To recognize the efforts of cement producers' innovative practices, programs, and projects throughout North America, the Portland Cement Association (PCA), the Cement Association of Canada (CAC), and Cement Americas are pleased to announce the winners of the third annual 2003 Cement Industry Environment and Energy Awards. The Awards also honor companies for their ability to communicate their ideas to others in the industry, thus raising the profile and priority of environmental and energy efficient programs in all industries. The program recognizes individual facilities that exemplify the spirit of continuous environmental improvement and back up their spirit with action.

To be eligible for the 2003 contest, environmental and energy-related programs and projects must have been completed between October 2002 and September 2003. Submitting more than one project from the same firm or plant was permissible. All North American facilities were eligible.

Judges selected first place winner and runners-up in each of the contest's six categories: Environmental Performance; Land Stewardship; Outreach; Innovation; Energy Efficiency; and Overall Environmental Excellence, incorporating all entries in the first five categories.

Serving as the judges for the 2003 Cement Industry Environment and Energy Awards were: Tom Carter, PCA, Director — Environment, Health & Safety, Regulatory Affairs; Rebecca Eaton, World Wildlife Fund-U.S., manager, Private Sector Initiatives, Climate Change Program; Carl Koch, Jr., U.S. Environmental Protection Agency (EPA), Sector Strategies Program; Peter Gage, World Resources Institute, research analyst, GHG Protocol Program; Garth Hawkins, PCA, Program Manager — Environment, Health & Safety, Regulatory Affairs; Elizabeth Dutrow, EPA, Energy Star Program; Vincent Camobreco, EPA, Climate Leaders Program; Alice Cornelissen, CAC, director — Environmental & Building Sciences; and Steven Prokopy, Editor, Cement Americas.

OVERALL ENVIRONMENTAL EXCELLENCE

Winner

Lafarge North America,
Alpena, Mich. Plant

The Alpena Plant provides an exemplary model of proactive environmental leadership within its community and among other Lafarge North America cement plants. Plant employees show their commitment to the environment by the projects they are involved in, such as landscaping, tree planting, plant open houses and tours, the Wildlife Habitat Council, Habitat for Humanity, and pollution-prevention projects. The Alpena Plant continues to focus on reducing air emissions from its five kilns. In 2003, the SO2 emissions were 64% of the permitted level. NOx emissions were at 80% and CO was well below the limit at 37%.

The Alpena facility continues to work on a stormwater control system for water discharged from its quarry. The new system is scheduled to be operational in mid-2004, and should improve the quality of water by increasing the flow path length, resulting in better control of suspended solids.

The plant initiated a project to mix cement kiln dust (CKD) with gypsum, then using the mixture in the final product. The blend is projected to reduce the amount of CKD going to landfills by about 14,000 tpy. Also regarding CKD, Lafarge is working to get approvals to re-use CKD in several different areas. Two approvals have been received: one for use as a cement substitute for certain applications, and the other for use as a sorbent material to scrub sulfur from stack emissions.

OVERALL ENVIRONMENTAL EXCELLENCE

Runner Up

Lafarge North America, Paulding, Ohio Plant

Although the Paulding facility does not have a regulatory NOx limit, it does enjoy low NOx emissions (about 1.67 lb per ton of clinker) due to the use of waste-derived fuels and the associated water content of the fuel.

In 2003, Paulding permitted as system to add limestone through a mid-kiln scoop system to increase the free lime content in the clinker. While testing the prototype delivery system with Ohio EPA oversight, the plant collected emissions data that indicated an 11% decrease in NOx emissions per ton of clinker produced.

Paulding is actively marketing a new CKD/fly ash-based product called Pozzolon Cement. In 2003, Lafarge re-used nearly 6,000 tons of CKD in this product, reducing the amount of CKD sent to a landfill to 51,000 tons.

