Six cement plants received recognition for their commitment to improving the environment and their communities at the Eighth Annual Cement Industry Environment and Energy Awards, presented by the Portland Cement Association (PCA) and Cement Americas magazine on April 28, 2009. The awards honor individual cement facilities that exemplify the spirit of continuous environmental improvement and support this spirit with action. Twentyfive cement plants in the U.S. and Canada were nominated for the awards. The winners in six categories were:

Overall Environmental Excellence-Titan America LLC/Roanoke Cement Company, Troutville, VA

A runner-up in the Energy Efficiency category and a finalist in the Environmental Performance category, the Roanoke Cement Company plant has initiated several programs to meet its goal to reduce, reclaim, and reuse wastes. It reuses 100% of its cement kiln dust (CKD) and is emptying its CKD landfill for use by local farmers. For the past 2 years, Roanoke Cement has received the U.S. EPA’s Energy Star® and in 2008 became an Energy Star partner. As an Energy Star partner, all Titan plants will submit to independent energy efficiency monitoring that includes establishing baselines and tracking the company’s energy performance. The plant and its employees also participate in several environmental community events including a creek cleanup.

Outreach-Holcim (US) Inc., Theodore, AL

The Holcim Theodore facility staff is involved with a number of community and environmental outreach activities each year. For the past several years, the plant has participated in the Annual Alabama Coastal Cleanup Day, part of a worldwide event to clean trash and debris from beaches, lakes, and streams. During the 2008 cleanup, Holcim-led volunteers collected more than 3000 lb (1360 kg) of debris from the Theodore Industrial Canal. In addition, the plant has a community advisory committee made up of neighborhood residents. This group helps Holcim maintain an open line of communication with the local community and engages stakeholders.

Environmental Performance Award-Holcim (US) Inc., Holly Hill, SC

In 2008, the Holcim facility completed several notable projects to improve their environmental performance in emissions and energy consumption. For example, the plant was able to reduce the amount of CKD by 44% compared to 2007 through better raw material analysis. The Holly Hill plant uses a significant amount of its generated waste material as an alternative fuel source, saving landfill space and fossil fuels. In 2008, alternative fuels supplied 32% of the fuel requirements for the plant.

Land Stewardship-CEMEX, Knoxville, TN

Plant representatives have joined with the National Resources Conservation Service (NRCS), local schools, and other organizations to improve wildlife habitats on their property. Working with University of Tennessee students, the 9 acre (3.6 ha) Cabbage Island in the Holston River has been preserved as a wildlife habitat. CEMEX also worked with the Wild Turkey Federation, NRCS, and Legacy Parks Foundation to locate 5.5 acres (2.2 ha) of wildlife food plots that improve nutrition for local wildlife.

Innovation-Buzzi Unicem USA, Greencastle, IN

This facility is the only cement plant in the U.S. using 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 developed 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. Buzzi Unicem USA is exploring the possibility of incorporating additional hard-to-handle waste materials from other industries.

Energy Efficiency-CalPortland, Mojave, CA

The plant’s efficiency program has resulted in major reductions in energy use and carbon dioxide emissions. In 2008, the plant completed a renewable wind project that represents the largest such program servicing a manufacturing facility in the world to date. Eight 3-megawatt wind turbines will generate 60 million kilowatts per year of renewable energy and supply approximately 35% of the plant’s annual electricity needs. This is the equivalent of powering more than 5000 homes for a year.

Source: American Concrete Institute Sep 2009