Cement Kilns

South Ferriby

Location:

  • Grid reference: SE97242096
  • x=497240
  • y=420960
  • 53°40'34"N; 0°31'41"W
  • Civil Parish: Winteringham, Lindsey: the raw material store, packing plant and quarry are in South Ferriby, Lindsey

Clinker manufacture operational: 6/1938 to date

Approximate total clinker production to 2015: 25 million tonnes (14th)

Raw materials: Quarry at 499500,420300 supplying crushed raw materials to the plant: initially quarried to the top of the Red Chalk and the chalk conveyed by ropeway: from 1974, the quarry was extended down into the underlying clay, and chalk and clay conveyed separately to the plant by 1.75 km belt. The Red Chalk and Carstone are side-cast. The quarry sequence (top to bottom) is:

  • Relatively flint-free, pure Upper Chalk (Burnham Chalk Formation: 85-90 Ma)
  • Flinty (but otherwise pure) Middle Chalk (Welton Chalk Formation: 90-94 Ma)
  • Slightly argillaceous Lower Chalk (Ferriby Chalk Formation: 94-97 Ma)
  • Red Chalk (Hunstanton Formation: 97-112 Ma) and Carstone
  • Kimmeridge Clay (Kimmeridge Clay Formation 151-156 Ma)
  • Corallian Clay (Ampthill Clay Formation 156-160 Ma)

Until 1974, boulder clay, alluvium and warp was supplied from 496900,420600, transferred to the plant by rail.

Ownership:

  • 1938-1962: Eastwoods Ltd
  • 1962-1979: Rugby Portland Cement Co. Ltd
  • 1979-2000: Rugby Group
  • February 2000 – March 2005: RMC
  • March 2005 to date: CEMEX

A1 was one of only three kilns ordered from Germany during the inter-war period (the others being Oxford B1 and B3). In addition to the existing rotary kiln, a shaft kiln was operated 1954-1966.

Kiln A2 was Rugby’s first efficient kiln venture: the hard, relatively dry chalk of the area is a reasonable raw material for dry processing. A2 was a close copy of the kilns already operated by Blue Circle at Weardale and Dunbar. A3, like Ketton A7, was an early example of a kiln with two tyres (apart from the cooler cold-end support), and unlike the latter, suffered major mechanical problems. It was modified to a more conventional design after 15 years. The plant made sulfate resisting clinker alongside ordinary clinker after this was phased out at Rugby and Rochester. The plant was damaged by floods in December 2013, and was out of action during most of 2014, during which time a major re-build was carried out.

The rawmills are located at the exhaust end of the kiln system, and no waste heat is available. Heat for raw material drying is provided by a coal fired furnace, with a typical heat usage of 0.47 MJ/kg.

The plant originally had a wharf on the river for shipping: there is no rail nearby. Post-war, the plant used road transport exclusively.

Please contact me with any relevant information or corrections. I am particularly interested in firmer dates and statistics.

Note: technical information on currently operational plants is ✄withheld in the public version of the site at present, except where already published (see references).

Rawmills

Wet rawmill: ?

One Polysius 1550 kW double-rotator mill for each Lepol kiln(1).

Three rotary kilns were installed:

Kiln A1

Supplier: Polysius
Operated: 6/1938-30/09/1967
Process: Wet, with Polysius slurry dryer.
Location: hot end 497292,421024: cold end 497283,420963: totally enclosed.
Dimensions: Metric 61.00 × 2.500
Rotation (viewed from firing end): ?
Slope: ?
Speed: ?
Drive: ?
Kiln profile: ?
Cooler: ?none
Cooler profile: ?
Fuel: Coal
Coal mill: ?
Typical Output: 200 t/d
Typical Heat Consumption: 8.7 MJ/kg
The output and heat consumption figures are from Jackson, and are all I have, but they are obviously seriously wrong. In fact I know almost nothing about this kiln.


Kiln A2

Supplier: Polysius
Operated: 10/1967 to 2009q1 and 2012q1 to date
Process: Lepol: details ✄
Location: hot end 497221,421007: cold end 497212,420948: totally enclosed
Dimensions: Metric 60.00 × 3.916BC / 4.351D(1)
Rotation (viewed from firing end): ?anticlockwise
Slope: ?
Speed: ?
Drive: ?
Kiln profile: ✄
Cooler: Recupol grate(1): details ✄
Fuel: ✄
Coal mill: Polysius ball mill: details ✄
Exhaust: via ID fan then precipitator to stack
Typical Output: ✄
Typical Heat Consumption: ✄


Kiln A3

Supplier: FLS
Operated: 1978 to date
Process: Lepol: details ✄
Location: hot end 497234,420991: cold end 497225,420936: totally enclosed
Dimensions, metric(1):

  • 1978-1993 (from cooler ports): 58.00 × 4.150BC / 4.400D
  • 1993 to date: 56.20 × 4.150BC / 4.400D

Rotation (viewed from firing end): anticlockwise
Slope: ?
Speed: ?
Drive: ?
Kiln profile: ✄
Cooler: Unax planetary: details ✄: later grate: details ✄
Fuel: ✄
Coal mill: Polysius ball mill: details ✄
Exhaust: via ID fan then precipitator to stack
Typical Output: ✄
Typical Heat Consumption: ✄



References:

  • (1) Jackson p 299

Sources: Cook, p 100: Jackson, pp 259, 299: see website.

© Dylan Moore 2011: commenced 16/01/2011: last edit 14/12/16.

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Old Maps

 DetailThis is a composite map containing details from different eras that may not have co-existed.

Approximate capacity: tonnes per year: ✄


 GeoScenicP213245©NERC1987
Picture: ©NERC 1987: British Geological Survey Cat. No. P213245. This shows the quarry viewed from the west in 1987. The quarry was extended down into the underlying Jurassic clays in 1974, at which point the alluvium quarries near the plant were abandoned. The chalk is divided into Welton Chalk above and Ferriby Chalk below, separated by a distinct thin black marl layer. The Ferriby Chalk corresponds to the Lower Chalk of Southern England, but here it is fairly pure calcium carbonate, with only a few thin marly bands towards the base.The Hunstanton Formation below consists of "Red Chalk" and a thin brown "Carstone" sandstone. This represents the Lower Cretaceous in condensed form, and is side-cast and forms the bank in the left foreground. The Jurassic clay represents part of the Kimmeridgian stage (150.8-155.7 million years old) above and the Oxfordian (155.7-161.2) below, the boundary roughly corresponding to the middle quarry bench. In England the Oxfordian is traditionally divided into Ampthill Clay above and Oxford Clay at the base. The Oxfordian here is Ampthill Clay. Both layers are highly carbonaceous, exuding greasy organics when ground. The organic matter can constitute 5-15% by mass. See Hull Geological Society report on quarry.