[Report] "Prioritizing Communication and Safety"... Ireland Briden Cement Plant

[Cement Industry, Looking 30 Years Ahead]
② Ireland Briden Kinnegard Plant
Alternative Fuels, Steady Persuasion of Local Communities and Groups
Strict Quality Control and External Environmental Audits

Editor's NoteThe cement manufacturing industry plays a crucial role in the construction sector. However, it is also a major contributor to global greenhouse gas emissions, accounting for 7% worldwide. With the government setting a goal to achieve carbon neutrality (Net Zero) by 2050, the domestic cement industry must tackle the dual challenges of reducing greenhouse gas emissions and improving performance. Additionally, the industry faces complex conflicts. Environmental groups opposing the use of alternative fuels such as waste, labeling the resulting cement as 'waste cement,' are causing obstacles, while disputes with incinerator companies over waste disposal methods continue. Although investing in eco-friendly facilities requires enormous costs, the ready-mixed concrete (Remicon) industry strongly opposes cement price increases, and a delivery price linkage system will be implemented starting this October. To examine the eco-friendly cement production sites and ESG (Environmental, Social, and Governance) management strategies in Europe, which is about 30 years ahead of Korea, a site visit was conducted from the 20th to the 27th in collaboration with the Korea Cement Association.

Briden Cement Plant in Kinnegad, Ireland.

"Blast in 30 seconds. Three, two, one... Boom!"

The tour of the Breedon cement plant in Ireland began with the blasting of a limestone quarry. This scene is rarely shown to the public in Korea due to safety concerns. Developed since 2002, this quarry spans 400 acres (approximately 1,600㎡). The blast on this day allowed for the extraction of about 6 tons of limestone. Blasting occurs about three to four times a month.

A plant official said, "After conducting a preliminary risk assessment, we determined there were no issues and decided to make this public." He added, "Employee safety is a key pillar of our company management, and thorough pre-education is conducted." The facility is continuously being upgraded to ensure the safety of quarry workers. Most of the employees working here have been with the company for over 20 years since the quarry development began.

The Breedon plant visited on the 23rd is located in Kinnegad, west of Dublin, the capital of Ireland. Situated in the middle of vast forests and fields, the plant is about 2 km away from residential areas. Its annual production is 500,000 tons, with a maximum capacity of around 700,000 tons. Since 2006, the plant has been using alternative fuels instead of bituminous coal, and currently, 77% of the fuel used is alternative fuel.

The press group felt the intense heat near the kiln where the cement semi-finished product 'clinker,' shaped like black stones, is produced, then entered the building to inspect the central control center. Here, the entire process from the quarry to the kiln and cement packaging line can be monitored in real time. Inside the kiln, massive flames were rising, and a display showed that alternative fuels currently account for 88% of usage.

Does the Breedon plant face difficulties in securing waste materials? A plant official said, "In the past, we exported waste, but now we do not export and balance supply and demand domestically." Strict quality control is also applied to alternative fuels to achieve thermal efficiency similar to bituminous coal. Tom McManus, the Sustainability Manager at Breedon Kinnegad plant, explained, "We have obtained six environmental certifications while using alternative fuels," adding, "As the use of alternative fuels increases, more certifications are required." Strict environmental standards are set, and independent external organizations audit compliance.

The central control center where the cement production process of the Briden factory can be seen at a glance.

The Breedon plant was able to increase the use of alternative fuels through active communication and win-win cooperation. Tom McManus said, "Our company values three relationships. The first is with the local community. The second is with environmental groups, and the third is with our employees. Since it is important to help them understand what we do, we share information in advance when starting projects." They built trust by holding meetings with local residents to show the process and sharing extensive information through their website.

Declan Carr, the plant manager, said, "Every cement company has its own challenges. It is difficult to convince everyone," but added, "The only way is to explain that using alternative fuels is the best path for the country and society."

Like the German case seen earlier, the Breedon plant also believes that cement price increases are inevitable. Declan Carr said, "The cost of achieving Net Zero is so high that a cement price increase is unavoidable," adding, "Currently, the price is 130 euros per ton, but we believe it needs to be doubled."

However, in Korea, it is not easy to raise cement prices. More than 90% of cement is sold to the ready-mixed concrete (Remicon) related industry, which consists mainly of small and medium-sized enterprises, making it difficult to get them to accept price increases. The delivery price linkage system, which will be implemented from October, is expected to be a variable factor in cement price increases.

The delivery price linkage system refers to a system that includes provisions to adjust delivery prices when raw material prices fluctuate in contracts between companies. The system is expected to apply to contracts between Remicon companies (small and medium-sized entrusted companies) for which cement accounts for more than 10% of delivery costs and construction companies (large entrusting companies). The Remicon industry reportedly insists that cement companies should also participate in the linkage system.