Holcim (U.S.) Inc.

Year Submitted: 2006

Process: Air compression

Industry: Cement Manufacturing

Wastes Reduced: Electricity

Location: Mason City IA

No. of employees: unknown

Contact: Bhavin Mehta

Phone: 641-421-3308

Description:

The energy conservation project was aimed at reducing the consumption of electrical energy in the compressed air system and thereby conserving natural resources used for the generation of electricity

P2 Application:

Compressed Air Leaks - The cost of leaking compressed air is often considered insignificant. However, the following results show that appreciable energy savings can be realized by repairing the leaking air lines. Fixing the air leaks would result in an energy reduction of 1.2 million kWh/yr, leading to cost savings of $30,177 per year. Compressed Air Lances - The plant uses compressed air lances to cool the outer shells of the kilns. Replacing the compressed air lances with fans would result in energy reduction of approximately 1.27 million kWh/ yr, leading to a cost savings of $31,949 annually. Grinding Aid Spillage Prevention - Preventing spillage of approximately 5,510 lbs/yr of grinding aid would result in raw material savings, labor costs savings, and absorbent costs savings of $2,757/yr. The prevention of grinding aid spillage also ensures compliance with spill regulations and ensures the safety of workers. Spill Prevention, Control & Counter Measure Plan and Oil Drum Management - The United States Environmental Protection Agency (U.S. EPA) promulgated regulations that established procedures and required equipment to prevent the discharge of oil from nontransportation-related facilities into or upon the navigable waters of the United States. The Spill Prevention Control and Countermeasure (SPCC) plan has been prepared for petroleum and other liquid storage. Preventive Maintenance of Bag Houses - Review of the Preventive Maintenance Schedule was carried out to ensure the proper operation and maintenance of air pollution control devices. The review was based on the plants Operation and Maintenance Plan (O & M Plan), which is prepared in accordance with the National Emission Standards for Hazardous Air Pollutants from the Portland Cement Manufacturing Industry.

Details of Reductions

• 1,200,000.0 - KwH of   energy
  

• 1,270,000.0 - KwH of   energy
  

• 5,510.0 - Pounds of   spillage
  

Additional Information :

Holcim is one of the world's leading suppliers of cement, as well as aggregates (gravel and sand), concrete and construction-related services. From its origins in Switzerland, the group has grown into a global player with strong market presence in more than 70 countries on all continents. Holcim employs close to 50,000 people. Holcim (US) Inc., formerly Holnam Inc., is a wholly-owned subsidiary of Holcim Ltd. and is one of the largest suppliers of portland and blended cements and related mineral components in the United States. It has 14 plants and more than 70 distribution terminals across the country, 2,400 employees and generates revenues of $1.1billion. The company is headquartered in Dundee, Mich. The Mason City plant is a manufacturing facility and has approximately 170 employees.

Source: P2RIC