Blue Circle Aggregates: Taking Care of the Environment

Blue Circle Aggregates operates 11 stone and sand quarries in Georgia and Alabama, which produce more than 12 million tons of crushed stone and sand products each year. When selling sand and stone, price differences of pennies per ton can mean the difference in making or losing a sale. Keeping operating costs to a minimum, yet maintaining long-term ability to produce high quality products are the reasons that Blue Circle Aggregates is implementing an Environmental Management System (EMS) that meets the standards of ISO 14000.

Why Implement an EMS? -- A decision was made to implement an EMS for four primary reasons: a desire to improve the operational efficiency of their plants, concerns for the environment, tighter environmental regulations, and a decision by Blue Circle UK, the parent company, that all of their plants worldwide would implement an EMS by 2000. Various environmental initiatives and programs had been implemented throughout the company's history; ISO 14000 was chosen as the model because it allowed the design of an EMS that encompassed traditional environmental concerns, identified new opportunities, set improvement goals, and is recognized globally.

What is ISO 14000? - ISO 14000 is a generic, widely applicable standard that is used for designing and implementing a specific EMS at a manufacturing plant or corporate office. ISO 14000 tells you how to design an EMS, but does not prescribe specific actions or goals. It does require the facility to develop an EMS, measure performance, set goals, and periodically reevaluate progress to allow for continuous environmental improvement.

Significant Environmental Aspects -- Dust, water, noise, and waste generation are the four areas that Blue Circle considers to be the most significant environmental aspects of mining and manufacturing aggregate and sand. When designing their EMS, these four concerns received the most attention in developing programs and procedures to minimize their environmental effects.

• Dust - generated by blasting, crushing, material handling

• Wastewater - from stone washing and equipment cooling

• Stormwater - which collects in quarries

• Noise - generated from equipment and blasting

• Waste - anything that is not sold as a finished product (used conveyor belts, silt from washing stone, oil from vehicle maintenance, worn out equipment, cardboard, energy for powering conveyors, trucks, and crushers)

Collecting Data and Setting Goals -- The goal is to improve operational and environmental performance in these areas. In order to accurately assess environmental performance, data on dust generation, water use, wastewater volume and quality, noise generation, and waste generation was collected. This baseline information was necessary in order to determine how well the company is currently performing and to set goals for the future. Baseline data identifies those programs and practices specific to individual plants which work best so that they can be implemented at each quarry. Data of this nature also allows the tracking of waste costs associated with individual processes. Setting waste reduction goals of reducing energy use or finding a market for silt from stone washing can reduce operating costs and make the company more profitable. Some of the goals are compliance related, such as to maintain 100% compliance with wastewater and stormwater discharge permits. Another goal is to design blasting practices so that noise will not disturb nearby individuals and businesses. Goals such as these have measurable targets.

Involving People -- A major aspect of the EMS is to include employees and citizens living near quarries in the program's development. Citizens' involvement groups have been formed at each quarry so that their concerns can be communicated to and addressed by the company. Each employee is given a card stating the company's environmental management policy. All employees are trained in EMS practices and know the importance of following environmental procedures, the four significant environmental aspects (dust, water, noise, and waste), the rules of the EMS, and the consequences of not following the plan. Perhaps most important, employees are aware that an EMS exists and that the company is concerned about the environment.

Benefits -- Blue Circle has allowed P²AD and Georgia Tech to assist in pollution prevention assessments, which allows the company to benefit from the experience of P²AD engineers and P²AD to learn effective best management practices that can be transferred to other mining operations. One quarry has already been certified as a member of the Pollution Prevention Partners program and has realized cost savings of $97,000 annually as a result of pollution prevention projects. Two more quarries will be certified by 1999. Other benefits are just starting to be realized. Some of the projects resulting from the EMS are listed below. These projects have reduced waste, saved money, and have been implemented at some or all quarries.

• Pollution prevention projects to reduce electricity and water use

• Stormwater treatment pond improvements

• Electricity price reductions

• Dust suppression systems

• New fueling stations

• Recycling programs

Redesign is also taking place at some quarries to move the jaw crusher to the quarry floor which saves fuel and tires by eliminating the need to truck stone out of the pit.

It is important to note that no law or regulation requires a company to implement an EMS or to closely work with citizens and employees on environmental initiatives. Implementing an EMS is seen as a viable way to remain a responsive, cost-effective, quality-conscious company in an increasingly competitive environment. According to Joyceann Lee, Environmental Supervisor and EMS Document Control Administrator for Blue Circle, "Employees are much more aware of how the company's environmental policy pertains to their specific jobs. Employees are also taking more responsibility and developing great ways to make improvements." For more information, call Joyceann Lee at 770-797-2070.