Displaying items by tag: US
TXI announces additions to the board
18 July 2012US: Texas Industries (TXI) has announced the addition of Sean Foley (54), Bernard Lanigan (64) and Tom Ryan (47) to its board of directors. The appointments of the directors is effective as of 11 July 2012. All three are from outside of the cement industry.
"We are delighted to have found directors of the quality and experience of Sean, Bernie and Tom to join TXI," said Bob Rogers, chairman of TXI's board. "Given the improvement in construction activity, the near completion of additional cement capacity, the high quality of the company's assets and the markets we participate in, this should be an exciting time for them to be a part of TXI."
US: Oakbio Inc, which develops speciality chemicals using novel microbial production processes, has announced that it has succeeded in producing bioplastic polymers by using only cement plant flue gas and electricity.
The company has developed bioreactors driven by non-toxic microbes that capture carbon dioxide emissions and turn them into sustainable products. Oakbio produced bioplastic polymers at Lehigh Southwest Cement Co's Permanente factory in Cupertino, California.
"Our carbon conversion process yields over 50% bioplastics in microbe biomass by dry weight from inputs of raw flue gas and electricity," explained chief scientist Brian Sefton, who pointed out that Oakbio's technology would help turn carbon dioxide into a feedstock for large-scale manufacturing processes.
According to the company, its process could support full-scale production of bio-chemicals without the use of petroleum or agricultural feedstock, help replace petroleum oil-derived plastics with bio-degradable ones and bolster capture of carbon dioxide to cut greenhouse gas accumulation.
EPA may slacken PM emissions rules
19 June 2012US: The US Environmental Protection Agency (EPA) appears poised to soften particulate matter (PM) limits in its pending revised air toxics rule for cement plants, while separately pursuing an extended compliance deadline for the rule. Both moves would represent major concessions to industry groups that sought a weaker rule but have the potential to rile environmentalists who say such changes would be unlawful.
According to an industry source, EPA will propose to soften the rule's PM limits on smokestacks for existing cement plants. New data submitted to EPA by the industry shows that the limit of 0.02kg/t of clinker set by the final rule prior to reconsideration is not realistically attainable. Instead, the EPA will probably revert to a higher number, closer to the 0.043kg/t that it offered in its original proposal.
Environmentalists oppose softening the air toxics rule and recently warned the agency in written comments that, "any changes diminishing or replacing the existing standards would be flatly unlawful." The likely changes to the rule follow a series of 11th-hour meetings that industry officials and others have held with EPA and White House Office of Management & Budget (OMB) staff seeking to shape the proposal.
The Portland Cement Association previously presented a paper to the EPA arguing for an increase in the emissions limit for PM. "The current PM limit of 0.02kg/t of clinker is very stringent," reported the paper. "Very few facilities can comply with the clinker limit without major investments in new and upgraded PM controls."
Ash Grove announces major upgrade at Midlothian
25 May 2012US: Kansas-based Ash Grove Cement has announced an investment of over US$125m at its Midlothian plant in Texas in an effort to make it one of the lowest-emitting cement producers in the state. The decision to install a new preheater/precalciner production system was taken at the company's May 2012 meeting on 24 May 2012 and has been prompted by the need for the plant to lower its emissions ahead of the US Environmental Protection Agency's (EPA) portland cement National Emissions Standards for Hazardous Air Pollutants (NESHAP) rule that is scheduled to take effect in September 2013.
The decision, which comes hot-on-the-heels of a request to close the plant's existing wet production lines, was one option being considered by Ash Grove."We concluded that we wanted to continue to provide Texans with locally-made cement from our Midlothian facility for the foreseeable future and therefore approved the modernisation project," said Ash Grove Chairman Charles Sunderland. The decision secures jobs for the 110 people that work at the plant.
Ash Grove has invested millions of dollars in the Midlothian facility over the past four decades to reduce production emissions. Since 1996, Ash Grove has reduced the plant's NOx emissions by more than 60%. "Our employees appreciate the confidence the board has shown in them by making this decision," said Midlothian plant manager Kevin Blankenship. "We have generations of employees working here, many with decades of service. This decision demonstrates that Ash Grove will maintain its strong north Texas presence for our families, our community and our customers."
