South Ferriby works has a nearly 80 year long history of providing cement. The works produces in the region of 800,000 tonnes of cement per annum (enough for more than 44,000 houses). It provides direct employment for nearly 150 people, supporting many more jobs indirectly.
The original cement factory was built in by 1938 by Eastwoods Humber Cement. The first chalk was dug by hand and transported by bucket conveyor to the works and the clay was excavated from behind the works and transported on a narrow gauge railway system. The works was commissioned by three German engineers, who were called home due to the outbreak of World War II before their work was completed.
Rugby Portland Cement Co.Ltd bought out Eastwoods Humber Cement in 1962 and installed a new kiln and conveyor. There are now two kilns in operations at South Ferriby: Numbers 2 and 3. The original kiln Number 1 was sold to a company in Jamaica following the works' first major plant upgrade in 1968.
Increasing the use of alternative fuels as part-replacement for fossil fuels to heat the cement kilns is key to improving environmental performance at the plant. Secondary liquid fuels (SLF) have been used successfully since 2002. SLF is made from industrial liquid wastes that can't be recycled, such as paint, thinners, inks and varnishes, which are blended to a strict specification, that smells a bit like paint and looks like engine oil.
In March 2007 the plant completed the trial of a further alternative fuel, Climafuel, which is made from household waste and could substantially reduce the amount of waste that goes to landfill. Early results from the 1,000 hour trial suggest that emissions, such as acid rain gases and other key emissions have been significantly reduced.
Based on data from the trial, CEMEX is submitting a comprehensive report to the cement industry regulator, the Environment Agency, to demonstrate that the critical success factors agreed at the outset of the trial have been met, in the hope that the plant will be given the permission to use Climafuel permanently.