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Completion of modernisation at Lafarge Exshaw

Published by , Assistant Editor
World Cement,

Lafarge Canada Inc has announced the completion of major modernisation and environmental upgrades at its Exshaw site. Physical construction commenced in 2013, with over 600 contracted employees on site at construction peak, alongside 160 permanent employees, The team achieved a very strong safety record, hitting nearly three million hours without a lost time incident.

"It is an incredible achievement, completing a project of this scale. Completing it safely takes focus and energy and I applaud the team for its dedication to this goal," says René Thibault, President and CEO, Lafarge, Western Canada. "By all accounts we consider the project to be a success, cementing our long term commitment to Exshaw, Alberta and western Canada."

The modernisation project centered around significant kiln upgrades.

  • Shut down of kiln 4 in November 2015 
  • Invested $20 million in kiln 5 to meet new emissions targets by retiring less efficient gravel-bed filter technology. 
  • Constructed a new kiln 6 with a state-of-the-art baghouse to collect particulates, as well as a vertical raw mill, the EcoDome storage facility, a pre-heater tower and a vertical cement mill to complete the expansion.

The modernisation increased Lafarge’s production capacity from 1.3 million tpy to 2.2 million tpy. Technology upgrades led to a 60% reduction in sulfur dioxide emissions, a 40% reduction in NOX emissions and a significant reduction on fugitive dust and noise coming from the plant’s equipment. The Exshaw plant has also acchieved zero water discharge from its operations.

Plant Manager, Jim Bachmann comments, "I want to especially thank our neighbours in the Municipal District of Bighorn, and Bow Valley residents for their support throughout this project," he added. "Their patience through the construction period and feedback contributed to our success."

The economic impact of the Plant's increased production and GDP of Alberta is estimated at CAN$1.2 billion per year. Lafarge's investment of hundreds of millions of dollars in the expansion will provide long term, well-paying employment opportunities as well as construction material for Alberta's entire built environment.

Adapted from press release by

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