Page 358 - Design for Environment A Guide to Sustainable Product Development

Ener gy Pr oduction Industries 333

advantage of this natural synergy, CertainTeed built a new wall-
board manufacturing facility in close proximity to AEP’s Kammer-
Mitchell and Cardinal power plants. The plant began operation in
2008, and is capable of producing up to 800 million square feet of
product a year.
AEP´s commitment to produce a very consistent, high quality,
synthetic gypsum was critical to CertainTeed´s decision to locate its
newest wallboard plant in Moundsville. The FGD systems at Cardinal
and Kammer-Mitchell use both chemical and mechanical methods to
remove sulfur dioxide (SO ) from the flue gas produced during coal
2
combustion. The SO is absorbed into limestone slurry and then
2
reacts with the calcium in the limestone to form a solid compound,
calcium sulfate, also known as gypsum. CertainTeed receives the
gypsum via a specially designed two-mile conveyor system that
spans a four-lane highway to transport the product from Kammer-
Mitchell directly into the wallboard plant´s gypsum storage facility.
Located in Brilliant, Ohio, the Cardinal Plant is nearly 40 miles from
the wallboard factory, and the gypsum produced at Cardinal is trans-
ported to CertainTeed on the Ohio River by barge.
CertainTeed features state-of-the art technology and makes use of
an environmentally sustainable approach in producing its ProRoc ®
line of gypsum wallboard. This wallboard is manufactured utilizing
96% recycled material, of which gypsum from Mitchell and Cardinal
is the main component. An estimated 800,000 tons of gypsum will be
used annually to produce wallboard at CertainTeed instead of being
sent to landfills. In addition, the wallboard plant will utilize 99%
recycled paper in the manufacturing process.

Chevron: The Power of Human Energy
Filling the Pipeline
Chevron is one of the world’s largest integrated energy companies,
headquartered in San Ramon, California, with annual revenues in
2007 of about $215 billion. The company has more than 65,000 employ-
ees in more than 100 countries, and is engaged in every aspect of the
oil and natural gas industry, including exploration and production,
manufacturing, marketing and transportation, chemical manufactur-
ing and sales, geothermal, and power generation.
Despite negative perceptions about the petroleum industry, Chev-
ron has made an effort to position itself as an environmentally respon-
sible company and to reach out to stakeholders in addressing the
challenges of climate change and energy efficiency [7]. Recognizing
that worldwide energy consumption is projected to rise more than
50% by 2030, Chevron sees a continuing role for oil and gas companies
to find new and better ways to deliver energy, including conventional