BridgeGap Engineering Blog » General Cement

Titan Achieves Energy Star at Four Cement Terminals

Lehigh Ben — Mon, 16 Jan 2012 17:46:37 +0000

Titan America LLC, a heavy building materials producer in the United States, recently announced the fact that four of its distribution terminals have achieved the Environmental Protection Agency’s (EPA) ENERGY STAR Challenge for Industry. The four sites include: Castle Hayne, North Carolina; Richmond, Virginia; Front Royal, Virginia; and Chesapeake, Virginia.

The challenge is a call to action to improve energy efficiency of America’s commercial and industrial sites. To receive recognition from the EPA for completing the challenge, the parent company must be an ENERGY STAR partner and the site must achieve a minimum of 10% improvement in energy efficiency within five years. At each of the four sites, Titan has achieved this goal with an average intensity reduction of 21.76%. Management at the plant and corporate level recognize the amount of team effort necessary to achieve this reduction. Don Ingerson, VP of Cement and Aggregates, Sales and Marketing, said, “This achievement was the result of a supreme team effort. The focus on reducing energy by each and every one of our people at the terminals is an excellent example of our commitment to continuous improvement; with that, our energy management knowledge continues to grow as we share it with our customers and our community”.

Hopefully the ENERGY STAR challenge will continue to spur many industrial and commercial sites to improve energy efficiency and reduce our impact on the environment.

CO2 emissions a good thing?

Lehigh Ben — Fri, 06 Jan 2012 14:45:36 +0000

Among other emissions, Carbon dioxide is a headache for many cement producers. Finding the right balance between environmental-responsibility and financial-stability is difficult. For industrial plants shifting towards carbon capture and sequestration (CCS), economic performance suffers due to the high cost of installing and running the necessary equipment. However, a way of offsetting those costs is now in development at Sandia National Laboratories.

A new type of turbine, utilizing supercritical carbon dioxide (S-CO₂) instead of traditional steam, is being tested at Sandia. These turbines use the S-CO₂ compressed at 73 bar and at 33 °C and run on the Brayton Cycle (where steam turbines utilize the Rankine Cycle). The benefits of this new type of system lie in footprint in the plant along with initial investment. The use of the Brayton Cycle allows for a drastic reduction in turbine size. A 300 MWe S-CO2 turbine has an outside diameter of approximately 1 meter and needs only three stages of turbomachinery. The corresponding steam turbine would require a diameter of five meters with 22-30 stages of turbomachinery. This reduction in size translates to a decrease in the initial investment on the system.

Any plant that could employ this system successfully should see the device pay for itself over a short interval of time. Depending on the turbine size chosen, a plant could remove itself from the grid by generating all its own power needs and perhaps even sell power back to the utility companies. With the ever-changing technology, what was once a headache for the cement industry might turn out to be a godsend for the financial competitiveness.

Information gathered for this article appears in the January 2012 issue of Mechanical Engineering, the official magazine of ASME. The article was entitled, “Mighty Mite” and was authored by Steven Wright.

Possible Relief for Cement Sector?

Lehigh Ben — Thu, 18 Aug 2011 16:22:53 +0000

Is relief is on the horizon for the cement industry? Recently, two representatives introduced a bill titled “Cement Sector Regulatory Relief Act of 2011.” If passed, this legislation will require the Environmental Protection Agency (EPA) to re-propose three rules aimed at the portland cement industry. These rules were targeting the solid waste incineration initiatives started by many companies.

The president and CEO of the Portland Cement Association (PCA) Brian McCarthy said, “The bill introduced…by Reps. Sullivan and Ross will allow the industry to continue its dialogue with the EPA with the goal of crafting rational and feasible emission standards. We are not shying away from environmental regulations. We take our environmental stewardship seriously and have a long history of investing in continuous improvements that preserve U.S. manufacturing capacity and the economy.” If current regulations remain in place, approximately a fifth of domestic plants could be forced to close and cost the industry $3.4 billion over three years.

Lafarge Faces Resistance in Environmental Push in Tulsa

Lehigh Ben — Mon, 01 Aug 2011 19:45:52 +0000

A Lafarge plant near Tulsa, Oklahoma, is facing last minute resistance to the planned installation of a fuel quality waste (FQW) storage system. Tulsa city Councilman Roscoe Turner and environmental group LEAD (Local Environmental Action Demanded) have begun openly opposing the plant’s efforts.

Lafarge desires to install a series of tanks to utilize forty-eight million gallons of FQW per year. The FQW is industrial waste such as paint solvents that the company will gather and burn in its kiln to supplement and eventually eliminate the plant’s dependence on coal for a fuel source. In response to the outcry, plant manager Jim Bachmann said, “These are common household materials that you probably have under your sink or in your garage right now. There are trucks coming through Tulsa with it every day…This is nothing new and nothing dangerous. We know how to handle it.” Lafarge is promoting the move as a win-win for the company and for the environment. It eliminates fossil fuel consumption while offering a viable alternate solution to landfilling for industrial waste. However, LEAD has a serious issue with this new system.

