Cement Americas

WIN 2015

Cement Americas provides comprehensive coverage of the North and South American cement markets from raw material extraction to delivery and tranportation to end user.

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CEMENT AMERICAS • Winter 2015 • www.cementamericas.com 14 FEATURE PCA/CA AWARDS Council's Wildlife at Work certification for their voluntary, employee-based wildlife habitat enhancement efforts that exceed regulatory requirements. INNOVATION Winner: Lafarge North America Inc., Paulding, Ohio The Innovation Award recognizes ce- ment industry leaders in the develop- ment and application of innovative technologies and techniques relevant to environmental protection or en- ergy efficiency. The Lafarge Paulding facility fully captured small grain cement kiln dust (CKD) for return back to the kiln feed bed by briquetting the CKD powder prior to reintroduction to the feed bed. Briquetting machines have been around for many years, however, this may be the first time the process has been used to improve CKD recycling rates. After an initial and successful trial using smaller equipment, the Pauld- ing plant installed a larger briquetting machine and feed system to the plant's kiln systems. As a result, the plant was able to return 1 ton of CKD per hour to the hood of the kilns. The project increased clinker produc- tion, reduced CKD going to the land- fill, increased kiln performance factor, reduced the chlorinated grinding aid accelerator, decreased Specific Heat Consumption, and reduced CKD haul truck hours to the landfill. With a yearly savings of $1 million, the proj- ect payback period was less than eight months. INNOVATION Finalist: Buzzi Unicem USA, Inc., Maryneal, Texas In 2013, the Maryneal plant commis- sioned the first Horomill grinding sys- tem in the United States, replacing a decades-old, inefficient, cement grinding system. The energy savings have been significant. From January 2009 through June 2013, the power consumption rate of the plant's grind- ing system was 78.3 kW/h per short ton of cement produced. Between July and December 2013, Horomill power consumption averaged 47.7 kW/h per short ton of cement pro- duced, representing a 40 percent re- duction in power consumption and related greenhouse gas emissions. Additional benefits from this new sys- tem include reduced noise levels and less off-spec cement. The plant has also seen a reduction in water con- sumption rates. ENERGY EFFICIENCY Winner: CalPortland Co., Rillito, Ariz. The Energy Efficiency award recog- nizes a plant's energy planning, appli- cations of efficiency technologies and practices, and climate change mitiga- tion efforts. The Rillito cement plant Runner Ups for the Land Stewardship Award were Lafarge North America's Alpena plant (see pg. 11) and Lehigh Hanson's Union Bridge plant (see pg. 12). Innovation winner: Lafarge North America, Inc. Lehigh Hanson's Union Bridge plant (see pg. 12) was the runner up for the Innovation Award.

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