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Case Study Database

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TXI Operations, L.P.

Year Submitted: 2003

Process: Stormwater

Industry: Cement Manufacturing

Wastes Reduced: Wastewater

Substance: Stormwater

Location: Midlothian Plant TX

No. of employees: 120

Contact: Eric Tiemeyer

Phone: (972) 647-3879


Nearly one million gallons of potable groundwater are utilized each day in a process to manufacture portland cement. Design involves construction and operation of a comprehensive storm water collection and recycling system to collect all stormwater runoff from plant process areas and return it to production processes. An additional project is a pipeline from City of Midlothian Wastewater Treatment Plant (CMWTP) to the cement plant that conveys city treated wastewater effluent to the TXI plant to replace an additional 50-75% of the plant’s process water requirement.

P2 Application:

The new pump station consists of two 1,500 gpm pumps located at the sedimentation basin where all runoff is collected. Storm water is then transferred to one of two 2 million gallon tanks. The tanks store water and are equipped with a pump station to transfer water to the manufacturing process. A new pump station consisting of one 1,500 gpm pump will also transfer storm water from raw material and coal storage areas into the two storage tanks. The second system is a pipeline that will transfer treated effluent from the treatment plant to storage tanks. CMWTP effluent provides 500,000 to 750,000 gallons of water per day. This effluent, combined with storm water, will almost completely replace the groundwater currently used in the manufacturing process.

Environmental Benefits:

Elimination of storm water discharges from the plant will reduce any potential environmental degradation to a receiving stream. Reuse of runoff from the cement plant will replace nearly 25% of the required volumes of process water resulting in a 200,000 gallon per day reduction in potable groundwater usage. With a pipeline system from CMWTP to the cement plant, almost one million gallons per day of groundwater will be conserved. In addition, discharge of treated effluent from CMWTP will be eliminated.

Details of Reductions

Additional Information :

Initial capital cost of the storage and pump system was approximately one million dollars, while the pipeline will cost approximately $700,000. Cost savings arise from reduced groundwater pumping and less liability for wastewater discharges.

Source: TCEQ

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