Displaying items by tag: Roanoke

The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).

Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production

Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO₂ from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO₂ emissions.

The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.

The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’

Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.

Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.

US: The US Department of Energy has selected four cement producers to receive funding under the Bipartisan Infrastructure Law and the Inflation Reduction Act.

Heidelberg Materials US secured up to US$500m for its planned 2Mt/yr carbon capture project at the Mitchell cement plant in Indiana. National Cement also received up to US$500m, for its Lebec Net Zero limestone calcined clay cement (LC3) project in California. Summit Materials received up to US$216m for a series of clay calcination projects in Georgia, Maryland and Texas. Lastly, Roanoke Cement will receive up to US$61.7m for an LC3 project at its Troutville cement plant in Virginia.  These projects also involve developing a training, education and certification consortium in the cement sector.

Portland Cement Association (PCA) president and CEO Mike Ireland said "This funding is a welcome acknowledgement from the government that America's cement manufacturers are taking ambitious and significant steps toward reaching carbon neutrality. This will move the needle closer to achieving what industry considers the 'heavyweight' of carbon solutions: carbon capture utilisation and storage (CCUS). Once established nationwide, CCUS will greatly accelerate cement manufacturers' charge toward net zero."

Senior vice president of government affairs Sean O'Neill added “From passage of the Bipartisan Energy Act of 2020 to securing funding through the Inflation Reduction Act and the Infrastructure Investment and Jobs Act, today's announcement is another major milestone in the cement industry's decarbonisation efforts. The PCA is committed to continuing to work with policymakers to ensure the regulatory environment facilitates rather than impedes these and future investments.

US: Roanoke Cement, part of Titan America, has held a ground-breaking ceremony for an expansion at its Chesapeake Terminal near Norfolk in Virginia. Council members, other state and local officials and Roanoke Cement team members gathered to launch the project, to build a new US$40m storage dome. In response to increasing demand for low carbon cement, the storage dome at the terminal will provide an additional 70,000t of capacity, tripling the site’s existing storage volume. The Chesapeake Terminal will see expanded truck and rail capacity as well, and the improved terminal will enable the import and distribution of other raw materials needed to produce concrete.

"This important capital improvement is another investment in anticipation of increased construction material demand for infrastructure development and other projects," said Kevin Baird, president of Titan America's Mid-Atlantic Business Unit, which includes Roanoke Cement. "Expanded storage and marine terminal upgrades permit us to make low carbon cement available for construction needs all over the region."

The company expects the expanded facility to be completed by the end of 2023, in time for the region’s 2024 construction season.

US: Green Business Certification (GBC) has recognised Titan America subsidiary Roanoke Cement’s successful implementation of its zero waste policy at the 1.5Mt/yr Troutville, Virginia plant with a Total Resource Use and Efficiency (TRUE) Gold award. In 2019 the plant won the GBC’s TRUE Silver award. Roanoke Cement environmental engineer Lindsey Layman said, “In order to elevate our TRUE Zero Waste certification, we ramped up our zero waste policy to include, for example, physical audits of waste and improving recycling practices on-site. As a result, we have created a zero-waste culture and achieved an average of 98% overall diversion from landfill and incineration of solid non-hazardous wastes.”

US: Titan America subsidiary Roanoke Cement has settled on a fine of US$3640 with the Virginia Department of Environment Quality (DEQ) for the breach of emissions regulations after a kiln gas outlet at its 1.5Mt/yr Troutville plant in Botetourt County, Virginia, recorded an average temperature of 121°C over a nine-hour period on 26 June 2019. Virginia DEQ enforcer Marvin Booth said there was ‘no documented harm to public health or the environment’ resulting from the violation.

US: The Portland Cement Association (PCA) has announced the winners of the 2019 Energy and Environment (E&E) Awards. The awards recognised environmental and community relations projects that were completed in 2018 and were presented at the 3rd Annual Cement and Concrete Fly-In.

