New filtration system for Cauldon cement plant

Multi-million-pound bag filter installation set to improve performance and reduce emissions

WORK is currently under way on the installation of a new multi-million-pound filtration system at Aggregate Industries’ Cauldon cement plant which will improve performance and reduce emissions at the site.

The £8.7 million kiln bag filter system will remove particulate matter such as dust, along with carbon dioxide and nitrogen oxides generated as part of the cement production process and prevent them from getting into the atmosphere.

Contractors CTP Inspire Evolution have started construction and installation work at Cauldon with a view to the system being fully operational in early 2024.

The new filter system is made up of 2,080 specialist fabric bags and will capture dust particles before they enter the atmosphere. It will be three times more effective than the existing electro-static-precipitation technology – which was installed in 1984 and has now come to the end of its life – and will also use less power.

It will result in a reduction in emissions – which has been agreed with the Environment Agency – from 30mg/Nm³ to 10mg/Nm³.

Cauldon plant manager Thierry Davila said: ‘The installation of the new system will help us provide a step change in our efficiency and effectiveness, and optimize kiln performance.

‘The plant and our operations will hugely benefit from up-to-date technology which will result in more consistent running of the site, but it will also improve environmental performance and benefit the local community.

‘The new filter system will mean less dust and emissions entering the atmosphere and a reduction in pollutants, which is hugely positive and in line with our approach to sustainability.’

Steve Curley, Aggregate Industries’ managing director of cement, said: ‘This scheme is part of our ongoing investment at Cauldon and connects with our wider commitment to decarbonize our operations across the business.

‘As a key contributor to the local economy, we also recognize our responsibility to local communities, to help drive sustainable transformation and reduce environmental impact wherever possible.’

Cauldon cement plant in the Staffordshire Moorlands is operated under Aggregate Industries’ Lafarge Cement arm.

Last year the plant opened a new £13.5 million Geocycle facility and associated gas bypass, driving decarbonization and circularity through the increased use of waste-derived fuels and a reduction in fossil fuels. The facility receives solid recovered fuel (SRF) generated from non-recyclable commercial and industrial residues that would otherwise go to landfill.

Cauldon was Britain’s first dry process cement plant when it opened in 1957. The plant produces one million tonnes of cement a year and employs 125 permanent staff and 30 contractors.