Hope

Location:

Clinker manufacture operational: 1929 to date

Approximate total clinker production to 2015: 68 million tonnes (1st)

Raw materials:

Ownership:

After 29 years of Blue Circle’s existence, Hope was its first UK green-field site. The next was Cauldon, 28 years later. The plant seems to have been planned as early as 1910, but plans were disrupted by WWI and the ensuing volatile economy. The site has raw materials perfect for dry process, but, installed at a time when the reputation of dry process was at its lowest ebb, wet processing was adopted. Uniquely among plants at the time, Hope was prohibited from discarding kiln dust from the outset, and recycled all its wet process dust in A1 and A2 slurry feeds. The plant became Blue Circle’s largest following installation of A5 in 1953 until 1962 when it was overtaken by Cauldon. The planning of the kiln A5 expansion caused a furore during 1949-1952, not because of the capacity expansion, but because of the accompanying new 120 m stack, although the existing plant, with no dust fitration, was already very prominent in the National Park landscape. Electrostatic precipitators were fitted to the existing kilns as part of the project, and dust emissions were dramatically reduced. The existing site became very cramped with the expansion, and when further expansion was called for, it was obvious that a new kiln area should be used. By that time, sufficient confidence had been gained in the Plymstock kilns to install two large KHD suspension preheater kilns. This became part of the major rationalization of Blue Circle’s capacity that also involved the construction of Northfleet, and accordingly the plant was nearly doubled in size. Kilns B1 and B2 ran neck-and-neck with the Northfleet kilns as the largest until they were overtaken by Platin A2 in 1977.

The plant had from the outset a purpose-built 3 km spur from the main Manchester-Sheffield railway, and this allowed easy transport into Earle’s depot network throughout the North. More recently, because the nearby Cauldon lacks rail, Lafarge considerably up-rated Hope’s rail facilities so that it could serve the longer-distance market with Cauldon covering the immediate area.

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

Seven rotary kilns were installed in five stages:

Kiln A1

Supplier: FLS
Operated: 15/11/1929 to 25/05/1970
Process: Wet
Location: Hot end 416733,382198: Cold end 416665,382152: entirely enclosed
Dimensions (from cooler ports): Metric:

Rotation (viewed from firing end): anti-clockwise
Slope: 1/25 (2.292°)
Speed: ?
Drive: ?
Kiln profile (from cooler ports):

Cooler: Unax planetary 12 × 4.85 × 1.060
Fuel: Coal
Coal mill: semi-indirect: ball mill
Exhaust: via ID fan direct to stack: an electrostatic precipitator was put in after the ID fan in 1953.
Typical Output: 1929-1941 266 t/d: 1941-1946 260 t/d: 1946-1958 275 t/d: 1959-1970 258 t/d
Typical Heat Consumption: 1929-1937 6.43 MJ/kg: 1937-1942 7.04 MJ/kg: 1943-1954 7.39 MJ/kg: 1955-1970 7.85 MJ/kg


Kiln A2

Operated: 25/11/1929 to 25/05/1970
Location: Hot end 416738,382191: Cold end 416671,382144: entirely enclosed
Dimensions (from cooler ports): Metric:

Kiln profile (from cooler ports):

Typical Output: 1929-1941 264 t/d: 1941-1946 260 t/d: 1946-1958 278 t/d: 1959-1970 255 t/d
Typical Heat Consumption: 1929-1937 6.57 MJ/kg: 1937-1942 7.21 MJ/kg: 1943-1954 7.49 MJ/kg: 1955-1970 7.86 MJ/kg
Identical in all other respects to A1

Kiln A3

Supplier: Vickers Armstrong
Operated: 23/04/1935 to 31/05/1970
Process: Wet
Location: Hot end 416747,382186: Cold end 416675,382137: entirely enclosed
Dimensions (from cooler ports):

Rotation (viewed from firing end): ?
Slope: ?
Speed: ?
Drive: ?
Kiln profile (from cooler ports):

