Orcem plans 'green' cement plant at Vallejo terminal

  • Orcem's proposed Vallejo cement plant, shown here in an artist's rendering as would be seen from Mare Island, is scheduled to be operational by the second quarter of 2016.

Orcem Americas, Inc., plans to build a $50 million "green" cement manufacturing facility on 4.8 acres that are part of the Vallejo Marine Terminal across from the Mare Island waterfront.

Orcem signed a 65-year lease for that part of the 34.3-acre terminal, the former home of a General Mills flour processing facility.

This project has an investment budget of $50 million and will involve 140,000 hours of union labor, according to Orcem President Stephen Bryan. Once California Environmental Quality Act (CEQA) certification is obtained, construction is set to run 18 months, positioning the plant for commissioning in the second quarter of 2016.

When fully operational, this plant is set to employ about 60, produce 2,200 tons of cement per day and have an almost zero carbon dioxide--equivalent emissions footprint. Emissions saving are projected to be 0.8 tons of gases per ton of cement produced.

The announcement came during a joint "Manufacturing Matters" meeting of the Vallejo Chamber of Commerce and the Solano Economic Development Commission on June 12 attended by nearly 100 local business leaders and representatives of elected officials at the Vallejo Courtyard by Marriott Hotel.

Orcem is the U.S. subsidiary of privately held Ecocem Materials Ltd., based in Dublin, Ireland. Other plants are in Rotterdam, Netherlands, Marseilles, France, and Dublin.

Ecocem sells 1 million tons of cement annually in six countries. The product produces almost-white cement, helping to reduce the urban heat island effect.

Made from high-quality granulated material resembling damp beach sand, this next-generation cement is a byproduct of processing ore into metallic iron in Japan.

The new plant will utilize energy-efficient processing equipment from Germany to grind and dry the raw, granular material into powder for distribution by truck. All equipment will be inside a vacuum-sealed, clean and energy-efficient building that is also being designed to reduce noise.

"For years the U.S. has been shipping grain to Japan on large ships that come back empty," Mr. Bryan said. "Now these vessels will carry our raw material on the return trip docking in Vallejo. Our product is more durable than traditional cement and delivers a longer life span for structures and road repairs."

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