For superior energy efficiency, Roanoke Cement Co. in Troutville, Va., was awarded the 2007 Energy Star by the U.S. Environmental Protection Agency (EPA) and the U.S. Department of Energy as part of their joint Energy Star program. Virginia's sole active cement plant, Roanoke's 1.4 million-tpy Troutville plant is one of only 10 facilities — among 118 U.S. cement operations — ranked by EPA as “Top Performing Plants” nationwide.

The Energy Star program recognizes manufacturers' energy-efficient solutions, which save money while protecting the environment and reducing greenhouse gas emissions. When Roanoke's original plant began production in 1951, a kiln feed setup using long dry kilns did not take full advantage of heat energy leaving the system; significant energy consumption was inevitable. By contrast, the upgraded cement operation saves energy by introducing preheated raw materials into the kiln.

The preheater tower functions as a heat exchanger by utilizing the kiln's hot exit gases; thus, a tower of high-efficiency cyclones delivers raw material into and through the kiln. The company obtains approximately a 40% reduction in fuel consumption through the heat exchange. Accordingly, the Roanoke plant now is recognized as one of the most energy-efficient cement plants in the world.

The Energy Star score, based on actual energy use, is calculated via an EPA tool known as the energy performance indicator (EPI). Using input values specific to a plant, EPI scores a cement facility's energy efficiency and compares it to that of the entire industry. On a scale where 100 percent is considered (unattainable) perfection, Roanoke Cement achieved a 98% rating.

“While we are pleased with the plant's progress, we are not satisfied,” asserts Roanoke Cement Plant Manager Kevin Baird. “We remain dedicated to continuous improvement, convinced that environmental stewardship is the most important characteristic to becoming a good corporate citizen.”

Roanoke Cement Co., a subsidiary of Norfolk, Va.-based Titan America LLC, is the producer's first plant to receive the Energy Star rating. That accomplishment contributes to environmental strides achieved by the domestic cement industry, even as a worldwide construction boom creating significant supply issues has spurred U.S. growth.

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This article was adapted from material provided by Roanoke Cement Co.