Our history
The new state of the art Dry Process Plant commenced production in Spring 2004 and was officially opened by HRH Princess Anne, the Princess Royal on the 12th October 2004.
After 40 years of operation, the original wet process cement plant has been replaced with a new dry process operation that will provide a significant increase in production capacity whilst utilising state-of-the-art, energy efficient dry process technology.
Why the new plant was created
It's a fascinating tale, drawing in everyone from the local community to the National Health Service.
The story began in the late 1990s. Buxton Lime had been stepping up environmental controls at the old plant, and there was an argument for staying with the existing set-up. The plant dated back to the mid 1960s. Could it be refurbished and improved to cope with future market demands?
As it was, Buxton Lime wanted to ensure it could meet anticipated environment legislation. Besides, starting a fresh had other benefits; greater efficiency and increased production whilst at the same time enabling proper and full use to be made of the natural limestone resources at Tunstead Quarry, near Buxton. The continuation of cement production maintains the highly sustainable and integrated range of manufacturing processes at Tunstead Quarry and in doing so secures and extends employment in the local community.
A pre-feasibility study was completed in April 1999 - a full five years before the new plant turned out its first cement. In between there was an extensive consultation process. Among those involved were local residents, the parish, borough and county councils, the Environment Agency and the Peak District National Park Authority. This was followed up with regular reports to ensure that everyone was kept fully informed of progress with the project.
Benefits of the plant
Buxton Cement's output has increased to more than 800,000 tonnes a year with the new plant. Previously, the capacity of the old plant was around 300,000 tonnes a year.
The plant is truly world class, employing the best technology available for cement production and utilising specialist minerals processing technology developed in South Africa by its parent company Anglo American.
Thermal efficiency of the new plant is approximately 40% better than the old plant.
The plant has been designed in order to utilise raw materials arising from the other operations on site at Tunstead.
Buxton Lime and Cement is the UK's largest producer of lime and lime products. The by-products of the manufacturing processes on site - fine limestone and clay slurry - are ideal raw feed for making cement. So, with the new plant, an otherwise costly waste disposal problem is turned into an economic and environmentally friendly enterprise.
Environmental Advances
Environmental considerations were a key factor in the decision to build a new plant as Buxton Lime Industries is committed to the highest practical environment standards. It has ISO 14001 accreditation.
And the result?
Total particulate emissions have been reduced by 70%, Sulphur Dioxide by 60%, Nitrogen Oxides by 9% and the energy efficiency, per tonne of product, has improved by 40%.
Unlike its predecessor, the new plant is sited in the centre of Tunstead Quarry, 35m below the rim of the quarry to minimise any visual intrusion on the surrounding area. It's also located further away from the nearest villages. In addition, an ongoing programme of infrastructure improvements, dry-stone walling, and tree planting has helped change the face of Tunstead.
Rail Delivery Expansion
Much of the increased output from the new plant will be despatched by rail, which is a break from the past.
Buxton Cement are seeking faster and more environmentally friendly delivery to Bulk customers nationwide.That means new rail depots, cement wagons and locomotives - and a dramatic upgrade of the company's Tunstead Quarry railhead.
Buxton Cement previously used this railhead to transport only roadstone and lime. Now it has been expanded and includes the most modern facilities available for bulk cement handling and distribution. Buxton Cement has also built its own rail depots in Walsall, Leeds and at Willesden in London.
It can also tailor rail delivery to the needs of individual bulk cement customers, using Rail Enterprise direct from Buxton or the new depots.
To view a detailed schematic diagram of the dry process manufacture of cement