Cooler: Reflex “Recuperator” planetary 12 × 13’6⅜”×4’0” (metric 4.12 × 1.207)
Fuel: Coal
Coal mill: semi-indirect: ball mill
Exhaust: via ID fan direct to stack: an electrostatic precipitator was put in after the ID fan in 1953.
Typical Output: 1935-1951 315 t/d: 1952-1970 326 t/d
Typical Heat Consumption: 1935-1961 7.27 MJ/kg: 1962-1970 7.63 MJ/kg


Kiln A4

Supplier: Vickers Armstrong
Operated: 1938 to 31/05/1970
Process: Wet
Location: Hot end 416752,382179: Cold end 416681,382130: entirely enclosed
Dimensions (from cooler ports):

Rotation (viewed from firing end): ?
Slope: ?
Speed: ?
Drive: ?
Kiln profile (from cooler ports):

Cooler: Reflex “Recuperator” planetary 12 × 14’6⅜”×4’0” (metric 4.43 × 1.207)
Fuel: Coal
Coal mill: indirect: Rema closed circuit ball mill
Exhaust: via ID fan direct to stack: an electrostatic precipitator was put in after the ID fan in 1953.
Typical Output: 1938-1944 341 t/d: 1944-1950 334 t/d: 1950-1957 339 t/d: 1958-1963 333 t/d: 1964-1970 339 t/d
Typical Heat Consumption: 1938-1962 7.40 MJ/kg: 1962-1970 7.79 MJ/kg


Kiln A5

Supplier: Vickers Armstrong
Operated: 4/1953 to 30/05/1970
Process: Wet
Location: Hot end 416731,382209: Cold end 416646,382150: a short part of the hot end was enclosed
Dimensions (from cooler ports): 338’10½”× 11’6”B / 10’0¼”CD (metric 103.29×3.505B/3.054CD)
Rotation (viewed from firing end): ?
Slope: 1/24 (2.388°)
Speed: ?
Drive: ?
Kiln profile (from cooler ports): -610×3353: 1422×3353: 4089×3505: 29794×3505: 32461×3054: 101765×3054: 102375×2121: 103289×2121: tyres at 6960, 22860, 39929, 59436, 78943, 98450: turning gear at 42748
Cooler: Reflex “Recuperator” planetary 12 × 14’6⅛”×4’0” (metric 4.42 × 1.207)
Fuel: Coal
Coal mill: direct: two Atritors
Exhaust: ID fan followed by electrostatic precipitator.
Typical Output: 1953-1961 426 t/d: 1962-1970 430 t/d
Typical Heat Consumption: 1953-1961 7.33 MJ/kg: 1962-1970 7.62 MJ/kg


Kiln B1

Supplier: kiln by Polysius: preheater by KHD
Operated: 01/04/1970 to date
Process: suspension preheater: details✄
Location: hot end 416587,382400: cold end 416532,382443: unenclosed
Dimensions: Metric 70.00 × 4.770(1)
Rotation (viewed from firing end): anticlockwise
Slope: ?
Speed: 0.284-1.7 rpm(1)
Drive: 330 kW(1)
Kiln profile: ✄
Cooler: grate: details✄
Fuel: ✄
Coal mill: ✄
Exhaust: ✄
Typical Output: ✄
Typical Heat Consumption: ✄


Kiln B2

Operated: 22/05/1970 to date
Location: hot end 416596,382411: cold end 416541,382454: unenclosed
Rotation (viewed from firing end): clockwise
Typical Output: ✄
Typical Heat Consumption: ✄
Identical in all other respects to B1


References:

>Sources: Jackson, pp 228, 282: Pugh, pp 155-156, 174: Circle 4 (1979) pp 13-18: “The New Hope Cement Works of Messrs. G. & T. Earle, Ltd.”, Cement and Cement Manufacture, 3, Jan 1930, pp 55-68: Earle's Cement Works at Hope, Blue Circle Publicity Department, 1930: "New kilns for Hope cement works", Cement Technology, 2, 1971, pp 65-66: "New extensions to Hope cement works", Cement Technology, 2, 1971, pp 187-192.