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 regulations to minimize their impact on the environment.

Runner Up:

Lafarge North America Inc.
Bath, Ontario

Finalists:

Lafarge NorthAmerica Inc.
Alpena, Michigan

Titan America LLC / Roanoke Cement Company
Troutville, Virginia

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 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. 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 protection or energy efficiency.

Runner Up:

CalPortland Cement Company
Mojave, California

Finalists:

Ash Grove Cement Company
Midlothian, Texas

Lafarge North America Inc.
Bath, Ontario

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:

Lafarge North America Inc.
Bath, Ontario

Finalists:

Lafarge NorthAmerica Inc.
Alpena, Michigan

Mitsubishi Cement Corporation
Lucerne Valley, 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 modifications 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 practices, and climate change mitigation efforts.

Runner Up:

Titan America LLC /Roanoke Cement Company
Troutville, Virginia

Finalists:

Salt River Materials Group / Phoenix Cement Company
Clarkdale, Arizona

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

Lafarge North America Inc.
Alpena, Michigan

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 assisted 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 community and provided compact fluorescent light bulbs to residents.

This category recognizes a facility that demonstrates excellence in multiple categories.

Runner Up:

Lafarge North America Inc.
Alpena, Michigan

Ash Grove Cement Company
Midlothian, Texas

Finalists:

CEMEX
Knoxville, Tennessee