EPA-600/2-77-023U
February 1977
Environmental Protection Technology Series
INDUSTRIAL PROCESS PROFILES FOR
ENVIRONMENTAL USE: Chapter 21.
The Cement Industry
1
industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-77-023U
February 1977
INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE
CHAPTER 21
THE CEMENT INDUSTRY
by
P. E. Muelberg and B. P. Shepherd
Dow Chemical
Freeport, Texas 77541
Terry Parsons and Glynda E. Wilkins
Radian Corporation
Austin, Texas 78766
Contract No. 68-02-1329
I. A. Jefcoat
Industrial Environmental Research Laboratory
Research Traingle Park, North Carolina 27711
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
Ten's report has been reviewed by the Industrial Environmental Research
Laboratory - Cincinnati, U.S. Environmental Protection Agency, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency,
nor does mention of trade names or commercial products constitute endorsement
or recommendation for use.
11
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TABLE OF CONTENTS
CHAPTER 21
Page
INDUSTRY DESCRIPTION 1
Raw Materials 2
Products 3
Companies 3
Envi ronmental Impact 4
Bibliography , 6
INDUSTRY ANALYSIS 7
Process No. 1. Mining 10
Process No. 2. Crushing 13
Process No. 3. Drying 15
Process No. 4. Grinding/Blending 17
Process No. 5. Calcining/Cooling 20
Process No. 6. Finish Milling/Loading 24
APPENDIX A - Raw Material List 27
APPENDIX B - Product List 29
APPENDIX C - Company/Product List 31
m
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LIST OF FIGURES
CHAPTER 21
No. Page
1 Cement Industry Chemical Tree 8
2 Cement Industry Flowsheet 9
iv
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LIST OF TABLES
CHAPTER 21
No. Page
1. Cement Plant Dust Collector Applicability 5
A-l. List of Raw Materials 28
B-l. List of Products 30
C-l. Company/Product List 32
C-2. Clinker Grinding Plants-1974 41
C-3. Masonry Cement Manufacturing Plants 42
C-4. Calcium Aluminate Manufacturing Plants 43
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ACKNOWLEDGEMENTS
This chapter of the Environmental Catalog of Industrial Processes was
developed for EPA by Dow Chemical U.S.A., Texas Division, under Contract
No. 68-02-1329, Task No. 8. The contributions made by J. T. Reding,
P. H. Muehlberg, and B. P. Shepherd in authoring this catalog entry are
gratefully acknowledged.
Helpful review comments from R. L. Bump, H. E. Hoon, and N. D. Phillips
were received and incorporated in this chapter.
vi
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CEMENT INDUSTRY
INDUSTRY DESCRIPTION
The cement industry consists of companies producing complex calcium-
si licate-aluminate-ferrite materials which when mixed with water form a
binding material for aggregates (crushed stone, gravel, and sand) in
"concrete." Products include a variety of portland cements, masonry
cements and calcium aluminate cement.
The portland cements are dominant in this industry. They account for
approximately 95 percent of the total volume. Masonry cement and calcium
aluminate cement account for the remaining 5 percent.
Portland cements of several types are manufactured using two
processes known as the "dry process" and the "wet process" (see Figure 2).
In both processes, the primary raw material, limestone or other calcium
carbonate deposit, is mined and crushed. Then the carbonate material
is blended and ground with alumina-containing, silica-containing, and
iron-containing materials. In the dry process, the raw materials are
dried before and/or during grinding. In the wet process, the raw
materials are mixed with water before grinding. In both processes, the
finely ground and intimately mixed raw materials are heated in a rotary
kiln until partially melted. Reactions occur to form a material called
"clinker." The clinker exits the kiln, is cooled, and then mixed and
ground with approximately 5 percent gypsum into a fine powder known as
portland cement.
Masonry cement is made by mixing crushed limestone and gypsum with
clinker and grinding to a fine powder. Calcium aluminate cement is
made by fusing a mixture of limestone and bauxite in a kiln and then
grinding the kiln product.
At the end of 1973, 166 plants in 41 states and Puerto Rico were
manufacturing portland cement. Of the 166 plants, 103 used the wet
process; 59, the dry process; and 4, both wet and dry processes. In
addition to these 166 plants, there were 7 plants which functioned
as grinding mills only, using imported, purchased, or interplant
transfers of clinker. Masonry cement was manufactured in 116 plants
at the end of 1972. However, only 4 plants produced masonry cement
exclusively. At the end of 1973, 4 plants were producing calcium
aluminate cement.
Size of portland cement plants, gauged by production capacity in
1973, ranged from 68,000 metric tons per year to 2,390,000 metric tons
per year. Mean plant production capacity was 480,000 metric tons per
year. Total mine and mill employment in the cement industry in 1973
was estimated to be 25,000.
Portland cement production in 1973 was 75 x 106 metric tons. This
included 2.6 million metric tons produced from imported clinker. Imports
1
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of portland cement were 3.6 million metric tons. Masonry cement produc-
tion was 3.7 million metric tons. It is estimated that calcium aluminate
cement production was less than 1 million metric tons.
Cement plants are located in 41 states and Puerto Rico. They are
located close to limestone or other calcium carbonate deposits. Because
of the relatively low value of portland cement ($23 to $55 per metric ton
in 1973 depending on type of cement), the marketing distance is limited.
Therefore, cement plants are usually fairly close to an urban market.
Approximately 45 percent of the U. S. and Puerto Rico cement production
is in California, Pennsylvania, Texas, Michigan, and New York. Transporta-
tion of product fs by rail, barge, and truck. In 1972, 91.4 percent of
cement shipments were bulk while 8.6 percent were in bags.
The portland cement industry is mature and is not experiencing a
large growth rate. An annual growth of 3 percent is expected through
1980.
Electric energy usage in the portland cement industry in 1972 was
10.6 x 109 kWh. Approximately 8 percent (0.85 x 109 kWh) was generated
at the cement plant while 92 percent (9.7 x 109kWh) was purchased.
Trends in the cement industry include increased used of:
•portable crushers in quarries
•roller mills to grind raw material
•suspension-type preheater kilns
•planetary clinker coolers
•computer control
•the dry process.
Raw Materials
The primary raw materials in cement production are the calcareous
minerals of limestone and cement rock. The most restrictive requirement
for the limestone material is that it cannot contain more than 3 percent
magnesium oxide. Most limestone and cement rock mines are open-pit
operations. In recent years, cement manufacturers have increased
efforts to landscape stripped areas.
The use of oyster shell as the calcareous mineral has been criticized
fay some conservation groups. Studies to determine the environmental
impact of this practice are underway.
-*.
A complete listing of raw material consumption for portland cement
in 1973 fs found fn Appendix A. Generally the argillacious (alumina-
containing), siliceous (silica-containing), ferrous (iron-containing),
and other materials are supplied to the cement manufacturer by other
companies or occur as impurities in the limestone deposit. Occasionally
the cement manufacturer mines separate deposits of these secondary
materials, using methods similar to those used in the limestone mining
operation.
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Products
The 78.6 million metric tons of portland cement consumed during 1973
were distributed among customers as follows:
Ready-mixed concrete 52.0 metric tons, 66%
Concrete product manufacturers 10.7 metric tons, 14%
Highway contractors 5.6 metric tons, 7%
Building material dealers 6.4 metric tons, 8%
Other contractors 2.2 metric tons, 3%
Federal, state, & other
government agencies 0.3 metric tons, <1%
Miscellaneous 1.4 metric tons, 2%
Masonry cement is used in mortar to bond brick and masonry. Calcium
aluminate cement is used primarily in refractory concrete for withstanding
temperatures up to 1500°C.