The facility has continuously reduced SO2 emissions as well through the use of low sulfur fuel quality wastes. Today, Paulding has reduced the use of high sulfur fossil fuels by substituting 90% of its energy demand with waste fuels. SO2 emissions have decreased to 324 tpy in 2003, representing a 71% decrease since 1996.

Other Finalists:
Lafarge North America, Buffalo, Iowa Plant; Mitsubishi Cement Corp., Lucerne Valley, Calif. Plant

ENVIRONMENTAL PERFORMANCE

Winner

Lafarge North America, Seattle, Wash. Plant

Lafarge's Seattle Plant distinguished itself through exceptional control of air emissions and stormwater runoff. Because of high levels of rain in Seattle, the plant processes around 25 million gallons of stormwater per year. Almost all of this is recycled at the plant.

In addition, the plant uses alternative materials for more than 30 percent of its raw feed. The facility has installed a comprehensive environmental management system (EMS) as part of the effort to achieve ISO-14000 certification. A web-based risk-assessment program was designed to generate effective employee environmental awareness though user-friendly participation. In addition, the plant has been recognized for its energy efficiency efforts by the city of Seattle.

ENVIRONMENTAL PERFORMANCE

Runner Up

Lafarge North America, Alpena, Mich. Plant

In addition to its previously mentioned environmental efforts, the Alpena plant made a voluntary commitment to undertake pollution prevention by partnering with the Michigan Department of Environmental Quality. The Michigan Business Pollution Prevention Partnership (MBP3) is a program MDEQ provides to help companies show their commitment to business, the community, and the environment. Lafarge is developing an action plan and goals for 2004 and beyond. The plant also has started an initiative to become ISO 14001 certified, and Alpena's EMS audit score went from 85% to 89%. The goal is to be ready for certification by the end of 2004.

Other Finalists:
Lafarge North America, Paulding, Ohio Plant; St. Lawrence Cement Co., Hagerstown, Md. Plant

LAND STEWARDSHIP

Winner

Lehigh Cement Co., Mason City, Iowa Plant

Lehigh's Mason City Plant conducted two major land stewardship activities in 2003. The first was a remediation of its former CKD pile. The site was engineered and covered with plants to prevent potential leaching t o a nearby wetland. The second request was the voluntary reclamation of a pond that had previously been drained at the request of the state. The area has been graded for the development of a habitat featuring native prairie plants. Approximately 30,000 cu yd of topsoil were added to the 15-acre plot along with 56 lb per acre of legumes and rye.

LAND STEWARDSHIP

Runner Up

Lafarge North America,
Alpena, Mich. Plant

In 2003, the Alpena plant received recertification from the Wildlife Habitat Council (WHC) for the plant's shale quarry area. Plant employees have put in many hours of work to return this area to a natural shale. With the help from a local elementary school class, plant employees planted 100 white pine and Norway spruce trees in the area. The students also scattered a mixture of wild flower seeds native to Michigan. Red oak trees were planted in the quarry area as well.

A fish stocking program was continued in the lake forming in the abandoned quarry and will continue for several years. Lafarge also teamed up with the WHC to discuss the Corporate Campaign for Migratory Bird Conservation and the possible use of the shale quarry for this purpose.

The Alpena plant participated with the Misery Bay Initiative in 2003, which is a study designed to protect and promote valuable coastal ecosystems in the Misery Bay area, close to the plant.

Lafarge has spent more than $6 million on demolition since taking over the plant in 1987. The plant, which has been in operation since 1908, includes old buildings and equipment that have been removed in an effort to enhance the plant's appearance. Demolition work and related beautification continued in 2003 with more than $125,000 invested. Since 1998, Lafarge has spent more than $1.4 million on landscaping, which includes the use of dredgings from the boat slips and placing topsoils in many areas to allow grass seeding.

