Buxton cement plant

About Buxton's Tunstead cement plant

As the original wet process cement plant has been replaced with a new dry process operation, a new plant was created at Buxton cement.  This has given the plant a significant increase in production capacity whilst utilising state-of-the-art, energy efficient dry process technology.

Why the new plant was created

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?

A five-year pre-feasibility study was carried out.  In between there was an extensive consultation process. Participants involved 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 - significant achievements

• Increased to more than 800,000 tonnes a year with the new plant (previously 300,000 tonnes a year).
• Thermal efficiency of the new plant is approximately 40% better.
• Plant designed in order to utilise raw materials and other by-products onsite.
• Major reductions in emissions and energy use per tonne of cement, partly because of our lime kilns upgrade at Tunstead and Hindlow.
• Process wastes from the cement plant are now recycled.
• Reduced emissions
  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%.
• Rail delivery expansion
  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.