A list of different types of cement products and 1973 shipments is
found in Appendix B. The different portland cements have slightly dif-
ferent compositions. These differences may be the result of variations
in materials going into the clinker or the result of adding materials to
the clinker before grinding.
Companies
Most of the major companies involved in cement manufacture are diver-
sified conglomerates. The diversification has increased in the last ten
years because of the low rate of return for cement manufacturers.
Rather than reinvesting money in cement, companies manufacturing cement
have preferred to diversify into other activities.
A total of 53 companies manufactured portland cement as of
1973. They are listed in Appendix C along with plant locations,
production capacities, and type of process used. The twelve largest
portland cement producers are listed below. In 1964 the twelve
Capacity
Company Plants (metric tons/yr.)
Ideal Basic Industries, Inc. 14 6.3 x 106
U.S. Steel (Universal Atlas) 11 4.8 x 106
Lone Star Industries, Inc. 11 4.7 x 106
General Portland Incorporated 9 4.5 x 106
Martin Marietta Corporation 9 4.4 x 106
Marquette Cement Mfg. Co. 12 3.7 x 106
Amcord (American) 5 3.5 x 106
Kaiser Cement & Gypsum Corp. 5 3.3 x 106
Medusa Corporation 6 3,1 x 106
National Gypsum Company 2 3.0 x 106
Lehigh Portland Cement Company 6 2.8 x 106
California Portland Cement Co. 3 2.3 x 1Q6
"9T 46.4 x 10"
Percent of US plants & capacity 56% 57%
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largest producers accounted for 64 percent of the plants and 65 percent
of the production capacity. In 1974, they only accounted for 56 percent
of the plants and 57 percent of the production. A slight movement toward
less concentration in cement production is thus evident.
Companies which operate clinker grinding plants, masonry cement manu-
facturing plants, and calcium aluminate manufacturing plants are also
listed in Appendix C.
Environmental Impact
During the 10-year period through 1971, approximately 216 million
dollars were spent by the cement industry on capital equipment for air
and water pollution control. Pollution control facilities comprise
10 to 15 percent of the capital cost of a new plant.
The primary air pollution problems are emissions from the kiln and
at other points in the cement manufacturing process. Heavy investments
primarily in electrostatic precipitators and fabric or glass bag dust
collectors are decreasing these problems.
Most techniques for control of particulate emissions from sources
other than the kiln involve the capture of dust by drawing ambient air
in through a hood or other partial enclosure at the source at a velocity
sufficient to entrain the dust and carry it away in the air stream.
For most applications in the cement plant, an air intake velocity of
1.0 to 1.25 m/s (200-250 ft/min) is necessary to assure capture of the
particulates generated.
The dust-laden air is then transported through a series of ducts
to the collectors. Capture and transport systems are designed for optimal
fluid flow (round pipe, large radius turns, and acute angle junctions)
and the cross-sectional area is matched to flow rate to maintain the
air velocity above 18 m/s (3500 ft/min) and preferably about 20-23 m/s
(4000-4500 ft/min), thereby preventing dust from falling out within the
system.
Selection of a dust collector depends upon a number of factors
including particle size, dust loading, flow rate, moisture content, and
gas temperature. Table 1 summarizes the applicability of a number of
collection systems for use by the cement industry.
The primary water pollution problem is the overflow from slurry
concentrating equipment such as thickeners. New plants using the wet
process are designed with closed-cycle water systems in which overflow
water is returned to the process.
In the cement industry, raw and finish-grinding mills produce noise
levels of 102-105 decibels and diesel trucks in quarry operations register
94 decibels. Quantitative information on efforts to decrease this level
or reduce employees' exposure is not available.
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Table 1. CEMENT PLANT DUST COLLECTOR APPLICABILITY
Operation
Primary
Grinding
Air
Separators
Mills
Storage
Silos
Feeders
and Belt
Conveyors
Packing and
Loading
Coal
Dryer
Kiln Gases
Clinker
Cooler
Mechanical
Collector
Unsatisfactory
Efficiency
Not
Applicable
Not
Applicable
Not
Applicable
Not
Applicable
Not
Applicable
Preliminary
Cleaning Only
Preliminary
Cleaning Only
Preliminary
Cleaning Only
Net
Scrubber
Not
Applicable
Not
Applicable
Not
Applicable
Not
Applicable
Not
Applicable
Not
Applicable
Practicable
Impractical
Not
Applicable
Fabric
Collector
Successful
Successful
Successful
Successful
Successful
Successful
Successful
12x30 Glass
Successful
Successful
Electrostatic
Not
Applicable
A Few
Installations
A Few
Installations
Not
Applicable
Not
Applicable
Not
Applicable
Not
Common
Successful
Not
Common
Gravel Bed
Filter
None in
Use
Questionable
Application
Questionable
Application
Impractical
Impractical
Impractical
Practicable
Practicable
Successful
Source: Hoon, Harry E., Dust Collection in Portland Cement Manufacture.
Flex-Kleen Corp., Division of Research-Cottrel1, Inc. Chicago,
Illinois (1976).
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Strip-mined areas are receiving attention from cement manufactures.
Revegetation of quarry sections where mining is complete is being
practiced in some cases. Quantitative information is not available.
Bibliography
Bogue, R. H. Cement. In: Kirk-Othmer Encyclopedia of Chemical
Technology, 2nd Edition, Standen, A. (ed.). New York, John Wiley & Sons,
Inc., 1964. 4:684-710.
Brown B. C. Cement. In: Minerals Yearbook, 1972, Schreck, A. E. (ed.)
Washington, U. S. Dept. of Interior, 1973. l_:247-287.
Clausen, C. F. Cement Materials. In: Industrial Minerals and Rocks,
3rd Edition, Gillson, J. L. (ed.). New York, The Am. Inst. of Min., Met.,
and Petr. Eng., 1960. p. 203-231.
Grancher, R. A. United States Cement: Return on Investment. Rock
Products. 77_:56-59, 86-88, Dec. 1974.
Levine, S. Cement: Growth Rate of 3 Percent Projected Through 1980.
Rock Products. 77;44-47, Dec. 1974.
Trauffer, W. E. Ideal's New $25 Million Plant at Portland, Colorado.
Pit & Quarry. 68_: 52-62, Feb. 1975.
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INDUSTRY ANALYSIS
The cement industry Is competitive and operations are relatively
standardized. Pollution emission limitations imposed in the 1970's have
forced modernization and replacement of old equipment. The recent rise
in fuel prices has also accelerated modernization and replacement of old,
inefficient equipment. Information presented in the process descriptions
later in this report is believed to be representative of the industry.
Availability of quantitative information on emissions has in some
cases been inadequate. In these cases, the magnitudes have been
estimated from qualitative statements on emissions.
The chemical tree of Figure 1 gives a qualitative overview of the
cement industry from a raw material-product standpoint. The dominant
products are Portland cements I and II which account for approximately
88 percent of the total cement volume. Included under other portland
cements are sulfate resisting cements, white cement (low iron content),
slag cement (steel furnace slag added to "normal" portland before
finish grinding), expansive cement (slag and a calcium sulfoaluminate
cement added to "normal" portland before finish grinding), oil well
cement (portland containing a set retarder), and pozzolan cement
(pozzolan added to "normal" portland before finish grinding).
The process flowsheet of Figure 2 shows the process used in manu-
facturing portland cements and masonry cement. Because of its small
sales volume and the lack of processing information, the processes for
manufacturing calcium aluminate cement are not included on the flowsheet.
The interior of each of the rectangular "process blocks" appearing
on the flowsheet represents at least one of the sequential, real
processes of the cement manufacturing operation. A number and title
have been placed within each of the process blocks. These identifying
symbols are used in the process descriptions later in this report.
