Displaying items by tag: Virginia

Heidelberg Materials North America held an official opening ceremony this week for its upgraded slag cement plant and terminal at Cape Canaveral in Florida. The US$24m project added a new roller press to the unit to increase its production capacity. In a statement Chris Ward, the president and chief executive officer of the company, said that it had made the investment to meet sustainability and resilient construction goals. Industrial Accessories Company (IAC) said in mid-2021 that it had been named as the engineering, procurement, and construction (EPC) contractor for the project. It planned to install a hydraulic roller press supplied by FLSmidth. IAC also said it was providing instrumentation equipment, hoppers, bins, belt conveyors, bucket elevators and dust collectors amongst other kit and services.

Other recent US slag cement-related news stories have concerned terminals. In late August 2022 Royal White Cement said it had leased a site on the Houston Ship Channel in Houston, Texas to handle and store approximately 100,000t of multiple cementitous products such as slag, ordinary Portland cement and white Cement. In May 2022 Titan America announced plans to spend US$37m on an upgrade to its Norfolk terminal in Chesapeake, Virginia. The major improvement was to add a 70,000t storage dome, with enlarged truck and railway capacity, to allow the site to import and distribute raw materials such as fly ash, slag and aggregates. Completion on this one was scheduled for some point in 2023. Titan added that the project was similar to the addition of a 70,000t dome under construction at the time at Titan's import terminal in Tampa, Florida.

The United States Geological Survey (USGS) estimates that domestic sales of iron and steel (ferrous) slags in the US amounted to 15Mt in 2022. Sales were around 20Mt in the 2000s but this fell to current levels in the 2010s as blast furnaces closed. In 2022 the USGS noted that, “domestic ground granulated blast furnace slag (GGBFS) remained in limited supply because granulation cooling was known to be available at only two active US blast furnaces while, elsewhere, only one domestic plant produced pelletised slag in limited supply.” It added that the grinding of granulated blast furnace slag was only being carried out domestically by cement companies. Imports of slag were 2Mt in 2022. This is a decline from a peak of 2.6Mt in 2018 but higher than the period 2000 – 2015. The price of slag, meanwhile, hit a high of US$53/t in 2022. This is the highest price recorded by the USGS since at least 2000. It is double that of 2017.

Charles Zeynel of ZAG International noted in the June 2023 issue of Global Cement Magazine that cement producers in Florida, California, Texas, Georgia and the Carolinas are far from steel mills, so they import granulated blast furnace slag (GBFS) and other secondary cementitious materials (SCM). This certainly fits with Heidelberg Materials’ plan to upgrade its slag cement plant and terminal at Cape Canaveral. Also on the US market, Zeynel added that due to rising global demand for SCMs more of the available share of GBFS was being purchased by ‘richer’ markets such as Europe, North America and Australia. He continued that GBFS and GGBFS producers had also started increasing the price of their wares internationally. This too is apparent in the prices published by the USGS.

One final story with links to slag to note this week concerns the launch of the Alliance for Low-Carbon Cement & Concrete (ALCC) in Europe. The group brings together companies producing products or services intended to decarbonise the cement and concrete sectors. Two of the members – Ecocem and Hoffman Green Cement Technologies – are Europe-based slag cement producers. Two other members – Fortera and TerraCO₂ – are companies based in North America that are marketing and selling low-carbon SCMs.

Various start-up companies have been emerging on a regular basis in both North America and Europe with the aim of decarbonising cement and concrete in various different ways. The formation of the ALCC can be seen as part of this trend as the more successful non-traditional cement-concrete-aggregate companies establish themselves. One point that cement producers in North America are likely to be well aware of is that concrete is becoming less linked to clinker as the cost of carbon mounts and the clinker factor of cement lowers. Slag supplies may be finite but Heidelberg Materials North America’s latest investment in Florida is further acceptance that one doesn’t just need clinker to make concrete.

