BORAL CEMENTBuild something great™
Cement manufacturing at
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.
BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523
VICTORIA1800 673 570
TASMANIA(03) 6427 0133
PRODUCT SUPPORT: 1800 721 258
www.boral.com.au/cement
BCC_10301_08/12
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 Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.
Berrima
Berrim
a
Marulan-Berrima-Maldon production line
Portland Cement
BORAL CEMENTBuild something great™
Cement manufacturing at
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.
BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523
VICTORIA1800 673 570
TASMANIA(03) 6427 0133
PRODUCT SUPPORT: 1800 721 258
www.boral.com.au/cement
BCC_10301_08/12
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 Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.
Berrima
Berrim
a
Marulan-Berrima-Maldon production line
Portland Cement
BORAL CEMENTBuild something great™
Cement manufacturing at
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.
BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523
VICTORIA1800 673 570
TASMANIA(03) 6427 0133
PRODUCT SUPPORT: 1800 721 258
www.boral.com.au/cement
BCC_10301_08/12
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 Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.
Berrima
Berrim
a
Marulan-Berrima-Maldon production line
Portland Cement
BLAST FURNACESLAG STOCKPILE
SLAG DRYER
Marulan Limestone Quarry
DRY SLAGSTORAGE
SHALE
COAL BLENDING& STORAGE
CRUSHERSHALE
LOCALSHALE QUARRY
LOCALIRON ORE
LIMESTONE
LOCALSAND
LABORATORY & CENTRAL CONTROL ROOM
DRY PROCESS
KILN
COAL MILL
ELECTROSTATIC
DUST COLLECTOR
DUST
RETURN
COND
ITIO
NING
TOW
ER
RAW MEALCO
NDIT
IONI
NGTO
WER
STACK
PREHEATERTOWER N02 RAWMEAL
BLENDING SILO
RAW
MAT
ERIA
L BL
ENDI
NGAN
D ST
ORAG
E
RAW
MAT
ERIA
LSAD
DITI
VE B
UILD
ING
BULK CEMENT STORAGE SILOS
BAGGED CEMENT
BULK CEMENT
BULK CEMENT & SLAG
CEMENT MILLS
GRATE COOLER
GYPSUMCLINKER STORAGE
BUILDING
CLINKER STORAGE
BUILDING
BULK CEMENT
BULK CEMENT STORAGE SILOS
BULK CEMENT
CEMENT MILLS
No.6 RAW MILL
KILN EXHAUST
GASES
No.7 RAW MILL
WASTE GASES
(TO STACK)
KILN EXHAUST
GASES
DUST
RETURNRAW MEAL
BULK LIME
BAGGED LIME
ROTARY LIME KILN
LIMESTONE
PRIMARY DRILL& BLASTING
SECONDARYPRIMARYCRUSHER CRUSHER
TO BERRIMA
GYPSUM
TO MALDON
CLINKERSTORAGE SILO
TROMMEL SCREEN
WAS
TE G
ASES
(TO
STAC
K)PREHEATERTOWER No1
Berrima Clinker and Cement Works
Maldon Cement Works
Berrima Colliery
Cement making is a simple
process in which carefully
measured quantities of limestone,
shale, iron ore and occasionally
sand are blended together,
ground to a fine powder and
fused at a very high temperature
in a rotary kiln. The fused material
or ‘clinker’ is cooled and then
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
of calcium carbonate. Chalk or
coral can also be used. At Berrima
limestone is used which comes
from Boral’s limestone quarry at
Marulan (70kms south of Berrima).
Limestone is a high grade stone
won by blasting, then crushed
before being transported by rail
to the cement works. Shale is
quarried on the cement works site.
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.
Berrima employs a dry process
for cement manufacturing in which
raw materials are ground to a fine
powder in a vertical raw mill, then;
1. The dry ground meal is stored
in a large blending silo.
2. From the silo it is conveyed
by elevator to the top of the
pre-heater tower with four
cyclone stages.
3. The raw meal falls by
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 hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.
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 lime-bearing 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.
The Marulan-Berrima-Maldon Production Line 2012
BerrimaCement manufacturing at
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.
GEELONGMELBOURNE
MARULAN
MALDONSYDNEY
NEWCASTLE
BERRIMA
How Portland Cement is made at Berrima
BLAST FURNACESLAG STOCKPILE
SLAG DRYER
Marulan Limestone Quarry
DRY SLAGSTORAGE
SHALE
COAL BLENDING& STORAGE
CRUSHERSHALE
LOCALSHALE QUARRY
LOCALIRON ORE
LIMESTONE
LOCALSAND
LABORATORY & CENTRAL CONTROL ROOM
DRY PROCESS
KILN
COAL MILL
ELECTROSTATIC
DUST COLLECTOR
DUST
RETURN
COND
ITIO
NING
TOW
ER
RAW MEAL
COND
ITIO
NING
TOW
ER
STACK
PREHEATERTOWER N02 RAWMEAL
BLENDING SILO
RAW
MAT
ERIA
L BL
ENDI
NGAN
D ST
ORAG
E
RAW
MAT
ERIA
LSAD
DITI
VE B
UILD
ING
BULK CEMENT STORAGE SILOS
BAGGED CEMENT
BULK CEMENT
BULK CEMENT & SLAG
CEMENT MILLS
GRATE COOLER
GYPSUMCLINKER STORAGE
BUILDING
CLINKER STORAGE
BUILDING
BULK CEMENT
BULK CEMENT STORAGE SILOS
BULK CEMENT
CEMENT MILLS
No.6 RAW MILL
KILN EXHAUST
GASES
No.7 RAW MILL
WASTE GASES
(TO STACK)
KILN EXHAUST
GASES
DUST
RETURNRAW MEAL
BULK LIME
BAGGED LIME
ROTARY LIME KILN
LIMESTONE
PRIMARY DRILL& BLASTING
SECONDARYPRIMARYCRUSHER CRUSHER
TO BERRIMA
GYPSUM
TO MALDON
CLINKERSTORAGE SILO
TROMMEL SCREEN
WAS
TE G
ASES
(TO
STAC
K)
PREHEATERTOWER No1
Berrima Clinker and Cement Works
Maldon Cement Works
Berrima Colliery
Cement making is a simple
process in which carefully
measured quantities of limestone,
shale, iron ore and occasionally
sand are blended together,
ground to a fine powder and
fused at a very high temperature
in a rotary kiln. The fused material
or ‘clinker’ is cooled and then
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
of calcium carbonate. Chalk or
coral can also be used. At Berrima
limestone is used which comes
from Boral’s limestone quarry at
Marulan (70kms south of Berrima).
