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ENERGY STAR Plant Profile

Midlothian Cement Plant
245 Ward Road
Midlothian, TX 76065
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The TXI-Midlothian, Texas Cement Plant began operations in 1960 with one kiln. By 1972 the plant had grown to four kilns and 30% of TXI-Midlothian's capital spending was on pollution control equipment.

 

To keep up with a growing market, Midlothian Cement commissioned a modern precalciner-kiln in 2001.  Consistent with TXI's philosophy of environmental stewardship and efficiency, the expansion included state-of-the-art technology with innovative emission control systems.  These include a sulfur scrubber and an RTO (Regenerative Thermal Oxidizer) system for conversion of carbon monoxide and hydrocarbons into non-hazardous compounds.

 

Energy efficiency has been a continual driver in optimizing TXI's facilities.  The Midlothian Cement plants Energy Efficiency Team draws from a diverse membership of plant employees. The team measures and tracks energy data and makes continual efficiency improvements to the plant.  This ongoing pursuit has resulted in the following improvements:

o         Maximizing production from the finish mills through regular inspections and maintenance, optimizing grinding media levels and automating the mill control loop systems.

o         Replaced two induced draft (ID) kiln fans with more efficient ones, leading to 6.7kWh/ton power saving.

o         Introduced compressed air and process false air monitoring and sealing campaign, leading to a drop of 10% of the total false air, resulting in reduced fan power consumption and reduced natural gas consumption.

o         Carried out regular pyro-process audits to locate heat losses and ways to minimize the losses in order to lower kiln energy consumption.

In addition, TXI initiated and patented the cement manufacturing CemStarSM process.  This EPA-recognized technology significantly reduces CO2 and NOx emissions in the cement-making process. The ENERGY STAR certification for the Midlothian Cement Plant aligns with TXI's philosophy of energy efficiency, environmental stewardship and continual improvement.  Maintaining and expanding the ENERGY STAR program is an important component of TXI's operational strategy going forward.   

 

The TXI Midlothian, Texas Cement Plant first earned the ENERGY STAR label for plants in 2010.

Year(s) Labeled:
2010, 2012, 2014

Facility Type:
Cement