Flag symbols at the upper right-hand corner of the process block
indicate the nature of the waste streams, if any, discharged from the
process. A circle is used for atmospheric emissions, a triangle for
liquid wastes, and a rhombus for solid wastes. The flags do not
differentiate between inadvertent (fugitive) and designed wastes.
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Raw materials
Industry
end-products
Applications
00
Gypsum or anhydrite
Calcareous materials*.
Argillaceous materials&*»
—{Clinker}-
Limestone
Gypsum
materials" -^
terials* -*•
to.
Portland
cements
Types I & II
TTT
Ul
Other
{Masonry cement}
General use in concrete
High early strength concrete
•Special property concrete
Mortar
Bauxite
Limestone
Calcium aluminate
cement
* See Appendix A for more specific identification of raw materials.
Refractory concrete
Figure 1. CEMENT INDUSTRY CHEMICAL TREE.
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[Talcineroiif *
material,^
usually
^limestone
^deposits
Mining
Crushing
alcinsrous
material,
limestone
pebbles
Heat
9
Drying
Other *
ngredientS"!
Heat-TJ
Grinding/
blending .
Other
additives—I
Gypsum"! I
Limestone 1
Gypsum—|
Finish
milling/loading.
Finish
millino/loading
* See Appendix A for more specific identification of raw materials.
Figure 2. CEMENT INDUSTRY FLOWSHEET.
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CEMENT INDUSTRY PROCESS NO. 1
Mining
1. Function - This process (See Figure 2) removes primarily deposits of
limestone and cement rock from their natural source to the cement
plant crushers (Process 2). Other cement raw materials* such as clay
or shale are sometimes found close to or intermixed with limestone or
cement rock deposits and are removed with them.
Most deposits are worked through open quarries although some are
mined underground. A typical mining process includes removing over-
burden by shovels or bulldozers, blasting of rock, loading of the
blasted rock by front-end loaders or power shovels into trucks or
railroad cars, and transporting of the rock to the crushing plant
located in the quarry or at the cement plant. Rock size is up to 1
meter diameter.
2. Input Materials
.1.3 to 2.0 metric tons of calcareous raw material per metric ton of cement
The calcareous material could be limestone, cement rock, marl,
oyster shell, or other.
•0.0 to 0.3 metric tons of other raw materials* per metric ton of
cement.
3. Operating Parameters
•Ambient temperature
•Atmospheric pressure
•Overburden from 1 to 30 meters deep
•Typical equipment:
3 1/2 cubic meter shovels
30-70 ton truck capacities
10 meter front-end loaders
•Quarry face height of 10 to 60 meters
•Variations in deposit composition from layer to layer often require
selective quarrying to obtain a fairly uniform quarry product.
* Raw materials used in North America for cement manufacture include
the following:
calcareous materials - limestone, cement rock, marl, alkali waste,
oyster shell, coquina shell, chalk, marble.
argillaceous materials - clay, shale, slag, fly ash, copper slag,
aluminum ore refuse, staurolite, dfaspore clay, granodiorite, kaolin.
siliceous materials - sand, "traprock," calcium silicate, quartzite,
Fuller's earth.
ferriferous materials - iron ore, iron calcine, iron dust, iron
pyrite, iron sinters, iron oxide, blast furnace flue dust.
10
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uui i
•Fuel for vehicles
4000 kcal per metric ton cement
•Electrical
2-3 kWh per metric ton cement
•Explosives
1000 kcal per metric ton cement
5. Waste Streams
•Dust emissions are released from mining steps such as blasting,
earthmoving, truck loading and unloading, and truck movement. Dust
from roads can be reduced by wet suppression techniques including
watering and treating with an oil emulsion. Most emissions are
heavy particles that settle out within the plant.
•Stripped overburden can sometimes be used as a raw material. If
not, disposal of the material is usually by local landfill. A
gross estimate of overburden used as landfill is from 0 to 3 metric
tons per metric ton of cement produced.
6. EPA Source Classification Code - None
7. Bibliography
Brown, B. C. Cement. In: Minerals Yearbook, 1971. Schreck,
A. E. (ed.). Washington, U. S. Dept. of the Interior, 1973.
1:257-290.
Clausen, C. F. Cement Materials. In: Industrial Minerals and
Rocks, 3rd Edition. Gillson, J. L. (ed.). New York, The Am. Inst.
of Min., Met., and Petr. Eng., 1960. p. 203-231.
Drake, H. J. Stone. In: Minerals Yearbook, 1971. Schreck,
A. E. (ed.). Washington, U. S. Dept. of the Interior, 1973.
1:1097-1118.
Garrett, H. M., and J. A. Murray. Improving Kiln Thermal Efficiency
Design and Operation Considerations, Part 1. Rock Products.
77:74-77, 124, May 1974.
Robertson, J. L. Gifford-Hill Onstream with Preheater Kiln. Rock
Products. 77.:70-73, May 1974.
Trauffer, W. E. Canada Cement Lafarge's New Bath, Ontario Plant.
Pit and Quarry. 67:74-86, July 1974.
Trauffer, W. E. Flintkote's Glens Falls Plant Expansion. Pit and
Quarry. 67;126-134, July 1974.
11
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Trauffer, W. E. Ideal's New $25 Million Plant at Portland, Colorado.
Pit and Quarry. 68:52-62, February 1975.
Trauffer, W. E. Phoenix Clarkdale Plant Expanded and Improved to
Meet Growing Demand. Pit and Quarry. 66:125-127, 130-131, July 1973.
12
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CEMENT INDUSTRY PROCESS NO. 2
Crushing
1. Function - This process (See Figure 2) decreases the size of mined
1imestone or cement rock from Process 1.
Various types of crushers are used depending on the nature of the
rock (hardness,lamination, quarry product size). These include
gyratory crushers, jaw crushers, impact mills, hammer mills, and
roll crushers. Often the crushing plant is located in the quarry and
is portable. Screening and conveying of crushed rock to storage is
included in this process.
In a typical crushing plant, a primary crusher may reduce the rock from
power shovel size to 0.1 to 0.25 meter and a secondary crusher may
again reduce this product to approximately 0,01 to 0.05 meter size.
This material is then transported to raw material storage piles or
compartments on a belt conveyor. This material will then be conveyed
with other raw materials to Process 3 or Process 4.
In some instances, partial drying of rock is accomplished in the
crushing process by passing kiln exhaust gases, clinker cooler exhaust
air, or furnace heated air through the crusher.
2. Input Materials
•Calcareous material
1.3 to 2.0 metric tons per metric ton of cement depending on
purity and composition
•Other materials
0.0 to 0.3 metric tons per metric ton of cement
3. Operating Parameters
•Ambient temperature (usually)
•Atmospheric pressure
•Typical modern equipment
Receiving hopper - 70 to 140 metric ton capacity.
700 ton per hour portable two-stage impactor crusher with 600 kW
and 800 kW motors for driving crusher.
2.5 meter x 5.5 meter inclined, vibrating screen.
Enclosed belt conveyors - 0.8 meter to 1.2 meters wide and up to
several thousand meters long.
Cyclone dust collector plus baghouse containing 1000 bags, each one
0.12 meter in diameter x 2.7 meters long.
13
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4. Utilities
•Electrical
2 to 5 kWh per metric ton cement
5. Waste Streams
•Dust is emitted during crushing, screening, and conveying steps.
Most of the emissions are heavy particulates that settle out within
the plant. Without emission abatement systems* estimated emissions
are 0.01 metric ton per metric ton of cement produced. Dust
collection systems reduce the emissions to 0.0005 metric ton per
metric ton of cement produced.
6. EPA Source Classification Code - None
7. Bibliography
Clausen, C. F. Cement Materials. In: Industrial Minerals and Rocks,
3rd Edition. Gillson, J. L. (ed.). New York, The Am. Inst. of Min.,
Met., and Pet. Eng., 1960. p. 203-231.
