Portland Cement assoCiation sUstainaBle...

Portland Cement assoCiation sUstainaBle manUFaCtUrinG

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Preserving OurWorld

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denvironmental sPiritin 2000, the Portland Cement association launched a program to foster continuous environmental improvement in the U.S. cement industry. One element of the program is to recognize individual facilities that have shown a commitment to continuous environmental and energy efficiency improvement.

PCA and Cement Americas magazine presented the first cement industry awards in 2002 to the winners for 2001. The awards program is open to any cement manufacturing plant in Canada, the United States, and Mexico. The awards honor activities conducted during the previous calendar year.

Since its inception, the program has relied on judges representing diverse groups within and outside the industry, including the U.S. Environmental Protection Agency; the United States Geological Survey; the National Stone, Sand and Gravel Association; the Cement Association of Canada; Cement Americas magazine; and the World Resources Institute.

Judges for the 2009 awards represent Cement Americas magazine, the Cement Association of Canada, the U.S. Geological Survey, the U.S. Environmental Protection Agency’s Cement Sector Program, the U.S. Environmental Protection Agency’s Energy Star Program, and the National Stone, Sand and Gravel Association.

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PCa enerGy & environment awards 2009

volUntary Code oF CondUCtTo transform its commitment to sustainable devel-opment into consistent, tangible actions, PCA has developed the Cement Manufacturing Sustainability (CMS) Program. The goal of the program is to balance society’s need for cement products with stewardship of the air, land, and water, conservation of energy and natural resources, and maintenance of safe work places and communities. The centerpiece of the CMS Program is a voluntary code of conduct, which is a set of principles, performance measures, and a reporting protocol, designed to guide decision making, business practices, and operating performance in a sustainable fashion.

The PCA Board of Directors in 1991 adopted seven principles that call on member companies in the U.S. to meet market demands while using environmentally responsible practices that minimize emissions, waste, energy consumption, and the use of raw materials. Taken together, these principles help U.S. manufac-turers to integrate the economic, social, and environ-mental dimensions of cement manufacturing, and to find a balance between short-term priorities and long-term needs.

1. The safety and health of our employees, our neigh-bors, and our customers is our first consideration in the production and distribution of a quality product.

Portland Cement manUFaCtUrinG is a FoUr-steP ProCess:1. Raw materials, including limestone and small

amounts of sand and clay, come from quarries usually located near the cement manufacturing plant. Limestone is typically about 80% of the raw mix and is the source of calcium. The remaining raw materials provide silica and the necessary small amounts of alumina and iron.

2. The materials are carefully analyzed, precisely combined and blended, and then ground for further processing.

3. The ground materials are heated in an industrial furnace, called a kiln; kilns are a rotating vessel ranging in length from 60 to more than 200 meters (200 to >650 feet) long with a diameter rang-ing from 3 to 7.5 meters (10 to 25 feet). The kiln reaches temperatures of 1,450° C (2,650° F). The heat causes the materials to turn into a new marble-sized substance called clinker. The kiln flame is fueled by powdered coal, powdered petroleum coke, natural gas, oil, and/or recycled materials burned for energy recovery.

4. Red-hot clinker is cooled and ground with a small amount of gypsum. The end-result is a fine powder called portland cement. At each stage, process data are continuously monitored to produce a high-quality product, improve energy efficiency, and minimize emissions.

Cement or Concrete? The terms cement and concrete are often misused. Cement is an ingredient of concrete. It is the fine powder that, when mixed with water, sand, and gravel or crushed stone, forms the rock-like mass known as concrete. Cement acts as the binding agent or glue in concrete.

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2. We will continue to implement effective controls, which reduce or eliminate the release of pollutants to the air, to the land, and/or to the water.

3. We will actively seek ways to manage wastes in a responsible and environmentally sound manner.

4. We will pursue effective improvements in energy efficiency and promote the conservation of re-sources.

5. We will seek ways to beneficially and safely utilize recyclable wastes as raw materials, fuels, and prod-uct components as part of our overall commitment to waste minimization and recycling.

6. We will continue to conduct mining operations in a responsible and environmentally sound manner.

7. We will participate with lawmakers, regulators, and other interested parties in the development of ratio-nal and effective health, safety, and environmental laws and regulations.

environmental PerFormanCe measUresThe Environmental Performance Measures translate the Cement Manufacturing Sustainability Program Principles into action. A long-term reduction target is identified for each key performance measure and then progress toward that target is measured against a baseline. Currently there are four goals approved by the PCA members:

Carbon Dioxide (CO2)—The U.S. cement industry has adopted a year 2020 voluntary target of reducing CO2 emissions by 10% (from a 1990 baseline) per ton of cementitious product produced or sold.

