Kick Ash Grove’s Wet Kiln Out of North Texas

When TXI announced in July 2010 that it was permanently closing its four old wet cement kilns in Midlothian in favor of operating only its larger dry kiln, it left Ash Grove in the embarrassing position of being the last cement maker in Texas to rely on such industrial dinosaurs.

Ash Grove’s Midlothian kilns were all built between 1965 and 1972. They all use copious amounts of water to mix the ingredients of cement, and so they’re called “wet” kilns. These kilns are notoriously inefficient, requiring up to twice as much energy to produce a ton of cement as newer kilns. They also release twice as much smog-forming pollution, more soot, or particulate matter pollution, more Sulfur Dioxide, a known respiratory irritant, and at least twice as much global warming pollution.

China and India are bragging about getting rid of their wet kilns at an accelerated rate. That's right; Ash Grove is operating a cement plant in DFW that's too dirty even for the Chinese government.  Their inefficiencies are so well known within the industry that no company has built a wet kiln in the US for decades. There are only approximately two-dozen left out of almost 200 kilns nationwide. The ones remaining, like Ash Grove in Midlothian, are relics.

What’s more, Ash Grove has steadily been replacing its older wet kilns around the country. Over the last decade the company has built new dry kilns in Utah, Kansas and Arkansas – all plants in rural areas with no chronic air pollution problems. On the other hand, it’s left its dirtiest kilns operating in Midlothian, upwind of 5 million people and located in a region out of compliance with the Clean Air Act for two decades. Why does Ash Grove hate DFW so much?

When local cities and counties started passing green cement policies that pledged them to buying cement that met cleaner, new kiln standards, Ash Grove sued claiming it was discrimination! Thanks to Ash Grove, your tax dollars are being used to defend the right of cities to buy products that are less harmful to their citizens.

As recently as 2006, Ash Grove was saying that pollution from their Midlothian cement kilns did not affect DFW air quality. Then, when larger cuts were looming, they flew to Austin and cut a deal with the state to put on less expensive controls.

Nowadays, according to Ash Grove, their wet kilns are the cat’s pajamas. Maybe you missed the quote from Ash Grove that ran in an updated AP report a day after TXI's July 6th, 2010 announcement:

"....Curtis Lesslie, Ash Grove vice president for environmental affairs, defended the cleanliness of its Midlothian wet kilns. He said Ash Grove operates the nation's only wet kilns that feature up-to-date pollution control technology "and other methods to reduce overall emissions by more than 65 percent since the 1990s."

This is like saying "I have the cleanest Model T on my block."  And his boast doesn't square with his company's own numbers.

Here's a chart comparing self-reported total pollution figures from Ash Grove's Midlothian three wet kilns from 1995 and the latest inventory, 2008.

In 1990, Midlothian’s Ash Grove kilns released approximately 13 million pounds of five major pollutants. In 2008, it released approximately 13.8 million pounds of those same five pollutants.

But wait! Hasn't Ash Grove reduced their smog-forming emissions of Nitrogen Oxide (NOx)?Yes, by 50% from 1990 levels. And you know what? That's still twice as much NOx as TXI's and Holcim’s Midlothian dry kilns are allowed to emit per ton of cement.

As Ash Grove's NOx pollution went down however, it's Sulfur Dioxide and Particulate Matter pollution went way up compared to 1990 levels.The result is we're right back at 1990 levels of total pollution from Ash Grove in 2010. That's not progress. And it shows the inherent limitations of the obsolete wet kiln technology.

CHART: Comparing levels of Ash Grove air pollution 1990-2008

Top Chart - Less NOx Pollution
Middle Chart - More Sulfur Dioxide
Bottom Chart - More Particulate Matter

Source: Ash Grove annual emission inventories submitted to Texas Commission on Environmental Quality, 1995 and 2008

As long as Ash Grove uses an obsolete wet kiln technology in Midlothian, it will never be able to reduce emissions as much as a newer dry kiln. That’s why the wet kilns must be replaced. Just like they were in Utah, Kansas and Arkansas.

New EPA emission standards taking effect in 2013 mean that Ash Grove will have to decide to spend more money on its old wet kilns in Midlothian or replace them. You can help tip the scales by joining Downwinders’ Kick Ash Campaign.

What you can do:

1. Sign up for Downwinders’ news alerts

2. Let Ash Grove Know You Want Their Wet Kilns Closed

3. Don’t use Ash Grove cement in any projects –personal or civic. Read more about Downwinders’ successful 2006-1010 Campaign for Green Cement

4. E-Mail ASH GROVE (Ash Grove Executive Vice-President David D’Hondt ddhondt@agcwa.com)