2016 was a milestone year for the Stockertown Plant of Buzzi Unicem USA.  Although the plant location was initially intended to begin development in 1906 under the name of Atlantic Portland Cement Co., due to the financial panic of 1907, the site laid idle until 1916 when Morris Kind of Philadelphia and a group of investors purchased the property and begin construction.  Hercules Cement was incorporated in August 1916. 

With the strength of what this name implies, Hercules Cement went on to become a survivor of the Lehigh Valley cement industry which at one time listed more than 60 cement plants.  Today, this plant is one of 5 remaining cement plants in the Lehigh Valley, an area known for its Jacobsburg limestone formation. 

The Stockertown cement plant is permitted to use up to 5.2 tph of alternative fuels split between the two kilns. The current system was installed in 2012 and provides the plant with a total fuel replacement of approximately 16% on a yearly basis. To accomplish this, a single loader fed hopper combined with individual screws, weigh belts and blowers is utilized. By blending three separate alternative fuels; Tire Chips, Tire Fluff and Green Fuel, the plant is able to strike a favorable balance between overall performance and economic benefit. In addition to these primary alternative fuels, the plant has the capability to mix switchgrass, grown on site, into the blend. This material provides a dual benefit by sequestering CO2 from the atmosphere while growing and also providing a carbon neutral low cost fuel source for the production of clinker once harvested. In 2021 the plant will upgrade the system to a walking floor configuration with the goal to stabilize the delivery of materials to the kilns and ultimately increase the usage to above 20%.  

Capabilities:

Kiln Type: Pre-Calciner & Pre-Heater 

Non-Hazardous Alternative Fuels: 

• Wood/Paper
• Rubber
• Plastic 

Alternative Raw Materials:

Filter Cakes

Synthetic Gypsum