Cement Kiln Dust (CKD)—The U.S. cement industry has adopted a year 2020 voluntary target of a 60% reduction (from a 1990 baseline) in the amount of CKD landfilled per ton of clinker produced.

Environmental Management Systems (EMS)—The U.S. cement industry has adopted a year 2006 voluntary target of at least 40% of U.S. cement plants having implemented an auditable and verifiable EMS with 75% of the U.S. plants implementing an EMS by the end of 2010, and with 90% by the end of 2020.

Energy Efficiency—The U.S. cement industry has adopted a year 2020 voluntary target of 20% improvement (from 1990 baseline) energy efficien-cy—as measured by total Btu-equivalent per unit of cementitious product.

With these ambitious goals, cement manufacturers will reduce their environmental impact and energy burden. Additional energy and environmental benefits will be realized by the use of concrete in the construc-tion of buildings and pavements. Portland cement concrete is a durable product that can provide years of benefits.


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environmental PerFormanCewinner:

Holcim (Us) inc., Holly Hill, south Carolina

The Holcim Holly Hill facility completed several notable projects in 2008 which improved their environmental performance in emissions and energy consumption. The plant was able to reduce the amount of cement kiln dust by 44% compared to 2007 through better analysis of the raw meal. The specific heat consumption was reduced by 5% compared to previous year by dust management and kiln optimization projects. By using alternative raw materials and fuels to replace 32% of its fuel use, the plant reduced its carbon dioxide to clinker ratio to 87.9% last year. One 2008 project which will also impact carbon dioxide emissions in the future is the use of clinker cooler off gases to dry marl for the finish mill.

This category honors facilities that go beyond laws, permits, and regu-lations to minimize their impact on the environment.

runner Up:

lafarge north america inc. Bath, Ontario

Finalists:

lafarge north america inc. Alpena, Michigan

titan america llC / roanoke Cement Company Troutville, Virginia

By using alternative raw materials and fuels to replace 32% of its fuel use, the plant reduced its carbon dioxide to clinker ratio to 87.9% last year.

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innovationwinner:

Buzzi Unicem Usa inc., Greencastle, indiana

The Greencastle Buzzi Unicem USA facility has found an innovative means to address a portion of its energy needs. It is the only cement plant in the U.S. utilizing spent pot liner (SPL) as an alternative fuel source. SPL, a waste product generated by the aluminum industry, traditionally has been sent to landfills. The Greencastle plant devel-oped a dedicated storage, handling, and injection system for off-site processed pot liner. In addition to recognizing a modest replacement of coal when using the byproduct, SPL’s raw material constituents also allow for modest replacement of raw materials such as sand and shale. Based on the success of the SPL project, Buzzi is exploring the possibility of incorporating additional hard-to-handle waste materials from other industries.

This category recognizes the development and

application of innovative technologies relevant to

environmental protec-tion or energy efficiency.

runner Up:

CalPortland Cement Company

Mojave, California

Finalists:

ash Grove Cement Company

Midlothian, Texas

lafarge north america inc.

Bath, Ontario

The plant uses a byproduct

from aluminum manufacturing as

a raw material.


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oUtreaCHwinner:

Holcim (Us) inc., theodore, alabama

The Holcim Theodore facility personnel participate in numerous environmental outreach activities each year. For the 2008 Annual Alabama Coastal Cleanup Day, the company’s safety and environmental managers solicited volunteers, gathered supplies, arranged dumpsters, and organized a thank-you meal. During the Cleanup, more than 3000 pounds of debris were collected by the 71 volunteers. Theodore staff also participated in the Derelict Crab Trap Removal Day to collect abandoned traps from Mobile Bay, removing 356 derelict traps from the bay, the facility joined Keep Mobile Beautiful and Waste Management in its electronics recycling days for the residents of Mobile County. Additionally, the plant has a Community Advisory Committee made up of neighborhood residents and also participates in the South Mobile Industrial Association to discuss environmental, safety, and other manufacturing issues among the local businesses and residents.

This category honors activities that enhance community, employee, and government relations.

runner Up:


Finalists:


mitsubishi Cement Corporation Lucerne Valley, California

During the Annual Alabama Coastal Cleanup Day, more than 3000 pounds of debris were collected by the 71 volunteers.