Other Finalist:
Lafarge North America, Paulding, Ohio Plant

OUTREACH

Winner

Lafarge North America,
Fredonia, Kan. Plant

This facility demonstrated exceptional outreach during 2003. The plant established a community panel to discuss the company's plans, activities, and concerns — including environmental issues — with community members and local government officials.

Another group, the Employee Green Team, oversees environmental projects, enhances awareness internally and externally, conducts wildlife inventories, and interacts with park and wildlife officials. They also hosted an environmental exploration day and a science camp for local students, as well as an Earth Day event for employees. In addition, the plant's annual open house had a strong environmental focus.

OUTREACH

Runner Up

Lafarge Canada, Bath, Ontario Plant

The Bath plant developed and implemented a public affairs program that incorporates management interaction in the community. A designated Citizens Committee, comprised of plant management and local resident, meets every two months to discuss a variety of environmental topics. The plant is rehabilitating vacant lands to natural wildlife habitat. Employees and local community groups are encouraged to participate by building nesting boxes.

The plant was awarded the “Corporate Citizen of the Year” honor for the county. The award was given based on the plant's efforts in reaching out to the community with regards to environmental issues, employee relations programs, and overall community involvement.

Other Finalists:
Lafarge North America, Sugar Creek, Mo. Plant; St. Lawrence Cement Co., Hagerstown, Md. Plant

INNOVATION

Winner

Lafarge North America,
Paulding, Ohio Plant

In 2003, the facility tested the injection of steel slag into the kiln via a mid-kiln feeder system. Due to the precalcined nature of the slag and the additional iron content, the energy demand per ton of clinker was reduced, and NOx emissions decreased 22%. Paulding has a permit application for slag addition in the final approval stages with Ohio EPA.

INNOVATION

Runner Up

Lafarge North America,
Harleyville, S.C. Plant

Through its wholly owned subsidiary Systech Environmental Corp., Lafarge developed and implemented an alternative fuel for the Harleyville plant. Plastic waste (polyvinyl butyral) and pre-consumer waste diapers (clean) are received at the facility, shredded, and used as a significant heat source in the kiln. At the rate of 10,000 to 20,000 tpy, these water materials were typically landfilled. Use of this fuel source not only diverts waste material from landfills, but it also lessens the facility's reliance on fossil fuels, which are a far more significant contributor to NOx emissions from the kiln. Harleyville is the first North American cement plant to use this type of alternative fuel.

Other Finalists:
Lafarge North America, Alpena, Mich. Plant; Lafarge North America, Seattle, Wash. Plant

ENERGY EFFICIENCY

Winner

Mitsubishi Cement Corp.,
Lucerne Valley, Calif. Plant

This facility demonstrated a commitment to energy management, planning, and efficiency that stood above the other entries. In 2003, the plant had a full-time energy manager who tracked usage and instilled management concerns throughout the facility. Specific efficiency projects include the installation of highly efficient fans and preheater exhaust ducts. The plant tracks greenhouse gas emissions and has achieved a reduction of 8% of these emissions. Also, Mitsubishi is an active participant in the EPA Energy Star program and the California Large Energy Users' Association.

ENERGY EFFICIENCY

Runner Up

Holcim (US) Inc., Devil's Slide Plant,
Morgan, Utah

From 1990 through 2003, the Devil's Slide plant has increased its thermal substitution rate from 0% to 29.1%, and reduced its CO2 emission in 2003 to 727 kg CO2 per ton of cementitious product from 862 kg in 1990 (a 15.7% decrease). In addition, the plant has reduced its electrical energy consumption from more than 130 kWh per ton in 2001 to 122.3 kWh per ton in 2003.

The facility has a comprehensive energy conservation program in place, which includes systematic energy audits of specific processes or cost centers at the plant. The operation pursued participation in a voluntary incentive program offered by its energy supplier to industrial customers who want to implement projects that clearly reduce electrical energy consumption. The energy management group works with an energy consultant and a member from the energy supplier to review the plant's ideas about projects that would reduce electrical energy consumption.