Alternative Fuel at the Whitehall Cement Plant

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Alternative Fuel at theWhitehall Cement Plant
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Profile and key figures
A WORLDWIDE PRESENCE IN 49 COUNTRIES
Central and Eastern Europe Workforce 7,180 16
Plants
Western Europe Workforce 4,543 27 Plants
Asia Pacific Workforce 9,637 28 Plants
North America Workforce 5,622 20 Plants
Eastern Mediterranean Workforce 4,714 11 Plants
Africa Workforce 5,550 12 Plants
South America Workforce 2,474 11 Plants
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Lafarge North America

• World leader in building materials in North
  America
• Cement Division
• Construction Materials
• Gypsum Division
• Operations in 50 states and 10 provinces of Canada

• 100 fulltime employees at Whitehall
• Diverse product portfolio
• Excellent safety environmental program
• Technological leader in alternative fuels

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Cement Manufacturing in the Lehigh Valley
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Whitehall Cement - 1926
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Whitehall Cement - Today
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Plant Partnerships and Outreach

• Wildlife Habitat Council Partnership
• World Wildlife Fund Conservation Partnership
• Wildlands Conservancy Partnership
• Various Local Civic Business Organizations

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What is Cement?
Raw Materials
Clinker
2600o F
CaCO3 SiO2 Al2O3 Fe2O3
C3S C2S C3A C4AF
CaO CO2
Clinker
Gypsum
Portland Cement
C3A C2S C3A C4AF CaSO4 ? 2 H2O
CaSO4 ? 2 H2O CaSO4 ? 1/2 H2O CaSO4
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Whitehall Plant Facilities Equipment
2 Preheater Kilns Kiln 2 Kiln 3
3 Active Quarries
2 Raw Feed Mills
Package Bulk Shipping
2 Finish Mills
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Kiln
Material flow
Gas flow
Feed
Fuel flow
Stack
1900 F
CEMS
3800 F
Tires
PDF
Kiln
Coal / Coke
Dust
Collector
Cooler
200 feet
Clinker
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Tire Derived Fuel

• Tested 1991 Started June 23, 1993 Going
  Strong
• Community Benefits
• gt20 million tires to date
• Reduces emissions
• Reduces dependency on fossil fuels
• Created local employment
• Company Benefits
• Reduces fuel costs
• Enhances long term viability in very competitive
  market
• Commitment to sustainable development

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Tire Derived Fuel

• Why does TDF work at Whitehall?
• State recognized need to eliminate tire piles
• I-95 Fire
• West Nile Virus
• Strong customer relationships
• Well run clean operation
• Storage in trailers NO tire piles
• Staged combustion improves NOx emissions
• Free tire removal for communities
• Didnt you use to burn tires?

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Tire Derived Fuel

• Air Quality Permit
• Annual testing requirements for metals/VOC
• Installation of NOx/SO2 CEMS
• Beneficial Use General Permit
• Issued through DEP Waste Program

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Tire Derived Fuel
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Plastic Derived Fuel Project Review

• Goal of project is to replace front-end fuel
  (coal) with shredded,processed Plastic Derived
  Fuel
• Increase sustainable fuel source
• Increase available landfill space
• Well over 10,000 ton/year of plastichas been
  identified as being availablefor this purpose
• Targeted waste plastic include Types 4-7
  (currently landfilled)

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Plastic Derived Fuel Preparation
Blue Box Recycling
Recyclable Plastic
Sorting at Recycle Facility
Plastic Rejects
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Plastic Derived Fuel Preparation
Recyclable Plastic
Baled Plastics
Plastic Plant
Plastic Product
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Plastic Derived Fuel Preparation
Plastic Rejects
Landfill
Shredded Plastic
Whitehall Plant
Concrete Products
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Test Your Environmental IQ

• If you lined up all the styrofoam cups made in
  one day, how long would it be?
• 100 feet
• 50 miles
• 500 miles
• Circle the Earth once

Answer d) Circle the Earth once!
Source EPA Mid-Atlantic Region
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Whitehall Alternative Fuel Usage Goal-2007
Future Opportunity