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enerGy eFFiCienCywinner:

CalPortland Cement Company mojave, California

The CalPortland Cement Company Mojave plant has an efficiency program that has resulted in major energy reductions, saved thousands of dollars, and prevented the emission of tens of thousands of tons of carbon dioxide. In 2008, eight 3-megawatt wind turbines were installed at the plant. Also, 2008 energy audits found numerous energy saving opportunities, and several larger projects were completed such as modi-fications to the compressed air system, raw mill, raw material analyzer, and finish mill. Unlike many alternative energy sources, the Mojave facility must use all produced energy on-site, which resulted in the plant changing operations to maximize the use of the electricity.

This category focuses on energy planning,

applications of efficient technologies and practic-

es, and climate change mitigation efforts.

runner Up:

titan america llC / roanoke Cement

Company Troutville, Virginia

Finalist:

salt river materials Group / Phoenix Cement

Company Clarkdale, Arizona

In 2008, the plant installed eight 3-mega-

watt wind turbines.


land stewardsHiPwinner:

CemeX, Knoxville, tennessee

In 2008, the CEMEX Knoxville plant worked with the National Resources Conservation Service, schools, and other organizations to improve wildlife habitats on their property. Two areas were selected and planted with wildlife supportive plants to attract white-tailed deer and various birds. The facility-owned nine-acre Cabbage Island in the Holston River has been preserved and dedicated as a wildlife habitat. Students from the University of Tennessee have studied the island and found more than 30 avian species (including bald eagle) and 16 mammalian species. A local high school assisted in building nesting boxes to foster more birds on the island.

This category recognizes efforts to protect and enhance the surrounding land and wildlife.

runner Up:

CemeX Demopolis, Alabama

Finalists:

CemeX Xenia, Ohio


The facility-owned nine-acre Cabbage

Island in the Holston River has

been preserved and dedicated as a

wildlife habitat.

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overall environmental eXCellenCewinner:

titan america llC / roanoke Cement Company, troutville, virginia

The Roanoke Cement Company has comprehensive environmental and energy programs. Particulate collection systems have been improved, cement kiln dust has been reduced, and any produced dust is used in the cement-making process or other alternative uses. The plant assist-ed local communities in determining their carbon footprint, participated in a creek cleanup, and maintained an access point to the Application Trail for hikers and backpackers. From various audits and equipment changes, energy consumption has been reduced by 3.8 million kwh in 2008. The company is the largest corporate sponsor to a local energy and environmental organization, which has educated the local commu-nity and provided compact fluorescent light bulbs to residents.

This award recognizes a facility that demonstrates

excellence in multiple categories.

runners Up:



Finalist:

CemeX Knoxville, Tennessee

From various audits and equipment

changes, energy

consumption has been

reduced by 3.8 million

kwh in 2008.

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d 2009 enerGy and environment award nominees:

ash Grove Cement Company, Chanute, Kansas

ash Grove Cement Company, louisville, nebraska

ash Grove Cement Company, midlothian, texas

ash Grove Cement Company, overland Park, Kansas

Buzzi Unicem Usa inc., Greencastle, indiana

CalPortland Cement Company, mojave, California

CemeX, Knoxville, tennessee

CemeX, lyons, Colorado

CemeX, odessa, texas

CemeX, wampum, Pennsylvania

CemeX, demopolis, alabama

CemeX, victorville, California

CemeX, Xenia, ohio

GCC of america, Pueblo, Colorado

Holcim (Us) inc., Holly Hill, south Carolina

Holcim (Us) inc., theodore, alabama

Holcim (Us) inc., ada, oklahoma

lafarge north america inc., alpena, michigan

lafarge north america inc., Bath, ontario

lehigh inland Cement limited, edmonton, aberta

mitsubishi Cement Corporation, lucerne valley, California

salt river materials Group / Phoenix Cement Company, Clarkdale, arizona

st. mary’s Cement inc. (Canada), Bowmanville, ontario

titan america llC / roanoke Cement Company, troutville, virginia

texas industries inc., oro Grande, California

Printed on recycled paper with 25% post-consumer waste

5420 Old Orchard Road Skokie, Illinois 60077-1083 847.966.6200 Fax 847.966.9781

500 New Jersey Avenue, NW, 7th Floor Washington, DC 20001-2055 202.408.9494 Fax 202.408.0877

www.cement.org

0023-09-200

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