ENERGY STAR Plant Profile
Holcim (Texas) L.P.
1800 Dove Lane
Middlothian, TX 76065
Holcim Midlothian plant is a major producer of Portland cement in Texas. The manufacturing facility consists of two production lines, each with a four stage preheater precalciner kiln system. Line 1 was commissioned in 1987 and Line 2 in 2000. The plant has a capacity to produce over 2.0 million metric tons of cement per year. Historically, cement has been shipped to as many as seven states, and more then 60% stays within the Dallas/Fort Worth Metroplex.
In its modern, onsite lab, the plant uses an automated robot for quality control testing. A central control room features a distributed control system where operators have a perfect view of the plant.
The Midlothian plant's cement products have been used in roads and highways in the Dallas/Fort Worth, Lubbock, and Houston areas. Notable projects include the Omni Hotel in Fort Worth, the Stonebriar Mall and Rough Rider Stadium in Frisco, the Texas Motor Speedway, and the Dallas/Fort Worth International Airport's new Terminal D.
Holcim's Midlothian plant was the first cement facility in North America to install scrubbers that help reduce sulfur dioxide up to 90%. It is also the first cement plant in Texas to install SNCR (Selective Non-Catalytic Reduction), cutting NOx emissions by half during ozone season.
The Midlothian plant was first awarded the ENERGY STAR label for plants in 2008. Several programs were initiated for continuous monitoring, tracking and reporting of results on daily, weekly and monthly basis. These programs focus on establishing baseline power consumption; developing tools for continuous tracking; identifying equipment exceeding limits and root cause analysis; and on line monitoring of power draw by big equipment. Through these efforts, the plant has reduced its energy intensity by 50 kBtu per ton of clinker manufactured. This has resulted in a savings of 32,400 mMBtu in 2008.