Lafarge North America Paulding cement plant in Paulding, Ohio, received the Innovation Award from the Portland Cement Association (PCA) and Cement Americas magazine as part of the 2014 Cement Industry
Energy and Environment Awards. The Innovation Award recognizes cement industry leaders in the development and application of innovative technologies and techniques relevant to environmental protection or energy efficiency.
The Lafarge Paulding facility fully captured small grain cement kiln dust (CKD) for return back to the kiln feed bed by briquetting the CKD powder prior to reintroduction to the feed bed. Briquetting machines have been around for many years, however, this may be the first time the process has been used to improve CKD recycling rates.
After an initial and successful trial using smaller equipment, the Paulding plant installed a larger briquetting machine and feed system to the plant’s kiln systems. As a result, the plant was able to return 1 ton of CKD per hour to the hood of the kilns.
The project increased clinker production, reduced CKD going to the landfill, increased kiln performance factor, reduced the chlorinated grinding aid accelerator, decreased Specific heat Consumption, and reduced CKD haul truck hours to the landfill. With a yearly savings of $1 million, the project payback period was less than eight months.
The Cement Industry Energy & Environmental Awards honor individual cement facilities that exemplify the spirit of continuous environmental improvement and support this spirit with action. These plants go beyond government regulations and local laws to ensure that their processes contributed to making their communities better places to live and work. Five categories are recognized: outreach, environmental performance, land stewardship, innovation, and energy efficiency. Additionally a special honor is presented to plants demonstrating excellence in multiple categories.