CEMEX used nearly one million tires to replace 10 percent of its conventional kiln fuel last year at its Lousville, Kentucky plant, one of several initiatives that won it overall environmental excellence honors at the 11th annual Cement Industry Environment and Energy Awards.
The CEMEX facility was among four cement plants that received special recognition for implementing environmental and energy efficiency improvements that went beyond government regulations and local laws. The awards were presented by the Portland Cement Association and Cement Americas magazine at PCA’s spring meeting in Chicago.
CEMEX’s Lousville, Kentucky plant made a series of improvements last year including modifying its preheater tower to improve capture efficiency and reduce the heat required to preheat raw material.
The company reduced maintenance costs and decreased energy consumption by replacing the plant’s traditional pug mill with a common material handling screw known as a pug screw—an improvement that won it a separate innovation award. The pug screw installation yielded an estimated annual savings of nearly $196,000, reduced maintenance and parts consumption by 70 percent and saved about 620,000 kilowatts per hour of energy, an 80 percent reduction in power use.
The CEMEX facility also was presented with an energy efficiency award for improving its processes through regular assessments that help it identify areas for energy efficiency at the plant. As a result, the plant has been awarded the Industrial Plant Energy Star Certifications five years in a row by the Department of Energy and EPA.
Holcim’s Theodore, Alaska cement plant replaced more than 25,000 tons of traditional fossil fuel with alternatives such as tires, wood chips, plastic by-products and used oil absorbent materials from the 2010 BP oil spill in the Gulf of Mexico. The company plant received an environmental performance award for its use of alternative fuels and its emissions monitoring and reporting program. The plant voluntarily installed continuous emissions monitoring units for sulfur dioxides, carbon monoxide and total hydrocarbons.
Titan America LLC/Roanoke Cement Company received an outreach award for several local initiatives by its Troutville, Virginia plant including visits from local Cub Scouts and high school physics students. Plant employees participated in creek clean-up activities for the sixth consecutive year.
The plant also was credited for reaching out to neighbors through letters, brochures and meetings in regards to a proposed quarry expansion and on-site mitigation, steps that led to scores of residents supporting the plan.