LEAD claims that burning the FQW will increase plant emissions. They predict an increase of particulate matter emissions from 19.3 to 400 tons per year and hazardous air pollutants to increase from 16 to hundreds of tons per year. LEAD’s other main concern centers around how the plant will receive the FQW. They predict that approximately 30 tractor trailers will be traveling to the plant through Tulsa’s highways every day. They are concerned for the potential for accident and exposure to hazardous waste that the area surrounding the plant will incur. Hatley said, “Within a mile or two of this plant, you can find schools, parks, churches. This is not a remote location.”

LEAD’s petition for a hearing to the Oklahoma Department of Environmental Quality could mean the end of the Lafarge project. A hearing could lead to the revoking of Lafarge’s permits which allow them to install the system. If not revoked, Lafarge plans to begin operating the system within months.

Cap and Trade Arrives in Quebec

Lehigh Ben — Sun, 10 Jul 2011 22:39:45 +0000

Earlier this week, the government of Quebec announced its voluntary implementation of a cap and trade system that takes effect in 2012. Environment Minister Pierre Arcand announced the plan on Wednesday amid praise from environmentalist groups. Quebec is third in a series of Canadian provinces and American states to enact a regional system instead of waiting for national governments to pass a law. California and British Colombia have already passed their own systems, and it is Arcand’s hope that a North American regional carbon market will be established to buy and trade carbon credits.

Quebec has previously demonstrated its commitment to proper environmental stewardship through its introduction of the “carbon tax” on the transportation business sector. By 2008, Quebec managed to reduce emissions by 1.2% over 1990 levels despite its population growth of 11% over the same period.

The new system will be introduced in two phases to ease the burden on industry. 2012 will be a trial year where caps will be established on companies emitting over twenty-five thousand tonnes annually, but they will not be required to meet the cap for the first year. In 2013, however, companies that break their limit will face heavy fines as well as having their cap lowered for the following year. It is Quebec’s goal to reduce emissions by 20% compared to 1990 levels by the close of 2020. Minister Arcand, during a press conference, said, “The cap-and-trade system is recognized as one of the most effective and least expensive ways of reducing greenhouse gas emissions.” He does admit, though, that the price of certain consumer goods may rise slightly due to the enactment of this law.

The Cement Association of Canada (CAC) is showing reserved appreciation for the new legislation. The CAC is concerned that the regional law will have dire effects on the bottom line since neighboring provinces and states do not share similar legislation, but is grateful for the government’s two step introduction of the new restrictions. CAC President Michael McSweeney said, “We understand Quebec’s decision to develop a cap-and-trade system and, given the potentially significant competitive and economic impacts of the program on our industry, we appreciate this staged approach…We reiterate our commitment to continue working with our government colleagues to develop measures that will ensure our common environmental and economic objectives are met.” Minister Arcand continues to reject the idea that it will have any negative impact on the industries economic performance. He said, “Because Quebec is acting as a pioneer, Quebec companies will be among the first to profit from the advantages of a system of capping and trading of greenhouse gas emission credits. They will be the first to adapt to the realities of the new carbon-free economy.”

Lafarge Sets New CO2 Emission Goals

Lehigh Ben — Thu, 30 Jun 2011 00:56:21 +0000

Cement industry giant Lafarge announced on Thursday a set of new goals in order to continue its agenda of reducing CO₂ emissions. The goals are divided into two main areas: straight emissions reductions and a sustainable construction development.

In developing the first goal category, Lafarge worked within a framework developed in cooperation with the World Wildlife Fund International (WWF). As such, Lafarge has announced its intention of reducing its CO₂ emissions by 33% by 2020 as compared to 1990 values. This comes on the heels of its success in reducing values by 20% by 2010. Not only did Lafarge meet this goal, but it was accomplished a year ahead of schedule and reductions totaled 21.7% at the close of 2010.

The second part of their goals will not help Lafarge comply with any regulations or standards, but is still vitally important to continued environmental improvement which Lafarge recognizes. Lafarge estimates that buildings account for 40% of global energy use. Lafarge hopes to mitigate this problem by launching at least ten new innovative construction products by 2015 along with contributing to five hundred energy-efficient construction projects globally.

Commenting on their recently set goals, Lafarge CEO Bruno Lafant said, “Lafarge has made the reduction of its CO₂ emissions a major objective, and has met its commitments. I am pleased with our partnership with WWF, which helps us to progress even faster. It is no longer a matter of just reducing the CO₂ emitted in the production of our materials, but also of developing construction solutions for buildings that consume less energy.”

