSW markets. The Berrima kilns are equal to the most modern in the world with continuous development upgrades featuring the latest technology and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known. Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings. BORAL CEMENT Build something great™ Cement manufacturing at Portland Cement Portland cement dates from its discovery by an English mason, Joseph Aspdin in 1824 who obtained the patent and gave the product its name ‘Portland cement’ because the mortar colour it produced resembled a natural building stone obtained from the Isle of Portland off the English coast. Portland cement significantly improved on earlier cement developments by preparing a synthetic mixture of lime and clay without depending on raw materials found in nature which might contain such elements in desirable proportions. In 1877 the first rotary kiln was patented in England. In 1885 Englishman Frederick Ransome patented the first rotary cement kiln. Since that time rotary kilns have developed in size, capacity, output quality and operational economy. Now with modern materials handling equipment, more efficient combustion techniques and computerized processing and control, kilns are capable of producing over four thousand five hundred tonnes of cement clinker per day. Berrima A.C.N. 008 528 523 A.B.N. 62 008 528 523 VICTORIA 1800 673 570 TASMANIA (03) 6427 0133 PRODUCT SUPPORT: 1800 721 258 www.boral.com.au/cement BCC_10301_08/12 Berrima Berrima Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year. Marulan-Berrima-Maldon production line The Berrima cement works are the longest in Australia. The 130km integrated manufacturing process begins at Marulan – where limestone is quarried, then railed to Berrima where clinker is produced. The clinker is then transported by rail to Maldon for cement milling, where it is bagged and distributed. Berrima’s plant capacity is 1.4 million tones of clinker per annum. Twenty five percent of this output is transported to the grinding plant at Maldon where it is converted to cement. The remaining clinker is ground at Berrima and dispatched in large quantities to Canberra, the NSW south coast and other NSW markets. The Berrima kilns are equal to the most modern in the world with continuous development upgrades featuring the latest technology and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known. Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings. Cement manufacturing at Berrima The Marulan-Berrima-Maldon Production Line 2012 The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed. How Portland Cement is made at Berrima ground with a small amount of gypsum in a ball mill to produce the finished cement powder. Limestone is the primary raw material in cement with a high level 1. The dry ground meal is stored in a large blending silo. 2. of calcium carbonate. Chalk or coral can also be used. At Berrima limestone is used which comes Marulan (70kms south of Berrima). quarried on the cement works site. LOCAL IRON ORE SLAG DRYER LOCAL SAND CLINKER STORAGE SILO COAL BLENDING & STORAGE BLAST FURNACE SLAG STOCKPILE RATOR Y & CEN TRAL CONTR OL RO OM TO PREHEATER PREHEATER TOWER No1 TOWER N02 RAWMEAL BLENDING SILO SS CE RO Y P KILN DR STACK E AT R LE O CO GR DRY SLAG STORAGE GE RA STO G KER ILDIN IN U B CL COAL MILL LABO MA GYPSUM LDO N LS CEMENT MIL ATIC OST OR CTR ECT ELE COLL T S U D ORAGE MENT ST BULK CE CEMENT MIL LS RAW MEAL No.6 RAW MILL HAUST KILN EX GASES SES GA K) C STE WA O STA (T BUL MENT ST ORAGE BAG GED SILOS NEWCASTLE B SYDNEY MALDON BERRIMA MARULAN NT EME C ULK ENT EM KC No.7 RAW MILL HAUST KILN EX ES GAS SILOS KC GYPSUM BULK CE AL to the cement works. Shale is SHALE CRUSHER ST N DU TUR RE before being transported by rail SHALE ME won by blasting, then crushed LIMESTONE hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC. W RA Limestone is a high grade stone 3. he raw meal falls by T gravity through each interconnected cyclone during which the hot gases from the kiln pass through the cyclones and heat the raw meal to approx. 