Boral — Corporate Update (December 2018)
37 slides from Boral's corporate update, Dec 6, 2018
Slide 1: Boral Berrima Cement Special Whole of Community Meeting
Build something great™ BORAL BERRIMA CEMENT > Special Whole of Community 6 December 2018 Meeting Mittagong RSL Club Mittagong
Slide 2: Agenda
Agenda ˃ Welcome, introductions, safety moment, administration ˃ Fuelling Our Future: The Solid Waste Derived Fuels Program ˃ Solid Waste Derived Fuels: Commissioning and Outcomes ˃ Solid Waste Derived Fuels: The Next Stages ˃ Berrima Cement 2019: Planned Changes, New Opportunities ˃ Our Community ˃
Slide 3: Administration
Administration ˃ Previous community meeting ˃ 2 August 2018 – Inaugural annual ‘Whole of Community’ meeting ˃ Note: Presentations from previous meetings are available from the Cement Works website – www.boral.com.au/berrimacement ˃ Matters arising ˃ Apologies for this meeting ˃ Safety moment
Slide 4: Fuelling Our Future: The Solid Waste Derived Fuels Project
Build something great™ BORAL BERRIMA CEMENT > Fuelling Our Future: The Solid Waste Derived Fuels Project
Slide 5: Fuelling Our Future: The SWDF Project
Fuelling Our Future: The SWDF Project ˃ Our ‘journey’ to establish Solid Waste Derived Fuels (SWDF) at Berrima began as far back as 2012 and has now almost at its end. ˃ Tonight, we’d like to recap this journey for you and report back to you on what we learned along the way. ˃ We wish to update you
Slide 6: Why SWDFs?
Why SWDFs? ˃ During the 2010s, domestic cement manufacturing has faced increasing and sustained challenges. Across the decade, there’s been: ˃ Rising production costs – energy and raw materials; ˃ The economic impact of cyclical market demand; ˃ At one point mid-decade, the strong Australian dollar;
Slide 7: Why SWDFs?
Why SWDFs? ˃ We therefore had to do something to reduce our production costs and secure long-term viability at Berrima. Energy costs were a standout opportunity. ˃ Securing enough energy for the cement kiln accounts for around 40 percent of operational costs. ˃ Costs associated with supply of ‘tradi
Slide 8: The six year timetable to achieve SWDF use
The six year timetable to achieve SWDF use… Preliminary investigations and planning for SWDF 2012 First major public communication about SWDFs Sep 2014 $4 million grant from NSW Environment Trust Dec 2014 Lodgement of planning modification Jun 2015 Approval - Modification 9 Development Con
Slide 9: What are SWDFs?
What are SWDFs? ˃ The SWDFs we are using at Berrima include wood waste-derived fuel (WWDF) and refuse-derived fuel (RDF). Wood waste-derived fuel (WWDF) Refuse-derived fuel (RDF) Combustible materials recovered ‘Leftovers’ from other industries from ‘mainstream’ waste Untreated waste like sawdust, p
Slide 10: How the SWDF system works
How the SWDF system works Auto grab Access & delivery crane Receiving and Loading bins storage shed Tube conveyor Calciner High temperature slide gate Aeration Multiflex feeder Supports
Slide 11: Changes made to accommodate SWDF use
Changes made to accommodate SWDF use ˃ To be able to use SWDFs at Berrima, we had to modify the Cement Works’ planning consent: ˃ Add WWDF and RDF to the permitted fuels (along with existing rubber tyre ‘chips’ and others) ˃ Gain permission to built the plant structures and equipment, and ˃ Seek som
Slide 12: SWDF Project: Commissioning and Outcomes
Build something great™ BORAL BERRIMA CEMENT > SWDF Project: Commissioning and Outcomes
Slide 13: Commissioning and Outcomes
SWDF – Commissioning and Outcomes ˃ The SWDF Proof of Performance Trial (PoPT) Plan was approved and ‘wet commissioning’ commenced on 20 August. ˃ Purpose to monitor performance and manage any process issues at varying feed rates and blends. ˃ Trial planned to go for up to eight months. ˃ ‘Real-time
Slide 14: Air quality results during use
SWDF – Air quality results during use ˃ Monitoring shows there have been no ambient air quality changes since we commenced using SWDFs.
Slide 15: Air quality results during use
SWDF – Air quality results during use ˃ Monitoring shows there have been no ambient air quality changes since we commenced using SWDFs.
Slide 16: Air quality results during use
SWDF – Air quality results during use ˃ Monitoring shows there have been no ambient air quality changes since we commenced using SWDFs.
Slide 17: Air quality results during use
SWDF – Air quality results during use ˃ Our Proof of Performance Trials have demonstrated we have good control of the plant’s emissions, and good compliance with the site’s Environmental Protection Licence (EPL). Extractive Stack Emission Test Results from Proof of Performance Trails Coal only AF Pa
Slide 18: Air quality results during use
SWDF – Air quality results during use ˃ Not everything went to plan, however. There were two times the trial gave us an opportunity to learn more about our new system. ˃ 20 September: Electrostatic Precipitator (ESP) ‘Trip’ – Elevated particulates and metals ˃ Trip lasted six minutes during extracti
Slide 19: Air quality results during use
SWDF – Air quality results during use ˃ Not everything went to plan, however. There were two times the trial gave us an opportunity to learn more about our new system. ˃ 19 November: Elevated Hydrogen Chloride (HCl) ˃ Around 9pm, the ‘real time’ HCl analyser within the kiln stack recorded an ‘averag
Slide 20: Commissioning and trial summary
SWDF – Commissioning and trial summary ˃ Despite these issues, we believe the commissioning and trial period is progressing successfully and are pleased with the outcomes. ˃ On track with target of using up to 100 000 tonnes/year of SWDF, replacing about 50000 tonnes/year of coal. ˃ Current SWDF con
Slide 21: SWDF Project: The Next Stages
Build something great™ BORAL BERRIMA CEMENT > SWDF Project: The Next Stages
Slide 22: Where to from here?