Conrad, G. Preprocessing in Crusher/Dryers Improves Milling
Efficiency. Rock Products. 7^:102-104, 129-130, November 1972.
Estimating Dust Control Costs for Crushed Stone Plants. Rock
Products. 78:49-53, April 1975.
Garrett, H. M., and J. A. Murray. Improving Kiln Thermal Efficiency -
Design and Operation Considerations, Part 1. Rock Products.
77^74-77, 124, May 1974.
Levine, S. Preheater Kiln Reduces Fuel Consumption at Arizona Plant.
Rock Products. 76:89-92, May 1973.
Robertson, J. L. Gifford-Hi 11 Onstream with Preheater Kiln. Rock
Products. 77:70-73, May 1974.
Trauffer, W. E. Canada Cement Lafarge's New Bath, Ontario Plant.
Pit and Quarry. 67^:74-86, July 1974.
Trauffer, W. E. Phoenix Clarkdale Plant Expanded and Improved to
Meet Growing Demand. Pit and Quarry. 66:126-127, 130-131, July 1973.
14
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CEMENT INDUSTRY PROCESS NO. 3
Drying
1. Function - This process (See Figure 2) reduces the moisture content
of cement raw materials moved by belt conveyor from Process 2 to less
than 1 percent. Usually the moisture content of the calcareous
raw material is 3 to 8 percent, but it may be as high as 20 percent.
The dried material is moved by belt conveyor to storage silos. The
drying process is necessary only in the "dry process" cement manu-
facturing technique.
Furnace heated air, kiln exhaust gases, or clinker cooler exhaust
air are commonly used to dry crushed stone in a cylindrical rotary
dryer. In modern installations drying and grinding are frequently
combined. Sometimes crushing and drying are combined.
2. Input Materials
•Calcareous material
1.3 to 2.0 metric tons per metric ton of cement
•Other materials
0.0 to 0.3 metric tons per metric ton of cement
3. Operating Parameters
•600°C temperature
•Atmospheric pressure
•Typical modern equipment
4.5 meter x 40 meter rotary dryer revolving at 160 rph
4. Utilities
• Fuel
200,000 kcal per metric ton cement
•Electricity
1-2 kWh per metric ton cement
5. Waste Streams
•Dust emissions from dryers are estimated to be 0.01 to 0.05 metric
tons per metric ton of cement. This is in addition to the amount
that is initially present in the heating medium which could be
furnace heated air, kiln exhaust gases, or clinker cooling air.
Electrostatic filters and/or fabric filters reduce the emission to
0.0002 metric ton per metric ton of cement.
15
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6. EPA Source Classification Code
3-05-006-02 Dryers/Grinder, etc.
7. Bibliography
Clausen, C. F. Cement Materials. In: Industrial Minerals and
Rocks, 3rd Editfon. Gillson, J. L. (ed.). New York, The Am. Inst.
of Min., Met., and Petr. Eng., 1960. p. 203-231.
Conrad, G. Preprocessing in Crusher/Dryer Improves Milling
Efficiency. Rock Products. 75:102-104, 129-130, November 1972.
Garrett, H. M., and J. A. Murray. Improving Kiln Thermal Efficiency-
Design and Operation Considerations, Part 1. Rock Products. 77:74-
77, 124, May 1974.
Robertson, J. L. Gifford-Hi 11 Onstream with Preheater Kiln. Rock
Products. 77;70-73, May 1974.
Sussman, V. H. Chapter 35. In: Air Pollution, 2nd Ed. Stern, A. C.
(ed.). New York, Academic Press, 1968. 3;123-142.
Weber, P. Utilization of Waste Heat from Dry-Process Rotary Kilns.
Pit and Quarry. 67:115-122, July 1974.
16
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CEMENT INDUSTRY PROCESS NO. 4
Gr1ndi ng/Blendi ng
1. Function - This process (See Figure 2) includes feeding of raw
material to the grinding mill, grinding of the materials to a fine
size suitable for feeding to a kiln, and blending of the ground
material to obtain kiln feed of the correct composition.
a. The dry process - Raw materials from several piles or bins are
withdrawn in carefully proportioned ratios through a weighing
machine or table feeder and moved by belt conveyor to the
grinding mill. Ball mills and tube mills in series or combined
into a single two-stage machine called a compartment mill are
usually used. Roller mills use less power and can accept larger
size and wetter feed. They are becoming more popular. Air
separators are usually used to divide mill discharge into a
coarse recycle fraction and a fine product fraction. The
product is a powder such that 75 to 90 percent passes through
a 200 mesh sieve. Often some drying of raw materials can be
accomplished in a compartment ahead of the grinding mill or within
the mill itself. This is done by passing kiln exhaust gases,
clinker cooler exhaust air, or furnace heated air through the
equipment. Finely ground raw meal is conveyed by pneumatic
pumps, elevators, or screw conveyors to storage silos. Agitation,
circulation, and homogenization techniques are used to obtain a
final blend from several silos. The final blend is air or
mechanically agitated and homogenized for one or two hours and
then pumped to the kiln (Process 5).
b. The wet process - Water or clay slip (containing minute amounts
of chemicals* known as slurry thinners) is fed along with
preproportioned crushed raw materials to ball, tube, and compart-
ment mills similar to those used in the dry process. Vibrating
screens, rake classifiers, hydroseparators, or thickeners are
used to remove oversize mill discharge and return it to the mill.
Finished slurry is pumped to slurry basins designated as mixing,
correcting, blending and storage. All tanks or basins are
agitated by compressed air and/or mechanical agitators. Material
from several tanks can be blended and homogenized in the kiln
feed storage tank and then pumped to the kiln (Process 5).
2. Input Materials
a. 1.7 metric tons of raw materials per metric ton cement.
* Chemicals include waste sulfite liquor, sodium carbonate, sodium
silicate, sodium tri-polyphosphate, and tetrasodium pyrophosphate.
17
-------
b. 1.7 metric tons of raw materials per metric ton cement.
1 metric ton of process water per metric ton cement.
.0005 to 0.001 metric ton chemical slurry thinner per metric
ton cement.
3. Operating Parameters
a. 'Atmospheric pressure
•Ambient temperature if no drying is required
•350°C to 700°C temperature if drying is combined with grinding
•Typical modern equipment
Compartment mill -3 meters diameter x 10 meters long with
1100 kW motor.
5 meters diameter air separator.
336 bag, 7-zone baghouse dust collector.
b. 'Atmospheric pressure
•Ambient temperature
•Typical modern equipment
Compartment mill -3.5 meters diameter x 10.5 meters long with
1500 kW motor.
110 metric ton per hour capacity of slurry containing 35
percent water.
Kiln feed tanks - 16 meters diameter x 13 meters high.
4. Utilities
a. Electrical
45 kWh per metric ton cement
b. Electrical
35 kWh per metric ton cement
5. Waste Streams
a. Dust emissions can occur from proportioning equipment, conveyors,
grinding mills, and storage silos. Total emissions are estimated
to be 0.03 metric tons per metric ton of cement produced. It
is estimated that dust collection equipment (such as bag filters)
reduces these emissions to less than 0.0003 metric tons per metric
ton of cement produced.
b. Dust emissions primarily from proportioning equipment are
estimated to be 0.01 metric tons per metric ton of cement.
It is estimated that dust collection equipment reduces these
emissions to less than 0.0001 metric tons per metric ton of
cement produced. Water effluent containing suspended solids is
eliminated in a closed cycle water system. If water is not
recycled, amounts up to 0.4 metric tons per metric ton of cement
produced could be rejected to natural streams. It is estimated
that this water could contain 1 percent solids.
18
-------
6. EPA Source Classification Code
3-05-006-02 Dryers/Grinder, etc.