1000ºC. 4. From the bottom cyclone the LOCAL SHALE QUARRY ST N DU TUR RE from Boral’s limestone quarry at rom the silo it is conveyed F by elevator to the top of the pre-heater tower with four cyclone stages. Berrima Colliery IME KE R BU ST ILD OR IN AG G E or ‘clinker’ is cooled and then Berrima employs a dry process for cement manufacturing in which raw materials are ground to a fine powder in a vertical raw mill, then; LN LIME KI GED L A CL IN in a rotary kiln. The fused material RIM E ROTARY BAG CONDITIONING TOWER fused at a very high temperature BER CONDITIONING TOWER ground to a fine powder and TO Marulan Limestone Quarry WAST E (TO S GASES TACK ) sand are blended together, SECONDARY CRUSHER RAW MATERIALS ADDITIVE BUILDING shale, iron ore and occasionally K LIM PRIMARY CRUSHER The small quantity of iron ore required to make cement is obtained from outside resources. Sand is supplied locally when required for fine correction of the mix. ERIA AND L BLEND IN STO RAG G E measured quantities of limestone, BUL MAT process in which carefully LIMESTONE PRIMARY DRILL & BLASTING RAW Cement making is a simple TROMMEL SCREEN BUL Berrima Clinker and Cement Works MELBOURNE GEELONG EME NT & BUL K CE MEN SLA G CEM ENT Maldon Cement Works T 5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage. The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and limebearing cement for buildings, roads, bridges and aqueducts. The word ‘cement’ was derived from the early Roman ‘Caementum’, a rough, unhewn stone or chips of marble from which a kind of ‘mortar’ was made. The term ‘Concrete’ came from ‘Concretus’- meaning ‘growing together’. The Romans used cement to make loose stones ‘grow together’ into a single rock-like mass to build concrete structures such as the Roman baths (27BC), the Colosseum and the Basilica of Constantine. The ruins still survive today. It is believed the Romans also developed the first known hydraulic cement – cement capable of hardening under water. Created by mixing slaked lime with a volcanic rock or sand called ‘Pozzolana’, the cement was named after the place where it was first found - Possuoli near Mount Vesuvius and is commonly known as Pozzolanic cement. Cement manufacturing at Berrima The Marulan-Berrima-Maldon Production Line 2012 The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed. How Portland Cement is made at Berrima ground with a small amount of gypsum in a ball mill to produce the finished cement powder. Limestone is the primary raw material in cement with a high level 1. The dry ground meal is stored in a large blending silo. 2. of calcium carbonate. Chalk or coral can also be used. At Berrima limestone is used which comes Marulan (70kms south of Berrima). quarried on the cement works site. LOCAL IRON ORE SLAG DRYER LOCAL SAND CLINKER STORAGE SILO COAL BLENDING & STORAGE BLAST FURNACE SLAG STOCKPILE RATOR Y & CEN TRAL CONTR OL RO OM TO PREHEATER PREHEATER TOWER No1 TOWER N02 RAWMEAL BLENDING SILO SS CE RO Y P KILN DR STACK E AT R LE O CO GR DRY SLAG STORAGE GE RA STO G KER ILDIN IN U B CL COAL MILL LABO MA GYPSUM LDO N LS CEMENT MIL ATIC OST OR CTR ECT ELE COLL T S U D ORAGE MENT ST BULK CE CEMENT MIL LS RAW MEAL No.6 RAW MILL HAUST KILN EX GASES SES GA K) C STE WA O STA (T BUL MENT ST ORAGE BAG GED SILOS NEWCASTLE B SYDNEY MALDON BERRIMA MARULAN NT EME C ULK ENT EM KC No.7 RAW MILL HAUST KILN EX ES GAS SILOS KC GYPSUM BULK CE AL to the cement works. Shale is SHALE CRUSHER ST N DU TUR RE before being transported by rail SHALE ME won by blasting, then crushed LIMESTONE hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC. W RA Limestone is a high grade stone 3. he raw meal falls by T gravity through each interconnected cyclone during which the hot gases from the kiln pass through the cyclones and heat the raw meal to approx. 1000ºC. 4. From the bottom cyclone the LOCAL SHALE QUARRY ST N DU TUR RE from Boral’s limestone quarry at rom the silo it is conveyed F by elevator to the top of the pre-heater tower with four cyclone stages. Berrima Colliery IME KE R BU ST ILD OR IN AG G E or ‘clinker’ is cooled and then Berrima employs a dry process for cement manufacturing in which raw materials are ground to a fine powder in a vertical raw mill, then; LN LIME KI GED L A CL IN in a rotary kiln. The fused material RIM E ROTARY BAG CONDITIONING TOWER fused at a very high temperature BER CONDITIONING TOWER ground to a fine powder and TO Marulan Limestone Quarry WAST E (TO S GASES TACK ) sand are blended