australian cement industry Statistics 2012
2 introduction In 2012 the Australian cement industry recorded a turnover of A$2.15 billion and directly employed over 1700 people, many of whom are based in regional Australia.
3 The continuing strength of the Australian dollar presents significant challenges to the competitiveness of the industry which are compounded with new and continuing federal and state government imposts. Despite the challenges the industry has improved environmental performance, particularly through the increase use and sale of cement extenders.
4 Cement production in Australia Cement is the key building ingredient in concrete, the most consumed material on earth behind water. CIF member companies produce cement in eight integrated clinker and cement facilities and six grinding plants. The product is delivered to market through 28 distribution terminals.
Cement and clinker production (million tonnes) 5 10 9 8 7 6 5 4 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 Clinker Cement
6 Cement production in Australia The industry adopts leading edge practices to reduce costs and emissions. Since 1990 the industry has moved toward more energy efficient clinker production techniques through the increased use of precalciner kilns and a reduction of clinker production using less efficient long wet kilns. In 2012, precalciner kilns accounted for almost 87 per cent of total clinker production in the Australian cement industry.
Clinker production by kiln type (million tonnes) 7 7 6 5 4 3 2 1 0 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 Kiln type Long wet Suspension preheater Semi wet/dry Precalciner
8 SALES and emissions Improvements in blending technology and increased use of byproducts from other industries has resulted in a significant reduction in the total emissions per tonne of cementitious materials sold whilst maintaining a steady increase in total sales since 1990. Byproducts used in blending include fly ash from coal fired power stations and ground granulated blast furnace slag from steel mills.
Cementitious materials sales and CO 2 emissions 9 12 11 10 9 8 7 6 1.0 0.9 0.8 0.7 0.6 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 Million tonnes of cementitious material sold Tonnes CO 2 emissions per tonne of material
10 energy use and emissions Since 1990, the increased use of alternative fuels in the cement manufacturing process has resulted in a significant reduction of both fuel and power use. Increasing the production capacities of kilns will be required for any further significant improvement in fuel efficiency. Increased fuel efficiency can sometimes come at the expense of power efficiency.
Fuel and (electrical) power efficiency gains 11 40% 35% 30% 25% 20% 15% 10% 5% 0% -5% 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 % Fuel reduction from 1990 per tonne of cement produced % Power reduction from 1990 per tonne of cement produced
12 energy use and emissions The Australian cement industry has consistently increased the use of alternative fuels lowering the industry s greenhouse emissions as well as waste going to landfill. The use of alternative fuel sources such as used oil, demolition timber and solvent fuels has steadied between 7 and 8 per cent in the Australian cement industry. Increased or maintained use of alternative fuels in the cement industry depends largely on more consistent enabling regulations across jurisdications, which have to date been lacking.
Alternative fuel as a percentage of total energy use 13 8% 7% 6% 5% 4% 3% 2% 1% 0% 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
14 energy use and emissions The use of cement extenders is one of the most effective ways to reduce emissions. The use and sale of cement extenders from CIF member companies exceeded 3 million tonnes for the first time in 2012.
Cement extenders: 15 Used in production and sold for concrete production (million tonnes) 3.0 2.5 2.0 1.5 1.0 0.5 0 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 Fly ash used in cement production Slag used in cement production Limestone used in cement production Extenders sold direct to market
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