3-05-007-02 Dryers/Grinder, etc.
7. Bibliography
Bogue, R. H. Cement, In: Kirk-Othraer Eycyclopedia of Chemical
Technology, 2nd Ed., Standen, A. (ed.). New York, John Wiley &
Sons, Inc., 1964. 4^684-710.
Clausen, C. F. Cement Materials. In: Industrial Minerals and
Rocks, 3rd Edition. Gillson, J. L. (ed.). New York, The Am. Inst.
of Min., Met., and Petri Eng., 1960. p. 203-231.
Dannielson, J. A. Air Pollution Engineering Manual, Air Pollution
Control District County of Los Angeles, 2nd Ed., 1973.
Garrett, H. M., and J. A. Murray. Improving Kiln Thermal Efficiency-
Design and Operation Considerations, Part 1. Rock Products. 77^:74-
77, 124, May 1974.
Robertson, J. L. Gif ford-Hill -Onstream with Preheater Kiln. Rock
Products. 77;70-73, May 1974.
Trauffer, W. E. Ideal's New $25 Million Plant at Portland, Colorado.
Pit and Quarry. 68:52-62, February 1975.
Trauffer, W. E. Phoenix Clarkdale Plant Expanded and Improved to
Meet Growing Demand. Pit and Quarry. 66:126-127, 130-131, July 1973.
Vandegrift, A. E. and others. Particulate Air Pollution in the
United States. J. of Air Pollution Control Association, 21. June
1971.
Weber, P. Utilization of Waste Heat from Dry Process Rotary Kilns.
Pit and Quarry. 67_:115-122, July 1974.
19
-------
CEMENT INDUSTRY PROCESS NO. 5
Calcining/Cooling
1. Function - This process (See Figure 2) converts the finely ground
kiln feed from Process 4 to portland cement clinker by heating it in
a rotary kiln to approximately 1500°C and then cooling it to ambient
temperature.
a. The dry process - Raw meal is pneumatically pumped to the upper
end of a steel kiln. The meal flows slowly down through the
sloped kiln. Heat is supplied from the lower end of the kiln by
the combustion of coal, fuel oil, or natural gas. Hot combustion
gases are pulled by forced draft up through the kiln in counter
flow .to the raw meal. Fire brick refractories line the inside of
the kiln in order to protect the steel shell from the heat and
to conserve fuel. Lifters are usually located inside the kiln
to facilitate heat transfer from the combustion gases to the.raw
meal. As the raw meal passes through the kiln, it gets hotter.
When its temperature reaches 800 to 1000°C, carbon dioxide is re-
leased by calcium carbonate. At 1500°C, the raw meal becomes
partially sintered and complex compounds are formed. The resulting
0.5 to 1 cm diameter material is called clinker. It is cooled
in rotary coolers, planetary coolers, or grate-type coolers by
air pulled into the cooler. The heated air is then used as com-
bustion air for the fuel. The cooled clinker is conveyed by
drag chains, vibrating troughs, or belt conveyors to storage.
Recently, because of increasing fuel costs, suspension gas pre-
heaters have come into use. These allow raw meal to pass through
a system of cyclones counter-current to kiln exit gases before
entering the kiln.
b. The wet process - Slurry is pumped to the upper end of a refractory-
lined steel kiln and flows down through the kiln. Wet process
kilns are somewhat longer than dry process kilns because a portion
of the kiln (1/4 to 1/5) is used for evaporation of slurry water.
Chain heat exchangers inside the upper section of the kiln
increase the surface of slurry exposed to the hot combustion
gases and facilitate heat transfer. They also reduce dust
emissions. Clinker formation and handling is similar to that
described in the dry process.
2. Input Materials
a. 1.7 metric tons raw meal per metric ton cement
b. 2.2 to 2.7 metric tons slurry per metric ton cement
(contains 20 to 40 percent moisture)
20
-------
3. Operating Parameters
a,b. 'Atmospheric pressure
•Maximum kiln temperature - 1450 to 1600°C
•Equipment size range
Kiln - 20 meters to 230 meters long
2 meters to 7 meters diameter
20 to 60 rph sloped at 0.3 cm per m
a. 'Typical modern systems
Long dry process kiln - 5 meters in diameter x 145 meters long
with capacity of 1200 metric tons per day.
Four-stage suspension preheater kiln - 4.3 meters in diameter
x 65 meters long with capacity of 1200 metric tons per day.
Four-stage suspension preheater height of 60 meters.
Four meters x 22-meter horizontal grate-type clinker cooler
with 7 to 10 fans and a total power requirement of 500 kW.
Kiln dust collector system - exit gas temperature from most
conventional process kilns exceeds the limits of all bag
fiber except glass. For this purpose, field-assembled,
insulated baghouses using large 0.3 meter x 9 meter bags
are usually employed. In order to prevent condensation
of moisture, the exit gas temperature should be kept 45°C
higher than the dew point. If the resultant temperature
exceeds 287°C, even glass fiber filters are unsuitable
because of deterioration. In such applications, electro-
static precipitators are used for dust collection, with
gravel filter beds a possible satisfactory alternative.
Because of the heavy dust loading in kiln exit gases,
mechanical collectors such as cyclones or multi-tube col-
lectors are usually employed to pre-clean the exit gas
stream.
Clinker Cooler dust collector system - 12-zone baghouse with
1900 bags measuring 0.12 meter diameter x 2.7 meters long.
Pulse-jet type filters using felted fabric find widespread
use. Dacron felted fibers may be employed if carefully
controlled water spray is used to limit gas temperature,
but Nomex is preferred because of its 232°C temperature
tolerance. The most common cement industry use of gravel-
bed filters occurs in the treatment of clinker cooler off
gases.
600 kW motor for kiln fan.
b. 'Typical modern systems
Wet process kiln - 5 meters diameter x 160 meters long
with a capacity of 1200 metric tons per day.
Dust collection system and motors similar to the dry process.
21
-------
4. Utilities
a. -Fuel
0.8 x TO6 to 2 x 106 kcal per metric ton cement
•Electrical
35 kWh per metric ton cement
b. -Fuel
1.3 x 106 to 2.5 x 106 kcal per metric ton cement
•Electrical
30 ph per metric ton cement
5. Waste Streams
a. Dust emissions from the kiln* range from 0.06 to 0.23 metric tons
per metric ton of cement produced if exiting combustion gases
are discharged directly into the air. When exiting kiln gases
pass through highly efficient electrostatic precipitators and/or
fabric filters, the dust discharge is reduced to 0.0002 metric
tons per metric ton of cement produced.
a,b. Clinker cooler air containing particulates may be discharged to
the atmosphere. It contains particulates in a quantity up to 0.10
metric ton per metric ton of cement produced. Ten to fifteen
percent of these dust particles are below 10 microns diameter.
When this air is passed through highly efficient electrostatic
precipitators, fabric filters or gravel bed filters, the dust
discharge is reduced to less than 0.00007 metric tons per metric
ton of cement produced.
b. Dust emissions from the kiln* range from 0.04 to 0.13 metric
tons per metric ton of cement produced if exiting combustion
gases are discharged directly into the air. When exiting kiln
gases pass through highly efficient electrostatic precipitators,
fabric filters, or in one case venturi scrubbers, the dust dis-
charge is reduced to 0.0002 metric tons per metric ton of
cement produced.
a,b. Some collected kiln dust* cannot be reintrodueed into the Mln
because of high alkali content. It then can be used as a sub-
stitute for agrtcultural limestone, fertilizer, or mineral filler.
