Our Berrima Cement team have been hard at work during their annual kiln shutdown and maintenance period.
Over three weeks in January and February, a combined 100,000 plus work hours were completed to undertake mechanical repairs and replace the kiln refractory, which is basically the kiln’s insulation or lining.
The $20 million shutdown saw the operations group manage 50 different contracting companies to complete the works which included ensuring the refractory was relined and able to protect the kiln shell from heat damage and ensure the safety of our operations and people.
Our use of Cement 4.0 technology – the integration of smart or intelligent digital technologies such as predictive maintenance sensors and kiln heat scanners, robotics and artificial intelligence into cement production – and advanced diagnostic tools helped the team determine ahead of time the nature and extent of repairs required.
Around 300 employees and contractors worked through the complex and specialist tasks required to ensure our kiln was able to get back up and running as quickly as possible, in order to produce clinker at peak temperatures of 1,500 degrees Celsius – which is hotter than a volcano!
Take a look at some of the ‘behind the scenes’ images from the shutdown.
The kiln is key
Kilns are essential to cement production. At Berrima our kiln, known as No 6, takes limestone delivered by rail from the Boral Marulan South Limestone Mine and, after blending it with other materials, burns it at high temperatures in the kiln to produce clinker. The clinker, in the form of pellets, is then ground to produce the cement powder and products.
“Thank you to the whole Berrima team, for completing the kiln annual shutdown with zero harm, on schedule and within the budget. I appreciate the cooperation that everyone displayed under such strenuous conditions to make the job run smoothly.”
Berrima Operations Manager, Waqas Ali.
Did you know?
- Boral’s Berrima Cement Works supplies more than 60 per cent of cement products used in New South Wales and the Australian Capital Territory.
- The Cement Works have been operating since 1929.
- The neighbouring town of New Berrima was established in 1928 as housing for employees of the site.
- Berrima cement has been used in some of our nation’s most recognisable infrastructure including the Snowy Mountains Hydro-Electric Scheme, Sydney Opera House, Federal Parliament House and Sydney Harbour Tunnel.