Read Charles Zeynel’s interview on SCM Trends in 2023 in the June 2023 issue of Global Cement Magazine

The 15th Global Slag Conference, Exhibition & Awards take place on 6 - 7 June 2023 in Düsseldorf, Germany

US: The Environmental Protection Agency (EPA) has announced that 10 cements plants have received its Energy Star certification in 2022 from a total of 86 manufacturing plants across all industries. The certification is awarded to the top 25% performers in energy efficiency in each sector. The EPA cited examples of how Titan America’s Troutville plant in Virginia and its Medley plant in Florida had converted production to Portland Limestone Cement (PLC), and achieved a 12% reduction in electricity use and an 18% reduction in CO2 emissions, respectively, thanks to improved energy management. It also mentioned Cemex’s Miami plant in Florida, which increased its energy performance in 2022 by modifying a finish mill, optimising the ball charge on the largest mill and identifying and correcting potential energy losses while also increasing the production of PLC.

Cement plants awarded the Energy Star certification in 2022 include: Drake Cement’s Paulden plant and Salt River Materials Group’ Clarkdale plant in Arizona; GCC’s Pueblo plant in Colorado, Cemex’s Miami plant and Titan America’s Medley plant in Florida; Argos USA’s Harleyville plant in South Carolina; GCC’s Rapid City plant in South Dakota; Buzzi Unicem USA’s Chattanooga plant in Tennessee; Titan America’s Troutville plant in Virginia; and Ash Grove Cement’s Seattle plant in Washington.

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: Titan America plans to spend around US$37m towards expanding its Norfolk terminal in Chesapeake, Virginia. The plans at the terminal, run by subsidiary Roanoke Cement Company, include building a 70,000t dome, enlarging truck and railway capacity and enabling the site to import and distribute raw materials such as fly ash, slag and aggregates. At present the unit has a bulk storage capacity of 35,000t. Titan says that the upgrade will enable it to meet growing demand for its products in the Mid-Atlantic region. The project also follows a similar investment in a 70,000t dome currently under construction at Titan's import terminal in Tampa, Florida.

"The major expansion and modernisation of these two marine terminals is another important step toward meeting fast-growing demand for our products and services in critical infrastructure, commercial and residential projects in our communities," said Bill Zarkalis, president and chief executive officer, Titan America.

The dome and associated expansion projects are scheduled for completion in 2023.

US: Charah Solutions has been awarded a marketing contract by Dominion Energy for the beneficiation and utilisation of up to 8.1Mt reclaimed ponded coal ash at its Chesterfield Power Station in Chester, Virginia. The contract will run from 2021 until 2032. It follows local state legislation requiring the power company to remove coal ash from sites at the Chesterfield Power Station within 15 years.

As part of the agreement, Charah Solutions will install processing and transportation infrastructure in 2021 to facilitate rail transportation of the ash from Chesterfield Power Station to cement kiln feed markets. The beneficiated ash product will replace other currently utilised virgin raw materials in the production of Portland cement at multiple cement kiln locations in the eastern US for the next decade and beyond, and help supply the growing demand for concrete in the construction industry.

US: The Portland Cement Association (PCA) has announced the winners of its Chairman’s Safety Performance Award for outstanding safety performance in Portland cement production in the US.

The winners were: Cemex USA’s Clinchfield, Georgia and Victorville, California plants; Lehigh Hanson’s Cupertino, California and Tehachapi, California plants; Titan America’s Medley, Florida and Troutville, Virginia plants; LafargeHolcim’s Morgan, Utah and Theodore, Alabama plants; Buzzi Unicem’s Chattanooga, Tennessee plant; GCC of America’s Pueblo, Colorado plant; and Argos USA’s Atlanta, Georgia grinding plant.

PCA chair Tom Beck said, “We’re proud to highlight these top safety performers. Our industry is constantly focused on doing everything possible to assure our employees go home in the same condition as they arrived.”

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: 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.