* Size distribution of kiln dust has been determined as follows:
93 percent less than 60 micron diameter
90 percent less than 50 micron diameter
84 percent less than 40 micron diameter
74 percent less than 30 micron diameter
58 percent less than 20 micron diameter
38 percent less than 10 micron diameter
23 percent less than 5 micron diameter
3 percent less than 1 micron diameter
-------
If no use can be found, it is often disposed of in abandoned
quarries or storage piles. If this is done, the dust piles
should be covered, enclosed, or sprayed with water to form a
surface crust. Dust collected could be as much as 0.2 metric
tons per metric ton of cement produced.
a,b. S02 emissions can occur if high sulfur coal is used as fuel to
heat the kiln. However, sulfur oxides passing through a cement
kiln are to a large extent removed from the combusfon gases and
become part of the clinker.
. EPA Source Classification Code
3-05-006-01 Kilns
3-05-006-03 Kilns - Oil Fired
3-05-006-04 Kilns - Gas Fired
3-05-006-05 Kilns - Coal Fired
3-05-007-01 Kilns
3-05-007-03 Kilns - Oil Fired
3-05-007-04 Kilns - Gas Fired
3-05-007-05 Kilns - Coal Fired
f
. Bibliography
Bogue, R. H. Cement. In: Kirk-Othmer Encyclopedia of Chemical
Technology, 2nd Ed. Standen, A. (ed.). New York, John Wiley & Sons,
Inc., 1964. 4:684-710.
Clausen, C. F. Cement Materials. In: Industrial Minerals and
Rocks, 3rd Ed. Gillson, J. L. (ed.). New York, The Am. Inst. of
Min., Met., and Petr. Eng., 1960. p. 203-231.
Garrett, H. M., and J. A. Murray. Improving Kiln Thermal
Efficiency - Design and Operation Considerations, Part 1. Rock
Products. 77:74-77, 124, May 1974.
Goldberger, R. H. Rx for Cement Dust. Rock Products. 76_:55, 76,
78, August 1973.
Koehler, W. Present Position in Combating Air Pollution and
Nuisance in the Cement Industry. November 1969.
Koonsman, G. L. Type of Cooling is Critical to Best Use of Fuel.
Rock Products. 76;56-57, 76-78, November 1973.
Norbom, H. R. Wet or Dry Process Kiln for Your New Installation?
Rock Products. 77:92-100, May 1974.
Sussman, V. H. Chapter 35. In: Air Pollution, 2nd Ed.
Stern, A. C. (ed.). New York, Academic Press, 1968. 3_:123-142.
Vandegrift, A. E., and others. Particulate Air Pollution in the
United States. J. of Air Pollution Control Association. Vol. 21,
June 1971.
23
-------
CEMENT INDUSTRY PROCESS NO. 6
Finish Mining/Loading
1. Function
a. Portland cements - This process (See Figure 2) receives clinker
from clinker storage, grinds it along with a 5 percent gypsum
addition to a fine powder (generally 94 to 98 percent will
pass through 325 mesh sieve], forwards the resulting portland
cement to cement storage, and loads it into bulk carriers or
packages it into bags. Other additives may be included along
with the gypsum to give specialty portland cements.
b. Masonry cement - this process (See Figure 2) receives clinker from
clinker storage, grinds it along with a 5 percent gypsum addition
plus a crushed limestone addition to a fine powder (generally
94 to 98 percent will pass through 325 mesh sieve), and forwards
the resulting masonry cement to storage.
a,b. Clinker and additives are drawn from storage using weigh
feeders to proportion the cement ingredients. Belt conveyors
deliver the ingredients usually to a two-compartment ball mill.
The mill may be rubber lined. An air separator usually recycles
oversize product and forwards correct size product to storage
silos. Either air or water cooling in the grinding step is
employed to prevent dehydration of the gypsum. Cement is trans-
ferred from storage silos to trucks, railroad cars, or boats
using airslide conveyors. Approximately 9 percent of the cement
produced is packaged fnto multi-layer paper bags using automatic
machines. These bags hold 42.7 kg of cement.
2. Input Materials
a. 0.95 metric tons clinker per metric ton normal portland cement.
0.05 metric tons gypsum per metric ton normal portland cement.
Specialty portland cements include pozzolan cement which contains
15 to 30 percent pozzolan, slag cement which contains 25 to 65
percent slag, expansion cement which contains 20 percent slag
and 10 percent calcium sulfoaluminate cement, and oil well cement
which contains a set retarder.
b. 0.5 to 0.8 metric tons clinker per metric ton masonry cement.
0.02 to 0.04 metric tons gypsum per metric ton masonry cement.
0.5 to 0.2 metric tons limestone per metric ton masonry cement.
3. Operating Parameters
a,b. •Atmospheric pressure
•Approximately 60°C temperature
-------
•Typical equipment
Two-compartment ball mill - 3 to 4.5 meters diameter, 6 to
16 meters long.
Motor - 1000 kW to 5000 kW.
Capacity 30 to 120 metric tons per hour.
2-meter-diameter x 5-meter-long cooler.
Storage silos - 10 meters diameter x 60 meters high.
4. Utilities
a,b, 'Electrical
75 kWh per metric ton of cement produced
•Cooling water
0 to 1 metric ton per metric ton cement produced
5. Waste .Streams
a,b. -Dust emitted from the grinding/loading process is collected by
multi-cyclone plus electrostatic precipitator systems or
fabric cloth systems. Estimated emissions to the atmosphere
are less than 0.00001 metric tons per metric ton cement.
6. EPA Source Classification Code
3-05-006-02 Dryers/Grinder, etc.
3-05-007-02 Dryers/Grinder, etc.
7. Bibliography
Bogue, R. H. Cement. In: Kirk-Othmer Encyclopedia of Chemical
Technology, 2nd Ed. Standen, A. (ed.). New York, John Wiley & Sons,
Inc., 1964. £: 684-710.
Clausen, C. F. Cement Materials. In: Industrial Minerals and
Rfccks, 3rd Ed. Gillson, J. L. (ed.). New York, The Am. Inst. of Min.,
Met., and Petr. Eng., 1960. p. 203-231.
Hackman, A. H., R. J. Pitney, and D. F. Hagemeier. Survey of U. S.
Cement Finish Mills. Pit and Quarry. 66:112-116, 118, 120, 122.
July 1973.
Morgan, J. T. Finish Mill Acts as Thermostat. Rock Products. 76;59-
60, 84. August 1973.
25
-------
APPENDIX A
RAW MATERIAL LIST
27
-------
Table A-l. LIST OF RAW MATERIALS
Raw Material
Calcareous
Limestone (includes aragonite)
Cement rock (includes marl)
Oyster shell
Argillaceous
Clay
Shale
Other*
Siliceous
Sand
Sandstone and quartz
Ferrous
Iron ore, pyrites, mill scale
and other iron-bearing material
Other
Gypsum and anhydrite
Blast furnace slag
Fly ash
Other
Total
Quantity**
(million metric tons)
78.9
23.7
4.7
7.2
3.7
0.2
1.9
0.7
0.9
3.9
0.6
0.3
0.0
126.7
%
85%
62%
19%
4%
9%
6%
3%
2%
1.5%
.5%
.7%
.7%
4%
3%
.5%
.2%
* Includes staurolite, bauxite, aluminum dross, pumice, and volcanic
material.
** For the year 1973.
-------
APPENDIX B
PRODUCT LIST
29
-------
Table B-l. LIST OF PRODUCTS
Cement
1973 shipments
in million
metric tons
(%)
Portland cements
Types I & II (general use and moderate heat)
Type III (high early strength)
Type V (sulfate resisting)
Oil -well
White (low iron)
Slag and pozzolan
Expansive
Other
Masonry cement
Calcium aluminate cement
72.5
2.6
0.6
0.6
0.5
0.9
0.1
0.9
3.7
<1.0*
88
3
.7
.7
.6
1
.1
1
4
1
* Estimated.