The CalPortland Mojave cement plant in California won the Energy Efficiency award for the installation of a new classifier system for its vertical roller mill that increased energy efficiency by reducing fan power requirements. The plant also installed a control system for the finish mill that will maximise performance and help reduce wear on equipment. The classifier installation reduced the finish mill energy intensity by 1.5 to 2.0kWh/t, and the control system reduced energy intensity by 13%. In 2018 22% of the electricity consumed by the plant came from on-site renewable wind energy generation. CalPortland has implemented significant energy efficiency measures and its energy management program has been recognised by the Environmental Protection Agency Energy Star program as the Energy Star Partner of the Year for 15 years in a row.

Roanoke Cement Company and Titan America’s Troutville plant in Virginia won the Environmental Performance award for being the first cement manufacturing plant in the US to receive ISO 50001 certification for energy management of all aspects of energy procurement, design and use. The plant reduced its total electrical consumption by 10% and fossil fuels use by more than 12%. The plant has also implemented an alternative fuels program as part of its certification for the True Zero Waste Program, administered by Green Business Certification and has received silver status achieving a 96% rate of waste divergence from landfills.

Lehigh Hanson’s Permanente cement plant at Cupertino in California won the Innovation award for the installation of a water treatment system reducing concentrations of metals, including selenium, to meet permit limits. Lehigh Hanson developed a treatment system that combined ultrafiltration and reverse osmosis (UF/RO) technology in conjunction with biological treatment technology to remove metals, including selenium and dissolved solids. This ensured applicable effluent limits were met while optimising treatment capacity and efficiency. This treatment system is the first of its kind in the cement industry ensuring that effluent limits are met while, at the same time, limiting the quantity of waste needed to be managed.

Buzzi Unicem USA’s Greencastle cement plant in Indiana won the Land Stewardship award for opening a 4km smooth packed stone trail in conjunction with the not-for-profit People Pathways organisation as Phase 2 of the Putnam Nature Trail. Buzzi Unicem USA staff and People Pathways used heavy equipment for rough clearing and grading of the overgrown former railroad bed and improved and expanded the physical trail. These areas were then landscaped with trees, native prairie vegetation plugs, interpretive signage, benches, birdhouses and other features. Additional nature trail enhancements include placement of wildlife monitoring cameras along the trail, installation of nesting boxes and interpretive signage, and maintenance of the recently completed restoration of native flora installed in 2017 and 2018.

Cemex’s Lyons cement plant in Colorado won the Outreach award for volunteering work by its staff at the Rocky Mountain National Park in Boulder, Colorado, performing campground improvement activities at Glacier Basin Campground by moving rocks and fallen timber and clearing existing fire pits of ash deposits. The plant then introduced a new community outreach initiative by hosting a Manufacturing Day event, providing local students tours of the quarry and plant to increase youth interest in pursuing a vocation in skilled trades. Additionally, the plant teamed up with the Celestial Seasonings B Strong Ride for cancer care and research for an event aimed at increasing safety awareness while fundraising for two local organizations and their efforts to fight cancer.

US: The Wildlife Habitat Council (WHC) has recertified four of Roanoke Cement Company’s terminals in Virginia and North Carolina. Units at Front Royal, Richmond and Bristol in Virginia and Winston-Salem, North Carolina received the certification.

"Having the Wildlife Habitat Council's recertification for each of them is a distinguished recognition confirming that all of Roanoke Cement's sites are on the right track ecologically. We look forward to continuing our conservation efforts providing pleasing, ‘green’ features within our terminal campuses. A few examples include pollinator meadows at Front Royal and Winston-Salem, avian habitats for the Eastern Bluebird in Richmond, and stream restoration in Bristol," said David Brinkley, Director of Distribution & Customer Resources at Roanoke Cement Company.

WHC's certification program, ‘Conservation Certification,’ is built on global recognition programs, reflects contemporary conservation efforts and applies its collective learning to the future of biodiversity in the US and the globe. Front Royal, Richmond and Winston-Salem were originally certified in 2013. Bristol was originally certified in 2015. Certification by WHC is valid for two years.