Reaction among community leaders also has been favourable."We are very pleased that Ash Grove has committed to investing to upgrade its plant here," said Midlothian Mayor Bill Houston. "Ash Grove is an outstanding corporate citizen and has always worked hard to be a good and responsible neighbour. "By investing in this key technology upgrade (the) plant will remain viable, competitive and environmentally-friendly for many years to come."
Cemex turns to the wind at Victorville
23 May 2012US: Cemex USA has announced a novel plan to install four 120m-tall wind turbines at one of its US cement terminals and quarry in order to cut carbon emissions and energy costs.
The Victorville Planning Commission has unanimously approved the two turbines proposed at Cemex's cement manufacturing plant, with the company stating the project would help keep jobs in the Victor Valley.
"Our operations will continue at Victorville even if the turbine permits are not approved," said Cemex spokeswoman Sara Engdahl. "However, the wind turbine project at our Victorville site is beneficial not only to our operations but to the environment as well. The project will contribute to the local economy through jobs created for the construction and engineering of the turbine, and the project directly partners with California-based Foundation Windpower."
The two turbines in Victorville will produce an estimated 6500MWh of electricity in an average year, enough to sustain 650 average homes, according to the company. The other two proposed turbines will be built at the Black Mountain Quarry in an unincorporated area of Apple Valley. They are under review by San Bernardino County.
The project will reduce greenhouse gas emissions and stabilise energy costs for Cemex, while preparing the company to comply with future carbon emission requirements, according to Cemex's proposal to the city of Victorville.
"The wind turbine project at our Victorville plant is part of our vision and commitment to reduce our environmental footprint and contribute to a cleaner environment," said Engdahl. "Cemex is increasingly using renewable energy to generate power for our operations."
She added that Foundation Windpower began working on foundations of the Victorville site in August 2011. It is scheduled to start erecting the turbines in September 2012.
Eagle Materials cement earnings up 60%
18 May 2012US: Eagle Materials Inc. has reported its financial results for the 2012 fiscal year and the fiscal fourth quarter that ended on 31 March 2012. Its results showed that the group's revenue was up by 7% for the fiscal year, to US$495m and cash flow from operations was US$60.2m, up by 37%. In the quarter ending 31 March 2012, the company netted revenues of US$116.8m, a 22% year-on-year increase.
Eagle said that its low cost operations continued to execute well during the 2012 fiscal year and that it was beginning to see improving construction activity across most of its markets. Eagle's earnings began to improve during the second half of fiscal 2012 and accelerated during the fourth quarter.
The company saw improved cement revenues, which were up by 8% for the full fiscal year to US$244m. Operating earnings from cement were up by 3% to US$46.9m. In the fourth quarter its cement operating earnings were US$7.5m, a massive 60% increase from the same quarter of the 2011 fiscal year.
Eagle said that the increase in its cement earning primarily reflected improved sales volumes and sales prices offset by US$2m of additional maintenance costs incurred in the quarter versus the prior year quarter. Cement revenues for the quarter, including joint venture and intersegment revenues, totalled US$49.8m, 23% greater than the same quarter of 2011. Cement sales volumes for the quarter were 0.53Mt, 20% higher than the same quarter of 2011.
FLSmidth receives contract for large US project
18 May 2012Denmark/US: FLSmidth has been awarded a contract worth approximately US$136m by an un-named customer in the US for the modernisation of its cement production facility.
The purpose of the engineering, procurement and construction project is to convert one of the plant's existing wet process kilns to a dry preheater/precalciner kiln. As a result, the customer will be able to better fulfil its key environmental objectives, namely reduction of emissions and achieving lower energy consumption.
The equipment includes an FLSmidth drier crusher, modification of the existing kiln, a new 1-stage preheater with calciner, a kiln bypass system, an FLSmidth Cross-Bar cooler, a coal dosing system by FLSmidth Pfister and an ATOX solid fuel mill with an FLSmidth MAAG Gear reducer.
With the installation of three new FLSmidth fabric filters, the project will significantly improve the plant's ability to reduce the particulate emissions. Similarly, an FLSmidth control system will optimise operational efficiency. The scope of supply also includes a new HOTDISC reactor that will allow the plant to increase its consumption of whole car tyres, thus increasing its use of alternative fuels.
