Don Valley Engineering Limited

The Breedon Cement Alternative Raw Materials (ARM) Project demonstrates a major step toward sustainable cement production by integrating recycled materials into the process. By using Pulverised Fuel Ash (PFA), a by-product of coal fired power generation, and slate waste from roofing tile manufacture, the system ensures Breedon achieve maximum efficiency in utilising site-won materials while maintaining cement strength and durability. All materials are delivered by rail, significantly reducing local road traffic and emissions. Don Valley Engineering designed and delivered a complex materials handling system at Hope Cement Works, overcoming significant site challenges such as restricted space, buried services, rail infrastructure, and proximity to high-voltage substations all without negatively affecting production or major maintenance activities. The solution included a rail unloading facility, conveyors, and blending hoppers designed to handle the very different properties of PFA and slate. Matching appropriate technology to the required duties ensured consistent flow and reliable blending. The ARM Project sets a benchmark for cement manufacturing through collaboration, engineering innovation, and environmental responsibility.