US: Roanoke Cement, a subsidiary of Titan America, has achieved its 11th consecutive annual certification in the US Environmental Protection Agency's (EPA) Energy Star certification for its Troutville plant in Virginia. To qualify for the certification the cement producer was required to perform in the top 25% of cement plants nationwide for total energy efficiency (thermal and electrical) and meet strict environmental performance levels set by the EPA.

“Roanoke Cement Company’s plant sits in the Roanoke Valley, in the shadow of the Blue Ridge Mountains. The stakes are higher for us, surrounded by all that beauty, to perform at the pinnacle of the cement industry in energy efficiency,” said Chris Bayne, Roanoke Cement’s Energy Manager.

USA: Titan America's Roanoke Cement has earned the US Environmental Protection Agency's (EPA's) Energy Star certification for the tenth consecutive year and Titan's Pennsuco plant celebrates nine years of certification. To qualify for Energy Star, Titan's plants must perform in the top 25 percent of cement plants in the US for total energy efficiency (thermal and electrical) and meet strict environmental performance levels set by the EPA.

To further its efforts, Titan America has implemented a series of processes that enable Titan employees to maintain and improve energy performance across the entire enterprise. The Titan Energy Management System (EnMS), operating at Titan's three largest facilities (the Roanoke Cement plant in Virginia and both the cement plant and aggregate plant located in Medley, Florida) enables employees to systematically manage total consumption of all energy sources. This program, which addresses the energy performance standard ISO 50001, also ensures that the company's business operations are as efficient as possible, increases plant reliability and supports Titan's operational goals.

"At Titan America we are passionate about continuously developing efficient, sustainable operating practices," said Bill Zarkalis, Titan America's CEO. "Titan's EnMS program is an excellent example of innovation and of our commitment to make our business operations more efficient, while contributing as much as we can to make the locations in which we operate better places to live and work. We are very proud of this recognition, but we do not take it for granted. We are poised to continue our efforts."

"We are extremely proud of the Energy Star certifications we have earned over the past decade," commented George Pantazopoulos, Senior Vice President of Titan America Cement Operations and Corporate Engineering. "We also consider this milestone to be a catalyst for reinvigorating our teams and increasing our efforts. We have no doubt that we can gain further efficiencies in our manufacturing processes using the EnMS program."

Roanoke Cement has applied electricity management best practices during the previous 18 months and has delivered an 11% reduction in electricity consumed per tonne of cement produced. Additionally, the company has partnered with electrical utilities to reduce their contribution to peaks on the power grid due to demand management and demand response. These efforts ensure that inefficient peak generators owned by the utilities can remain offline during times when homeowners and businesses place a large demand on the electrical grid.

"The EnMS program is scheduled to be fully operational by 3Q 2017," reported Chris Bayne, Titan America's Corporate Energy Manager and director of the EnMS program. "We organised teams to oversee the program at our three main facilities. Roberto Duran will lead the Pennsuco Aggregates Plant team, Sonny Cruz will lead the Roanoke Cement Plant team and Diwakar Mishra will lead the team at Pennsuco Cement." Bayne also noted that the implementation teams would routinely incorporate energy management practices into the daily operations of Titan's manufacturing facilities. Titan is targeting a reduction in total energy consumption of 3%, year-over-year.

Energy Star was introduced by EPA in 1992 as a voluntary, market-based partnership to reduce greenhouse gas emissions through energy efficiency. Today, the Energy Star label can be found on more than 60 different kinds of products as well as new homes and commercial and industrial buildings that meet strict energy-efficiency specifications set by the EPA. Over the past twenty years, American families and businesses have saved a total of nearly $230 billion on utility bills and prevented more than 1.7 billion metric tons of greenhouse gas emissions with help from Energy Star.

US: Roanoke Cement Company has been accepted as an Exemplary Environmental Enterprise within the Virginia Environmental Excellence Program (VEEP). VEEP was established to encourage superior environmental performance by encouraging organisations within the state of Virginia, that have strong, established environmental records, to surpass their own performance levels.