-------
APPENDIX C
COMPANY/PRODUCT LIST
31
-------
Table C-l. COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year) Process
Alpha Portland Industries, Inc.
Alpha Portland Cement Co. Div.
Birmingham, Alabama '
Lime Kiln, Maryland-
St. Louis, Missouri /
Cementon, New York '
James ville, New York"
Orange, Texas
-------
Table C-l. (Continued) COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year) Process
Capitol Aggregates, Inc.
Capitol Cement Div.
San Antonio, Texas v/
Centex Cement Corp. (Centex Corp.)
Corpus Christi, Texas /
Century Cement Manufacturing Co., Inc.
X Rosendale, New York
Columbia Cement Corp. (subs. Filtrol Corp.)
Barberton, Ohio S
Zanesville, Ohio!/ .
Bellingham, Washington *
Citadel Cement Corp.
% Birmingham, Alabama
Demopolis, Alabama ^
\ Roanoke, Virginia
Coplay Cement Manufacturing Co.
Coplay, Pennsylvania/
Nazareth, Pennsylvania v
Dundee Cement Co.
Dundee, Michigan !i/
- Clarksville, Missouri iX
Flintkote Co.
Calaveras Cement Div. ,
San Andreas, California/
Redding, California *
Diamond- Kosmos Cement Div.
Kosmodale, Kentucky/
Middlebranch, Ohio^
Glen Falls Cement Div.
Glen Falls, New York •
299,000
239,000
154,000
257,000
598,000
324,000
1,179,000
307,000
205,000
667,000
1,179,000
718,000
513,000
1,231,000
1,025,000
1,196,000
2,221,000
854,000
273,000
600,000
513,000
513,000
2,753,000
Wet
Wet
Dry
Wet
Wet
Wet
Wet
Dry
Dry
Dry
Dry
Wet
Wet
Wet
Dry
Dry
Dry
Dry
Continued
33
-------
Table C-l. (Continued) COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year) Process
General Portland Co.
Peninsular Div.
Paul ding, Ohio-/ 452,000 Wet
Southeastern Div.
Tampa, Florida/^ 1,196,000* Wet
Miami Floridav' 462,000 Wet
Chattanooga, Tennesseev 462,000
Trinity Div.
Dallas, Texas\/ y 598,000 Wet
Fredonia, Kansasv 393,000 Wet
Houston, Texas^ 427,000* Wet
Fort Worth, Texas\/ 622,000 Wet
California Division .
Lebee, California^ 542,000 Dry
5,154,000
Giant Portland Cement Co.
Harleyville, South Carolina- 684,000 Wet
Gifford-Hill Portland Cement Co.
Southwest Div.
Midlothian, Texas - 769,000 Wet
Eastern Div.
* Harleyville, South Carolina 513,000 Dry
1,282,000
Gulf Coast Portland Cement Co.
Div. McDonough Co.
Houston, Texas- 257,000 Wet
Hudson Cement Co. Div.
Colonial Sand & Stone Co.
Kingston, New York v 684,000 Wet
Hawaiian Cement Corp.
Ewa Beach, Hawaii . 171,000 Dry
Ideal Cement Co. Div.
Ideal Basic Industries, Inc.
Mobile, Alabama, 478,000 Wet
Okay, Arkansasy 324,000 Wet
Boettcher, Colorado* 427,000 Dry
Portland, Colorado- 377,000 Wet
v Houston, Texas 649,000* Wet
Continued
34
-------
Table C-l. (Continued) COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year) Process
Baton Rouge, Louisiana/ 513,000 Wet
Trident, Montana/ 291,000 Wet
Superior, Nevada ^ 341,000 Wet
Tijeras, New Mexico^ 462,000 Dry
Castle Hayne, North Carolina 598,000 Wet
Seattle, Washington/ 427,000 Wet
Ada, Oklahoma i 598,000 Wet
Devil's Slide, Utah^ 324,000 Wet
Knoxvilie, Tennessee- 478.000 Wet
6,287,000
Illinois Cement Co. (Centex Corp.)
LaSalle, Illinois^ 341,000 Dry
Kaiser Cement & Gypsum Corp.
Permanente, California^ 1,368,000 Wet
Lucerne Valley, Californiav 891,000 Wet
Nanakuli, Hawaii 273,000 Wet
Montana City, Montana v 240,000 Wet
San Antonio, Texas^ 409.000 Wet
3,181,000
Keystone Portland Cement Co.
Bath, Pennsylvania-- 564,000 Wet
Lehigh Portland Cement Co.
Alsen, New York 462,000 Dry
Mason City, lowa^ 564,000 Dry
Metaline Falls, Washington- 205,000 Dry
Miami, Florida^ 462,000 Wet
Mitchell, Indiana-- 462,000 Dry
Union Bridge, Maryland- 837.000 Dry
2,992,000
Lone Star Industries, Inc.
Nazareth, Pennsylvania^ 615,000 Dry
Greencastle, Indiana-- 684,000 Wet
Bonner Springs, Kansas- 410,000 Wet
Houston, Texas^ 564,000 Wet
Maryneal, Texas* 547,000 Wet
New Orleans, Louisiana-' 377,000 Wet
Seattle, Washington- 684,000 Wet
Davenport, California^ 769,000 Dry
4,650,000
Continued
35
-------
Table C-l. (Continued) COMPANY/PRODUCT LIST
Capaei ty
Company/location (metric tons/year)
Louisville Cement Co.
Speed, Indiana-
Logansport, Indiana /
Bessemer, Pennsylvania
Marquette Cement Manufacturing Co.
Branden, Mississippi^
Cape Girardeau, Missouri^
Catskill, New York
Cowan, Tennessee^
Des Moines, Iowa-/
Hagerstown, Maryland-/
Milwaukee, Wisconsin^
Nashville, Tennessee
Oglesby, Illinois^
Pittsburgh, Pennsylvania-/
Rockmart, Georgia*
Superior, Ohio*
• "
Martin Marietta Cement
Eastern Div.
Martinsburg, West Virginia/
Northampton, Pennsylvania
Thomaston, Maine ^
Great Lakes Div.
Essexville, Michigan^
Midwest Div.
Davenport, Iowa /
Southern Div.
Atlanta, Georgia/^
Roberta, Alabama /
Western Div.
v Lyons, Colorado
Tulsa, Oklahoma v
889,000
274,000
804,000
1,967,000
222,000
257,000
564,000
171,000
377,000
427,000
222,000
205,000
684,000
341 ,000
222,000
222,000
3,914,000
820,000
410,000
427,000
171,000
513,000
581 ,000
495,000
393,000
581 ,000
4,391,000
Process
Dry
Wet
Wet
Wet
Wet & Dry
Wet
Wet
Wet
Wet
Dry
Wet
Dry
Wet
Dry
Dry
Wet
Dry
Wet
Wet
Wet
Dry
Dry
Dry
Dry
Maule Industries, Inc.
v Miami, Florida 958,000 Wet
Medusa Cement Co.
Div. Medusa Corp.
Clinchfield, Georgia* 718,000 Dry
Continued
36
-------
Table C-l. (Continued) COMPANY/PRODUCT LIST
Company /location
Dixon, Illinois*"
^Charlevoix, Michigan
Sylvania, Ohio^
Wampum, Pennsylvania^
*York, Pennsylvania
Manitowoc, Wisconsin-"
Missouri Portland Cement Co.
Joppa, Illinois*"-
Kansas City, Missouri-
St. Louis, Missouri v
Monarch Cement Co.
Humboldt, Kansas V"'
Monolith Portland Cement Co.
Laramie, Wyoming v^
Monolith, California^
Capacity
(metric tons/year)
598,000
684,000
257,000
701 ,000
444,000*
68,000*
3,470,000
595,000
513,000
855,000
1,963,000
431,000
182,000
1,200,000
1,382,000
Process
Dry
Wet
Dry
Dry
Wet
Wet
Dry
Dry
Wet
Dry
Wet
Wet
National Cement Co. Div.