Ethiopia Cement Boom

Hannah — Tue, 28 Jun 2011 09:59:45 +0000

Ethiopia is in the news for its upcoming advance in concrete production. In the past, Ethiopia has imported about one million tons annually, an eighth of its approximate total demand. However, by the end of 2012 the country should be able to more than meet its own cement demand. Plentiful limestone deposits are present across the country, waiting to be tapped into by expanding cement production plants. Two such plants are the Mugher Cement Enterprise, owned by the state, and the Ethiopian People’s Revolutionary Demoncratic Front’s Messebo Building Marerials Production Plc. Both done work to expand and renovate their plants – work which is scheduled to be completed in July 2011 – and hope hope to add another 1 million tons to the country’s total production. Furthermore, Ethiopian-born Saudi billionaire Sheikh Mohammed al-Amoudi recently spent $351 million to build a new plant that plans in open in September 2011, and should attain full production capacity early in 2012. Much of the additional cement will be used by state-funded projects aimed at the further development and improvement of the country.

Titan Cement Caught in the Crossfire

Hannah — Fri, 24 Jun 2011 01:18:21 +0000

The Titan Cement plant of Castle Hayne, NC is taking quite a hit from the residents of that area. What began three years ago as a fight against Titan’s acquisition of and subsequent building permits for the land has continued as a battle to shut down the newly operating plant. With an organized force (http://stoptitan.org/), the people of Castle Hayne are a formidable foe – ready to take the necessary steps to stop what they see as a direct and serious environmental and public health hazard. However, is it possible that the people of Castle Hayne are missing the forest as they hack at this tree? In order to develop the land and build the plant Titan had to obtain multiple permits – each of which they petitioned for and received. Then, once in operation, Titan must comply with a litany of regulations including emission levels and environment impact standards. And indeed, each of these has been followed by the company. Thus, if the people of Castle Hayne are convinced that the Titan Cement plant is a serious health hazard, shouldn’t they be attacking the root of the issue – the existing zoning laws and emission standards – rather than attacking this law-abiding and standard-meeting company? In what boils down to a fight between advance and expansion versus environmental and health safety, Titan Cement is getting caught in the cross-fire.

Taking a step back, however, reveals an even broader but extremely pertinent issue. On one hand the Environment Protection Agency (EPA) is looking at toxic emissions and their effect on the world, and tightening the emissions standards accordingly. On other hand the EPA is ignoring half of the issue. As the Portland Cement Association (PCA) points out, the stringent standards issued by the EPA will greatly retard industrial and economic growth, with comparatively small recompense by way of reduced environmental impact (see PCA on impact of regulations). It remains to be seen if the PCA and its supporters will carry their point in the future or if restrictions will continue become stronger. In either case, it is companies like Titan Cement who will be affected, and often caught in the middle.

Cement Demand to Increase with Rebuilding of Infrastructure

Hannah — Thu, 16 Jun 2011 22:06:41 +0000

With America’s infrastructure crumbling and the economy still struggling to recover from its nosedive, a game of passing the buck has begun. The federal government has no money to foot the enormous bill of rebuilding and expanding roads, bridges, water and waste treatments systems, etc. Just recently a group of senators has drafted a bill that will give about $56 billion a year towards highway and transit construction. While this is a step in the right direction, America’s infrastructure needs hundreds, not tens of billions of dollars of work. Thus, much of the responsibility of finding funding is passed off to the state government. These men, in turn, look at the trillions of dollars of debt they face, and pass the responsibility on to more local governing bodies. Where will it stop? At some point it must. Indeed, maintaining and rebuilding the country’s infrastructure is necessary for the operation and safety of society, much less for America to keep up in the global race of technology and expansion. Given that America cannot ignore the state of its infrastructure, what does this mean for cement companies who produce one of the primary materials needed for this massive renovation project? Whether America attacks the problem – beginning with the passing of this new bill – or waits until the last minute in each situation, there will be an enormous need for quality cement. It may come as a slow but steady need, or in the form of mass contracts – only time and the government will tell.

Residents in Jordan Oppose Alternative Fuel Proposal

Lehigh Ben — Sat, 11 Jun 2011 14:42:54 +0000

Residents of the Jordanian town of Qadisiyah are actively demonstrating against the Rashadiyeh cement factory, an affiliate of Lafarge, which plans to burn tires and oil shale to supplement its fossil fuel program.

The villagers are concerned over the potential health and environmental concerns that the new fuel will pose. After demonstrating for an hour or so, the residents dispersed; leaving a committee behind to negotiate with the company’s representatives. The demands the committee brought to the company’s attention: reconsider the use of tires as a fuel source and add a health clinic to deal with respiratory illnesses from company work whose medical benefits had been denied.

The Rashadiyeh company heard the requests of the community, but it will remain to see the course of action it will take. The Cement Plant has already installed $20 million filters in order to reduce particulate emissions from the plant.