Production restarts at Cemex South Ferriby cement plant after flooding

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UK: Production has restarted at the Cemex UK South Ferriby cement plant following flooding in December 2013. One of the two cement kilns has been commissioned and is producing clinker.

"Rebuilding the plant in 12 months has been no mean feat and I am immensely proud of what we have achieved. The refurbished plant will allow us to continue our heritage of producing quality cement, sustainably, safely and efficiently, now and for many years to come," said Philip Baynes-Clarke, plant director. "South Ferriby plant had grown organically through the site for the last 80 years, the flood gave us the opportunity to rebuild it in a logical way to today's standards with tomorrow's production in mind."

The flood cut off the 11,000 volt electric supply and destroyed 30 switch rooms and two substations. Today over 6.4km of high voltage cable has been laid to create a new infrastructure of cables to supply the various operations throughout the site. These cables lead to one electrical substation, which houses modern electrical switchgear. In addition 30 switchrooms have been rebuilt along with the vast majority of the site's electrical systems. Other efficiencies such as LED lighting have been built in to the systems to provide savings in electricity.

With the failure of the electric supply when the flood hit, one of the kilns stopped in mid-production with hot material still in it. This caused the kiln shell to bend due to the high thermal load. Subsequently a 22m section of the 65m long kiln was replaced. All elements of the cement production process are now controlled from a centralised computer. This new control system replaces five control rooms, which are all marked for demolition in the coming months.

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