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: 5/1938 to 4/2020
Approximate total clinker production: 28 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 2020: 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. During the COVID-19 downturn, the plant was shut down on 17/7/2020.
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.
Power Supply
The plant was entirely electrically powered from the grid from the outset.
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: 30/5/1938-30/09/1967
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: "Solo" kiln with integral cooler section
Cooler profile: ?
Fuel: Coal
Coal mill: ?
Typical Output: 354 t/d
Typical Heat Consumption: 7.72 MJ/kg
Kiln A2
Supplier: Polysius
Operated: 10/1967 to 2009q1 and 2012q1 to 3/2019
Process: Lepol: 27.7×3.91 m grate
Location: hot end 497221,421007: cold end 497212,420948: totally enclosed
Dimensions: Metric 60.00 × 3.916BC / 4.352D(1)
Rotation (viewed from firing end): anticlockwise
Slope: 3.5% (2.00°)
Speed: 0.6-1.5 rpm
Drive: ?kW
Kiln profile: 0×3520: 911×3520: 1811×3916: 49036×3916: 52311×4352: 59011×4352: 59620×3640: 60000×3640: Tyres at 5000, 27500, 48000: Turning gear 45000
Cooler: Recupol P2019 grate(1)
Fuel: coal; from 1981 up to 85% replaced with petcoke; supplemented by liquid wastes from 2002 and by solid refuse from 2006.
Coal mill: Polysius air-swept ball mill
Exhaust: via ID fan then precipitator to stack
Typical Output: 1967-1979 1041 t/d: 1979-1992 975 t/d: 1993-2020 1060 t/d
Typical Heat Consumption: 1967-1979 3.92 MJ/kg: 1979-1992 3.96 MJ/kg: 1993-2020 3.70 MJ/kg
Kiln A3
Supplier: FLS
Operated: 1978 to 13/4/2020
Process: Lepol: 27.7×3.91 m grate
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: 3.5% (2.00°)
Speed: 0.6-1.5 rpm
Drive: ?kW
Kiln profile (cut down form): 0×3520: ?×3750: ?×4150: 49036×4150: ?×4400: ?×4400: 55580×3640: 56200×3640: Tyres at 4500, 23500, 47000: Turning gear ?
Cooler: Unax planetary: 10 tubes: later grate: details ?
Fuel: as A2
Coal mill: Polysius air-swept ball mill
Exhaust: via ID fan then precipitator to stack
Typical Output: 1978-1992 1008 t/d: 1993-2020 1150 t/d
Typical Heat Consumption: 3.76 MJ/kg
References:
- (1) Jackson p 299
Sources: