Cement Manufacturing 1 AT A GLANCE 1996-2005 87.4 million 24% 115 facilities 115 0% 13,800 employees 13,800 0% 70.4 million metric tons of clinker produced 18 Cement Manufacturing <strong>2008</strong> SECTOR PERFORMANCE REPORT
Latest <strong>Environmental</strong> Statistics 2 Energy Use: 410.8 trillion Btu Emissions of Criteria Air Pollutants: 576,000 tons Releases of Chemicals <strong>Report</strong>ed to TRI: 13.5 million lbs. Air Emissions: 10.6 million lbs. Water Discharges: 3,300 lbs. Waste Disposals: 2.9 million lbs. Recycling, Energy Recovery, or Treatment: 412 million lbs. Hazardous Waste Generated: 17,000 tons Hazardous Waste Managed: 31,000 tons The data discussed in this report are drawn from multiple public and private sources. See the Data Guide and the Data Sources, Methodologies, and Considerations chapter for important information and qualifications about how data are generated, synthesized, and presented. Profile The Cement Manufacturing sector produces Portland cement, a binding agent that when mixed with water, sand, and gravel or crushed stone forms the rock-like mass known as concrete. Concrete, in turn, serves highway, commercial, and residential construction projects. Limestone is the key ingredient to manufacture cement. Limestone and other ingredients, including material that is aluminous, ferrous, and siliceous, are placed into a kiln where a thermochemical process occurs to make cement clinker. The cement clinker is mixed with additives (e.g., gypsum) to make Portland cement. The U.S. Cement Manufacturing sector is concentrated among a relatively small number of companies; many U.S. cement plants are owned by or are subsidiaries of foreign companies. Together, 10 companies accounted for about 80% of total U.S. cement production in 2005. 3 California, Texas, Pennsylvania, Florida, and Alabama are the five leading cement-producing states and accounted for about 48% of recent U.S. production. 4 Although production, imports, sales volumes, and prices of cement all reached record high levels in 2005, cement consumption is expected to decline in the near future. 5 Energy Use Cement Manufacturing is an energy-intensive industry. The thermochemical production process requires very high temperatures; grinding and crushing operations also use energy. On average, producing one metric ton of cement requires 4.7 million Btu. 6 Between 2000 and 2006, the sector’s energy consumption, when normalized by clinker production, decreased about 7%. 7 To make cement, the manufacturer places limestone and other ingredients into the upper end of a rotary kiln. At the lower end of the inclined kiln, a burner pipe emits a large flame, providing the intense heat required for the thermochemical process. The limestone and other materials go through several chemical processes that require temperatures reaching almost 1,500 degrees Centigrade (C). During the process, the raw materials, fuel molecules, and the air inside the kiln break apart. The limestone becomes calcium oxide and carbon dioxide (CO 2 ). Calcium oxide and silicates bond to form the principal compounds that cool into solid pellets called clinker. The manufacturer grinds clinker with gypsum and smaller amounts of other ingredients to create Portland cement. Kilns employ either a wet or dry process. The wet process uses raw materials ground with water to create a slurry material to be fed into the kiln, while the dry process uses dry materials in a powder-like input to the kiln. The wet process was initially used to improve the chemical uniformity of raw materials being processed; however, it Figure 1 Fuel Use for Energy 2006 Wastes 9% Electricity 11% Petroleum Products 1% Source: Portland Cement Association Total: 410.8 trillion Btu Coal and Coke 75% Natural Gas 3% <strong>2008</strong> SECTOR PERFORMANCE REPORT Cement Manufacturing 19
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Metal Casting 1 AT A GLANCE 1996-20
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using a cupola furnace can dehumidi
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Table 1 presents the top TRI-report
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Waste Management Reported to TRI hi
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Oil & Gas AT A GLANCE 1996-2005 1,2
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equipment helps recover the gas. In
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The most widely used EOR technique
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Petroleum refining Latest Environme
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Figure 2 Al TRI HA s Air Emissions
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energy technologies, and improving
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Paint & Coatings 1 AT A GLANCE 1996
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Figure 1 Air Emissions Reported to
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Owned Treatment Works, but may also
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Ports 1 AT A GLANCE 2005: 360 publi
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Increasing Use of Solar Power The P
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developing retrofit and replacement
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shipbuilding & ship repair 1 AT A G
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Table 1 Top TRI Air Emissions 2005
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Shipyards’ stormwater runoff is t
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data Sources, Methodologies, and CO
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Facilities described above must rep
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Data Processing RSEI calculates tox
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• Section 6.2: Transfers to other
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Cement Manufacturing 1. Facilities:
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12. Charles Heizenroth, EPA, person
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Forest Products 1. Facilities: Cens
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Public Data Release (PDR) (includes
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