Mead Co.
Ragland, Alabamavx
National Gypsum Co.
Allentown Portland Cement Co.
Evansville, Pennsylvania-
Huron Cement Div.
Alpena, Michigan
National Portland Cement Co., Inc.
Bethlehem, Pennsylvania^
Nevada Cement Co. (Centex Corp.)
Fern 1 ey, Wew-~¥0Hc A* «, u „-
Northwestern States Portland Cement Co,
Mason City, Iowa-
OKC Corp.
Oklahoma Cement Co. Div
Pryor, Oklahoma ••--
341,000
855,000
2.391.000
3,246,000
341,000
377,000
727,000
410,000
Dry
Dry
Dry
Wet
Dry
Dry
Dry
Continued
37
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Table C-l. (Continued) COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year)
Louisiana Cement Div.
xNew Orleans, Louisiana
Oregon Portland Cement Co.
Lake Oswego, Oregon7
Lime, Oregon /
Idaho Portland Cement Co. Div.
Inkom, Idaho/
Penn-Dixie Industries, Inc.
West Des Moines, Iowa /
Petoskey, Michigan /
Howes Cave, New York /
Nazareth, Pennsylvania V f
West Winfield, Pennsylvania *!
Kingsport, Tennessee (/
Richard City, Tennessee /
Portland Cement Co. of Utah
Salt Lake City, Utah v
Puerto Rican Cement Co.
Ponce, Puerto Rico
San Juan, Puerto Rico
River Cement Co. Div.
River Corp. /
Selma, Missouri ^
San Antonio Portland Cement Co.
Cementville, Texas v
San Juan Cement Co., Inc.
Dorado, Puerto Rico
Santee Portland Cement Co.
Holly Hill, South Carolina *
South Dakota Cement Commission /
Rapid City, South Dakota I/
613,000
1,123,000
171,000
547,000
200,000
918,000
393,000
598,000
307,000
307,000
324,000
274,000
274,000
2,477,000
171,000
1,454,000
513,000
1,967,000
1 ,064,000
427,000
427,000
1,025,000
410,000
Process
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Dry
Wet
Wet
Wet
Wet
Wet
Wet
Dry
Wet
Wet
Wet & Dry
Wet
Continued
38
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Table C-l, (Continued) COMPANY/PRODUCT LIST
Capacity
Company/location (metric tons/year) Process
Southdown, Inc.
Southwestern Portland Cement Co.
California Div.
Victorville, California /
Eastern Div.
Fairborn, Ohio v
Southwestern Div.
El Paso, Texas '
Odessa, Texas
Amarillo, Texas i/
Texas Industries, Inc. ,
Midlothian, Texas *
^United Cement Co.
Artesia, Michigan
Universal Atlas Cement Div.
United States Steel Corp.
Hudson, New York t
Northampton, Pennsylvania/
Universal, Pennsylvania/
Fairborn, Ohio -'
Buffington, Indiana/
Duluth, Minnesota/
Hannibal, Missouri /
Independence, Kansas/
Leeds, Alabama /
Waco, Texas ,
1,025,000
597,000
307,000
274,000
222,000
2,425,000
1,094,000
341,000
1,435,000
684,000
393,000*
444,000
531 ,000
547,000
291 ,000
632,000
377,000
307,000
341,000*
4,547,000
Wet & Dry
Wet
Dry
Dry
Wet
Wet
Wet
Dry
Wet
Dry
Wet
Dry
Dry
Wet
Dry
Wet
Dry
Whitehall Cement Manufacturing Co.
Cementon, Pennsylvania 427,000 Dry
* Includes white portland cement manufacturing facilities as follows:
xAmC°C?es{Uore, California 103,000 Dry
General Portland, Inc.
Houston, Texas,' ;8:'?°° „
Tampa, Florida, 128,000 Wet
./Ideal Cement Co. Div.
* Houston, Texas 68,000 Wet
Continued
39
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Table (XI. (Continued) COMPANY/PRODUCT LIST
Company/location
Capacity
(metric tons/year)
Process
*Medusa Cement Co. Div.
^ Manitowoc, Wisconsin
> York, Pennsylvania
Universal Atlas Cement Div.
Northampton, Pennsylvania/
Waco, Texas /
68,000
136,000
77,000
86,000
Wet
Wet
Wet
Dry
40
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Table C-2. CLINKER GRINDING PLANTS - 1974
G. & W. H. Corson, Inc.
(International Utilities)
Plymouth Meeting, Pennsylvania
M. J. Grove Lime Co. Div.
(Flintkote Co.)
Frederick, Maryland
Edward C. Levy Co.
^Detroit, Michigan
Lone Star Industries, Inc.
Norfolk, Virginia
Martin Marietta Corp.
North Birmingham, Alabama
National Sypsum Co.
W. Conshohocken, Pennsylvania
Superior, Wisconsin
National Portland Cement Co. of Florida
Bradenton, Florida
Riverton Corp.
Riverton, Virginia
Universal Atlas Cement Div.
Milwaukee, Wisconsin
41
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Table C-3. MASONRY CEMENT MANUFACTURING PLANT
Riverton Lime & Stone Co., Inc.
Riverton, Virginia
M. J. Grove Lime Co. Div.
(Flintkote Co.)
Frederick, Maryland
Cheney Lime and Cement Co.
All good, Alabama
Martin Marietta Cement
Birmingham, Alabama
42
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Table C-4. CALCIUM ALUMINATE MANUFACTURING PLANTS
Aluminum Co. of America
Bauxite, Arkansas
Universal Atlas Cement Div.
Buffington, Indiana
Lone Star Lafarge Co.
Norfolk, Virginia
Riverton Corp.
Riverton, Virginia
43
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-T7-023u
2,
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Industrial Process Profiles for Environmental Use:
Chapter 21. The Cement Industry
5. REPORT DATE
February 1977
6. PERFORMING ORGANIZATION CODE
70A.4'T.tR0eHing, P.E.Muehlberg and B.P.Shepherd (Dow Chemical8)
Terry Parsons and Glynda E. Wilkins, Editors
PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
8500 Shoal Creek Boulevard
P.O.Box 99)48
Austin, Texas 78766
10. PROGRAM ELEMENT NO.
1AB015
11. CONTRACT/GRANT NO.
68-02-1319, Task 3k
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. ENVIRONMENTAL PROTECTION AGENCY
Cincinnati, Ohio ^5268
13. TYPE OF REPORT AND PERIOD COVERED
Initial: 8/75-11/76
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The catalog of Industrial Process Profiles for Environmental Use was developed as an
aid in defining the environmental impacts of industrial activity in the United States.
Entries for each industry are in consistent format and form separate chapters of the
study. The cement industry consists of companies producing complex calcium-silicate-
aluminate-ferrite materials which when mixed with water form a binding material for
aggregates in "concrete." One chemical tree, one process flow sheet, and six
process descriptions have been prepared to characterize the industry. Within each
process description available data have been presented on input materials, operating
parameters, utility requirements and waste streams. Data related to the subject
matter, including company, product and raw material data, are included as appendices.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
Pollution
Calcium-Silicate
Alurainate-Ferrite
Concrete
Pozzolana
Lime
Fabric Filters
Process Description
Air Pollution Control
Water Pollution Control
Solid Waste Control
Stationary Sources
Building Materials
COSATI Field/Group
07B
13B
13C
13M
3. JTSTRIBUTION STATEMENT
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PARES
50
20. SECURITY CLASS (Thispage)
Unclassified
22. PHICE
EPA Form 2220-1 (9-73)
44
*USGPO: 1978 — 757-086/0807
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