together, SECONDARY CRUSHER RAW MATERIALS ADDITIVE BUILDING shale, iron ore and occasionally K LIM PRIMARY CRUSHER The small quantity of iron ore required to make cement is obtained from outside resources. Sand is supplied locally when required for fine correction of the mix. ERIA AND L BLEND IN STO RAG G E measured quantities of limestone, BUL MAT process in which carefully LIMESTONE PRIMARY DRILL & BLASTING RAW Cement making is a simple TROMMEL SCREEN BUL Berrima Clinker and Cement Works MELBOURNE GEELONG EME NT & BUL K CE MEN SLA G CEM ENT Maldon Cement Works T 5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage. The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and limebearing cement for buildings, roads, bridges and aqueducts. The word ‘cement’ was derived from the early Roman ‘Caementum’, a rough, unhewn stone or chips of marble from which a kind of ‘mortar’ was made. The term ‘Concrete’ came from ‘Concretus’- meaning ‘growing together’. The Romans used cement to make loose stones ‘grow together’ into a single rock-like mass to build concrete structures such as the Roman baths (27BC), the Colosseum and the Basilica of Constantine. The ruins still survive today. It is believed the Romans also developed the first known hydraulic cement – cement capable of hardening under water. Created by mixing slaked lime with a volcanic rock or sand called ‘Pozzolana’, the cement was named after the place where it was first found - Possuoli near Mount Vesuvius and is commonly known as Pozzolanic cement. Cement manufacturing at Berrima The Marulan-Berrima-Maldon Production Line 2012 The New Berrima works are the longest works in Australia - they begin their 130km integrated manufacturing process at Marulan - when limestone is railed from there to New Berrima, where clinker is produced. It is then transported to Maldon for cement milling, where it is bagged then distributed. How Portland Cement is made at Berrima ground with a small amount of gypsum in a ball mill to produce the finished cement powder. Limestone is the primary raw material in cement with a high level 1. The dry ground meal is stored in a large blending silo. 2. of calcium carbonate. Chalk or coral can also be used. At Berrima limestone is used which comes Marulan (70kms south of Berrima). quarried on the cement works site. LOCAL IRON ORE SLAG DRYER LOCAL SAND CLINKER STORAGE SILO COAL BLENDING & STORAGE BLAST FURNACE SLAG STOCKPILE RATOR Y & CEN TRAL CONTR OL RO OM TO PREHEATER PREHEATER TOWER No1 TOWER N02 RAWMEAL BLENDING SILO SS CE RO Y P KILN DR STACK E AT R LE O CO GR DRY SLAG STORAGE GE RA STO G KER ILDIN IN U B CL COAL MILL LABO MA GYPSUM LDO N LS CEMENT MIL ATIC OST OR CTR ECT ELE COLL T S U D ORAGE MENT ST BULK CE CEMENT MIL LS RAW MEAL No.6 RAW MILL HAUST KILN EX GASES SES GA K) C STE WA O STA (T BUL MENT ST ORAGE BAG GED SILOS NEWCASTLE B SYDNEY MALDON BERRIMA MARULAN NT EME C ULK ENT EM KC No.7 RAW MILL HAUST KILN EX ES GAS SILOS KC GYPSUM BULK CE AL to the cement works. Shale is SHALE CRUSHER ST N DU TUR RE before being transported by rail SHALE ME won by blasting, then crushed LIMESTONE hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC. W RA Limestone is a high grade stone 3. he raw meal falls by T gravity through each interconnected cyclone during which the hot gases from the kiln pass through the cyclones and heat the raw meal to approx. 1000ºC. 4. From the bottom cyclone the LOCAL SHALE QUARRY ST N DU TUR RE from Boral’s limestone quarry at rom the silo it is conveyed F by elevator to the top of the pre-heater tower with four cyclone stages. Berrima Colliery IME KE R BU ST ILD OR IN AG G E or ‘clinker’ is cooled and then Berrima employs a dry process for cement manufacturing in which raw materials are ground to a fine powder in a vertical raw mill, then; LN LIME KI GED L A CL IN in a rotary kiln. The fused material RIM E ROTARY BAG CONDITIONING TOWER fused at a very high temperature BER CONDITIONING TOWER ground to a fine powder and TO Marulan Limestone Quarry WAST E (TO S GASES TACK ) sand are blended together, SECONDARY CRUSHER RAW MATERIALS ADDITIVE BUILDING shale, iron ore and occasionally K LIM PRIMARY CRUSHER The small quantity of iron ore required to make cement is obtained from outside resources. Sand is supplied