SWDF – Where to from here? ˃ As reported, our commissioning and trial period has gone very successfully and we are now steadily increasing our use of SWDFs in production. ˃ More than 8400 tonnes of SWDF has already been used – material diverted from landfill. ˃ Our coal consumption has reduced by mo
Slide 23: Where to from here?
SWDF – Where to from here? ˃ At present, we’re intaking and consuming at a rate of 55000 tonnes of SWDF per year. ˃ Average of five tonnes/hour RDF and three tonnes/hour WWDF ˃ Reaching our approved target of 100 000 tonnes per year will, however, require more to be done at site. The next stage rate
Slide 24: SWDF Intake shed extension
BORAL. SWDF -— Intake shed extension —PUSM TRAILER TRPER TRALER ~FEL ENTRY / CRANE MAINTENANCE AREA — 12T BIOMASS HIANDLING CRANE -\ N<fo A TNUUONT NDNA PIPE CONVEYOR ¢ Hl MAGNETIC SEPARATOR | ROE MATERIAL SHEETING REMOVED FOR CLARITY WWOF MATERIAL HOnrER HOPPER
Slide 25: Delivery hours variation
SWDF – Delivery hours variation ˃ At present, there is around one truck per hour delivering SWDF material to Berrima ˃ This compares with an average of around five cement tankers per hour entering and leaving site. ˃ As usual, our policies and practices with regard to safe driver behaviour and drivi
Slide 26: Other fuels?
SWDF – Other fuels? ˃ The encouraging results of the commissioning has prompted us to start considering other fuel options and opportunities. One which might be available soon is a fuel called carbon anode. ˃ By-product of the aluminium smelting process. ˃ Supply of up to 15000 tonnes may be availab
Slide 27: Using HiCal 50 / carbon anode
SWDF – Using HiCal 50 / carbon anode ˃ To make use of the available carbon anode supply, and stop it from being sent for disposal, we can make use of our existing planning consent with a slight modification. ˃ Under the current (old) consent, as with all non-standard fuels, HiCal 50 cannot be used i
Slide 28: Berrima Cement 2019: Planned Changes, New Opportunities
Build something great™ BORAL BERRIMA CEMENT > Berrima Cement 2019 Planned Changes, New Opportunities
Slide 29: Introducing isotainers
Introducing isotainers… ˃ While we’ve made mention of broadening the delivery window for SWDF trucks, we’re also looking at removing trucks off the road by using isotainers. ˃ Isotainer technology has recently advanced, making it a very viable option to transport large volumes of product over large
Slide 30: Introducing isotainers
Introducing isotainers… ˃ To make use of isotainers and their advantages, we’re starting to plan for a new handling facility at the site. ˃ Hoping to bring online in the first half of 2019 ˃ Once established, we’ll be looking at starting to load three trains per week with 56 isotainers per train. ˃
Slide 31: Proposed isotainer facility - Berrima
Proposed isotainer facility - Berrima ˃ Facility would be located on the ‘old main line’ and up to 100 isotainers stored in the old workshop area. It would not be visible from Taylor Avenue.
Slide 32: Off-white clinker storage
Off-white clinker storage ˃ We’re also developing plans to build a covered clinker store for our off-white clinker product. ˃ Significant reduction in on-site clinker handling. ˃ Reducing need for outside storage of clinker. ˃ 21000 tonnes total and 16000 tonnes ‘live’ storage capacity. ˃ The storag
Slide 33: Our Community
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Slide 34: Stakeholder Perception Benchmark (SPB)
Stakeholder Perception Benchmark (SPB) ˃ The SPB is Boral’s way of assuring itself that community relations objectives are being met by its operations. ˃ Random selection of sites across entire country made each year ˃ Involves direct gathering of feedback from neighbours in-person and/or electronic
Slide 35: Community Liaison Group (CLG)
Community Liaison Group (CLG) ˃ In 2017, we announced a change to our community engagement approach. ˃ Closer alignment to Cement Works planning consent ˃ Addresses long run of declining attendances at regular community meetings ˃ The change now sees annual (and ‘special’ like tonight) ‘whole of com
Slide 36: General business and contacts
General business and contacts ˃ Items of general business ˃ Next meetings ˃ Community Liaison Group – re-formation by March 2019 ˃ Next ‘Whole of Community’ meeting will be Jul-Aug 2019 unless needed earlier ˃ Boral Berrima Cement contacts: ˃ Berrima Cement Works Reception 4860 2222 / madeline.westn
Slide 37: Thank you for your attendance
Build something great™ BORAL BERRIMA CEMENT > Thank you for your attendance