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November 2018
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World Cement
Energy stars
Titan’s sister cement plants, Roanoke and Medley, are
among the few in the US to be ENERGY STAR certified
for 12 and 11 consecutive years, respectively. RCC’s
achievements with ENERGY STAR are particularly
notable.
RCC renewed its focus on energy management in
2014 by establishing aggressive internal sustainability
targets for 2020. As recently as 2016, savings models
showed reductions in total electrical consumption when
compared with 2014 baselines, of approximately 10%,
and a plant-wide total energy (thermal and electrical)
reduction of more than 8%. RCC engineers made use
of ENERGY STAR tools and shared data with the EPA,
as the plant developed a solid relationship with the
agency.
Combined with a renewed focus on demand
management and response, RCC achieved energy
spending reductions in excess of US$2 million.
Particulate emissions from the main kiln stack were
reduced by 53% during the 11 year ENERGY STAR
period (the latest available).
Kevin Baird, President of Titan America Mid-Atlantic
Business Unit, places the credit with the Virginia plant’s
employees and managers. “Titan advances a core value
of environmental stewardship and Roanoke Cement’s
initiatives have succeeded through dedicated employees
who encourage and commit. Their energy awareness
generated good ideas, leading to innovative practices
and energy-saving results.”
Last July, RCC was honoured by ENERGY STAR
and the EPA for its major energy reductions in
one of the most energy intensive industries.
Representative Bob Goodlatte (VA-6
th
) of Roanoke
applauded RCC’s ENERGY STAR achievement. “RCC
is well-known to me as one of the largest employers
and taxpayers in Botetourt County. To be sure, this is
not ‘your grandfather’s cement company.’ With over
US$100 million in capital upgrades since 1992, RCC has
propelled itself into the highest echelon of 21
st
Century
industry – environmentally aware and technologically
savvy. RCC’s limestone lake restoration, Appalachian
Trail access, and Catawba Creek improvements
have created a legacy its community recognises and
appreciates.”
To qualify for ENERGY STAR, RCC and Titan Florida
were required to perform in the top 25% of cement
plants nationwide for total (thermal and electrical)
energy efficiency and to meet strict environmental
performance levels set by the EPA. The EPA’s
ENERGY STAR designation is based on actual energy
use and is calculated using a tool prepared by the EPA,
called an energy performance indicator (EPI).
In 2017, the plant’s ENERGY STAR team, upon
invitation, presented to the EPA Region 3 office
in Philadelphia. The meeting was comprised of
approximately 40 EPA attendees, including the
ENERGY STAR, Air Protection, Sustainability, and
Pollution Control teams.
The tenure of the RCC’s ENERGY STAR certification,
sustainability, and environmental compliance was
summarised. Highlights of RCC’s presentation
included innovative reclamation projects, including
trout pond creation, stream cleanup and bank
development, and quarry conversions that provided
benefits across the plant’s constituencies. Onsite
mediation with continuous improvement programmes
proved to be the formula for RCC’s plant-wide
progress. RCC was the first cement company to be
invited to present at EPA Region 3.
Energy management
In 2015, Titan America implemented a series of
processes that enabled 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
(RCC in Virginia and both the cement and aggregate
plants located in Medley, Florida) enabled employees
to systematically manage total consumption of all
energy sources. This programme, which addressed
the energy performance standard ISO 50001,
also guaranteed that the company’s business
operations were as efficient as possible, increased
plant reliability, and supported Titan’s operational
goals.
“We are passionate about continuously
developing efficient, sustainable operating practices,”
said Bill Zarkalis, CEO of Titan America. “Titan’s EnMS
programme is an excellent example of innovation
and of our commitment to make 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 the
recognition, but we do not take it for granted. We
are poised to continue our efforts.”
Conclusion
The efforts in these areas by Titan America are
not just domestic US projects but occur around
the globe. Parent company, Titan Cement Co.
was among the first 500 signatories, and is now
a participant of the UN Global Compact (UNGC).
UNGC is the world’s largest corporate sustainability
initiative based on CEO commitments to implement
universal sustainability principles and to undertake
partnerships in support of UN goals.
About the author
Lance Clark is the Alternative Fuels/Raw Materials and
Environmental Senior Manager for Roanoke Cement Co.,
a subsidiary of Titan America LLC, in Troutville, Virginia.
Clark is a 2004 graduate of the University of Virginia with
a bachelor’s degree in environmental sciences. He is active
in his community, participating in organisations such as the
Upper James River Roundtable and Botetourt Community
Partnership. He is an avid mountain-biker, hiker, and
outdoorsman.