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Holcim breaks ground on Hagerstown modernisation project

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World Cement,

On Monday 21 July, the ground-breaking ceremony took place for the modernisation project at the Holcim US Inc. Hagerstown plant. A number of high profile guests, including U.S. Rep. John Delaney, a proponent of infrastructure investment in the US, joined senior staff and plant operatives to mark the start of a 2-year, US$95 million project that will see the plant increase production and energy efficiency and substantially reduce greenhouse gas emissions.

Plant manager Fernando Valencia told local press after the ceremony that the staff were “very excited”, adding: “This is an important project for the company”.

As previously reported on, KHD Humboldt Wedag has been selected as the contractor for the project. KHD will be responsible for the engineering, delivery of equipment and site services. The agreement includes the supplying of a KHD designed pyroprocessing system, and will increase the existing line’s production rate to 2400 tpd.

A five-stage single-string KHD LowNOx Preheater will be built over the existing kiln, while the kiln is in operation. The existing six-pier rotary kiln will be modified to a two-pier kiln and will be cut to 51 m to make it more energy efficient and environmentally friendly. A new KHD PYROFLOOR2® clinker cooler will also be added. The system will be supplied with a new whole tyre handling system and will be capable of co-processing up to approximately 7% of whole tyres as an alternative fuel.

KHD will also supply a dry lime injection system to reduce SOx emissions, and supply PYROJET LowNOx burners, a PYROCLON® Low NOX calciner with PYROLOOP® and modify the existing SNCR system to control NOX emissions. New dust collectors will also be supplied as part of the new machinery in order to meet particulate emissions requirements. The modernisation is expected to cut NOX emissions by around 60% and SO2 emissions by 48%.

In July last year, Holcim agreed to a settlement with the EPA after it was hit with Clean Air Act violations. In the settlement, Holcim agree to invest US$20 million or more to reduce NOX and SO2 emissions by 92 tpa and 230 tpa respectively. 

Edited from various sources by

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