Limestone is a high grade stone
won by blasting, then crushed
before being transported by rail
to the cement works. Shale is
quarried on the cement works site.
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.
Berrima employs a dry process
for cement manufacturing in which
raw materials are ground to a fine
powder in a vertical raw mill, then;
1. The dry ground meal is stored
in a large blending silo.
2. From the silo it is conveyed
by elevator to the top of the
pre-heater tower with four
cyclone stages.
3. The raw meal falls by
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 hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.
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 lime-bearing 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.
The Marulan-Berrima-Maldon Production Line 2012
BerrimaCement manufacturing at
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.
GEELONGMELBOURNE
MARULAN
MALDONSYDNEY
NEWCASTLE
BERRIMA
How Portland Cement is made at Berrima
BLAST FURNACESLAG STOCKPILE
SLAG DRYER
Marulan Limestone Quarry
DRY SLAGSTORAGE
SHALE
COAL BLENDING& STORAGE
CRUSHERSHALE
LOCALSHALE QUARRY
LOCALIRON ORE
LIMESTONE
LOCALSAND
LABORATORY & CENTRAL CONTROL ROOM
DRY PROCESS
KILN
COAL MILL
ELECTROSTATIC
DUST COLLECTOR
DUST
RETURN
COND
ITIO
NING
TOW
ER
RAW MEAL
COND
ITIO
NING
TOW
ER
STACK
PREHEATERTOWER N02 RAWMEAL
BLENDING SILO
RAW
MAT
ERIA
L BL
ENDI
NGAN
D ST
ORAG
E
RAW
MAT
ERIA
LSAD
DITI
VE B
UILD
ING
BULK CEMENT STORAGE SILOS
BAGGED CEMENT
BULK CEMENT
BULK CEMENT & SLAG
CEMENT MILLS
GRATE COOLER
GYPSUMCLINKER STORAGE
BUILDING
CLINKER STORAGE
BUILDING
BULK CEMENT
BULK CEMENT STORAGE SILOS
BULK CEMENT
CEMENT MILLS
No.6 RAW MILL
KILN EXHAUST
GASES
No.7 RAW MILL
WASTE GASES
(TO STACK)
KILN EXHAUST
GASES
DUST
RETURNRAW MEAL
BULK LIME
BAGGED LIME
ROTARY LIME KILN
LIMESTONE
PRIMARY DRILL& BLASTING
SECONDARYPRIMARYCRUSHER CRUSHER
TO BERRIMA
GYPSUM
TO MALDON
CLINKERSTORAGE SILO
TROMMEL SCREEN
WAS
TE G
ASES
(TO
STAC
K)
PREHEATERTOWER No1
Berrima Clinker and Cement Works
Maldon Cement Works
Berrima Colliery
Cement making is a simple
process in which carefully
measured quantities of limestone,
shale, iron ore and occasionally
sand are blended together,
ground to a fine powder and
fused at a very high temperature
in a rotary kiln. The fused material
or ‘clinker’ is cooled and then
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
of calcium carbonate. Chalk or
coral can also be used. At Berrima
limestone is used which comes
from Boral’s limestone quarry at
Marulan (70kms south of Berrima).
Limestone is a high grade stone
won by blasting, then crushed
before being transported by rail
to the cement works. Shale is
quarried on the cement works site.
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.
Berrima employs a dry process
for cement manufacturing in which
raw materials are ground to a fine
powder in a vertical raw mill, then;
1. The dry ground meal is stored
in a large blending silo.
2. From the silo it is conveyed
by elevator to the top of the
pre-heater tower with four
cyclone stages.
3. The raw meal falls by
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 hot meal enters the rotating kiln and travels toward the fusion zone, when it is heated to 1450ºC.
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 lime-bearing 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.
The Marulan-Berrima-Maldon Production Line 2012
BerrimaCement manufacturing at
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.
GEELONGMELBOURNE
MARULAN
MALDONSYDNEY
NEWCASTLE
BERRIMA
How Portland Cement is made at Berrima
BORAL CEMENTBuild something great™
Cement manufacturing at
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.
BerrimaA.C.N. 008 528 523 A.B.N. 62 008 528 523
VICTORIA1800 673 570
TASMANIA(03) 6427 0133
PRODUCT SUPPORT: 1800 721 258
www.boral.com.au/cement
BCC_10301_08/12
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 Works is situated at Berrima 150kms south of Sydney and supplies much of Sydney’s annual cement requirement - over one million tonnes per year.
BerrimaBerrim
aMarulan-Berrima-Maldon production line
Portland Cement