FLSmidth said that the award of this contract demonstrates the company's ability to help US cement producers prepare for the anticipated National Emission Standards for Hazardous Air Pollutants (NESHAP) regulations. "The United States cement industry is facing a number of challenges, ranging from a slowly recovering economy to significant regulatory changes in plant emission standards. We are very pleased to work with one of our much valued customers as it takes a leading role in investing in the future of this industry," said Group CEO Jørgen Huno Rasmussen. The order will contribute beneficially to FLSmidth's earnings until mid 2014.
Ash Grove seeks tax break for Midlothian plant
16 May 2012US: Ash Grove Cement is seeking tax abatement for upgrade projects on its Midlothian plant in Texas. Plant manager Kevin Blankenship presented plans to the Ellis County Commissioner's Court on 14 May 2012.
Ash Grove needs to upgrade its plant in line with Environmental Protection Agency (EPA) regulations that will go into effect September 2013. The company is considering two options that will put the plant in compliance with the new regulations. The first option is to upgrade the plant enough so that it will comply with the new emissions standards. The second option is to fully modernise the plant by upgrading to a single dry kiln and shutting the other two existing wet kilns, a project that would cost US$130m. Since the presentation was not an agenda item at the meeting the court took no action.
The Midlothian plant has been in operation since 1966. Ash Grove currently intend to continue running the plant until 2050, but filed a request to shut the wet kilns in April 2012.
US: The Environmental Protection Agency (EPA) has sent for the White House Office of Management and Budget (OMB) to review its proposed revisions to its emissions rules for the Portland cement sector, ahead of a tentative 15 June 2012 deadline for issuing the revisions in line with a proposed consent decree with the industry.
The pending proposed revised rules undergoing OMB review will address not only the remand but also the EPA's May 2011 partial reconsideration of the cement rules - including standards for open clinker storage piles and start-up and shutdown monitoring requirements - as those provisions included in the recent proposed consent decree with industry.
In the Register notice on the consent decree, the EPA says that it "would also agree to propose to extend the existing source compliance date of 10 September 2013, or in any case to discuss the possibility of extending that date, and to take final action by 20 December 2012 regarding the date of compliance," if such provisions are 'supported by the administrative record.'
While stalling the compliance deadline would be a 'win' for the cement industry, it would likely draw protests from environmentalists supportive of the current air toxics rule. The deadline for comments on the proposed consent decree is 7 June 2012.
Japan/US: After a preliminary visit to the island of Pagan, part of the US's Commonwealth of the Northern Mariana Islands (CNMI), Japanese investors have announced that they are looking to lease roughly 2000 hectares of public land on the island to mine what they consider 'best quality' pozzolan for a period of 10-15 years and to recycle pre-treated tsunami debris that they plan to bring in from Japan. Pozzolan is a siliceous volcanic ash used to produce hydraulic cement.
However, some CNMI residents are already expressing opposition to what they describe as the 'desecration' of Pagan by turning it into a dumping ground. Others have expressed concerns that the eventual use of the island will go beyond pozzolan mining and tsunami debris recycling.
The Japanese investors, aware of these sentiments, are trying to quell public opposition to their project, saying that the tsunami debris will be pre-treated, non-toxic and non-radioactive. They added that Japanese and international laws prohibit the shipment of highly toxic materials from one country to another. They added that at least 80% of the tsunami debris would be recycled on Pagan and brought back to Japan and other destinations. The tsunami debris would come from the Miyagi and Iwate Prefectures, which are both north of Fukushima where the damaged nuclear power plant is located.
One of the Japanese visitors, Oku Shigeharu, who is chairman of Japan Southwest Islands Security Institute, said that depending on the results of further study of Pagan, the investors are interested in mining all pozzolan deposits on the island for a period of 10 to 15 years. He said they do not plan to lease the whole island but only about 2000 hectares of it, including the pozzolan mining area and a site where tsunami debris will be 'disposed of and recycled.' The investors were also keen to highlight that the CNMI will generate revenue from the multimillion-dollar land lease, from royalty fees as a result of pozzolan mining and through securing new jobs for local residents. "In my personal opinion, maybe pozzolan (mining) can help save the CNMI economy," said Shigeharu."There's at least 100Mt of pozzolan on Pagan," said Pagan (CNMI) Development Corp. chair Juan Demapan, citing a previous study.
The delegation said that it would return to CNMI in three weeks, bringing with them engineers, scientists and other experts to further study and assess Pagan.