locally when required for fine correction of the mix. ERIA AND L BLEND IN STO RAG G E measured quantities of limestone, BUL MAT process in which carefully LIMESTONE PRIMARY DRILL & BLASTING RAW Cement making is a simple TROMMEL SCREEN BUL Berrima Clinker and Cement Works MELBOURNE GEELONG EME NT & BUL K CE MEN SLA G CEM ENT Maldon Cement Works T 5. As the hot clinker leaves the kiln it passes through a grate cooler where it is cooled to 120ºC and is then conveyed to storage. The origin of cement dates back to man’s earliest beginnings when builders’ sought a material to bind stones together to build shelter and later homes. In the early Egyptian era, cement material was produced by burning gypsum. The early Greeks and Romans used lime and limebearing cement for buildings, roads, bridges and aqueducts. The word ‘cement’ was derived from the early Roman ‘Caementum’, a rough, unhewn stone or chips of marble from which a kind of ‘mortar’ was made. The term ‘Concrete’ came from ‘Concretus’- meaning ‘growing together’. The Romans used cement to make loose stones ‘grow together’ into a single rock-like mass to build concrete structures such as the Roman baths (27BC), the Colosseum and the Basilica of Constantine. The ruins still survive today. It is believed the Romans also developed the first known hydraulic cement – cement capable of hardening under water. Created by mixing slaked lime with a volcanic rock or sand called ‘Pozzolana’, the cement was named after the place where it was first found - Possuoli near Mount Vesuvius and is commonly known as Pozzolanic cement. BORAL CEMENT Build something great™ Cement manufacturing at Portland Cement Portland cement dates from its discovery by an English mason, Joseph Aspdin in 1824 who obtained the patent and gave the product its name ‘Portland cement’ because the mortar colour it produced resembled a natural building stone obtained from the Isle of Portland off the English coast. Portland cement significantly improved on earlier cement developments by preparing a synthetic mixture of lime and clay without depending on raw materials found in nature which might contain such elements in desirable proportions. In 1877 the first rotary kiln was patented in England. In 1885 Englishman Frederick Ransome patented the first rotary cement kiln. Since that time rotary kilns have developed in size, capacity, output quality and operational economy. Now with modern materials handling equipment, more efficient combustion techniques and computerized processing and control, kilns are capable of producing over four thousand five hundred tonnes of cement clinker per day. Berrima A.C.N. 008 528 523 A.B.N. 62 008 528 523 VICTORIA 1800 673 570 TASMANIA (03) 6427 0133 PRODUCT SUPPORT: 1800 721 258 www.boral.com.au/cement BCC_10301_08/12 Berrima Berrima Boral Cement Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year. Marulan-Berrima-Maldon production line The Berrima cement works are the longest in Australia. The 130km integrated manufacturing process begins at Marulan – where limestone is quarried, then railed to Berrima where clinker is produced. The clinker is then transported by rail to Maldon for cement milling, where it is bagged and distributed. Berrima’s plant capacity is 1.4 million tones of clinker per annum. Twenty five percent of this output is transported to the grinding plant at Maldon where it is converted to cement. The remaining clinker is ground at Berrima and dispatched in large quantities to Canberra, the NSW south coast and other NSW markets. The Berrima kilns are equal to the most modern in the world with continuous development upgrades featuring the latest technology and equipment. Electronic controls, video display, computer control systems and a chemical and physical testing laboratory (with x-ray fluorescent spectrometer) have enabled Berrima to maintain the high quality of cement production for which it is known. Environmental considerations are a priority at the Berrima cement works. Dust collectors are located at all possible emission points, water run-off filters through settling ponds and noise levels are reduced by sound-proof enclosures around noisier equipment. Tree planting and landscaping assist the Berrima plant design to blend with the natural surroundings.