Presentation on theme: "The Challenges and Successes of Creating an Environmentally Sustainable Cement Industry in East Africa Presented by: Kephar L Tande Chair, EA Cement Producers."— Presentation transcript:
The Challenges and Successes of Creating an Environmentally Sustainable Cement Industry in East Africa Presented by: Kephar L Tande Chair, EA Cement Producers Association
Challenges and Successes of Creating… Cement is used to bind materials that make concrete and mortar Next to water, concrete is the second most consumed substance on earth. Industry has a large ecological footprint – uses significant amounts of natural resources. Cement industry accounts for 7-8% of planet’s human-produced carbon dioxide
Challenges and Successes… Cement Industry constitutes a significant part of region’s development. Summary of the sector : 11 companies in 5 countries – area covered 1.8msq. km Cement capacity 10.41m tons pa Consumption (2012) 7.64m tons pa Over usd 500m CAPEX in the last 5 years Users mainly home builders and govt infrastructure projects. Average annual growth +10% in consumption
Challenges and Successes… Cement is an extractive Industry Natural materials mined include: Limestone & kunkur Bauxite Iron ore Pozzolana Gypsum
Challenges and Successes…. Conversion to clinker involves crushing grinding and heating Produces dust, carbon dioxide and other gases Uses large amounts of fuels usually fossil fuels e.g. coal, Furnace oil, diesel etc. 60-130kg of fuel needed to make 1 ton of clinker. Uses large amounts of electricity. Cement industry is second only to power generation in carbon emissions worldwide.
Challenges and Successes… Conversion of clinker to cement involves grinding and ultimately packing Produces dust Uses large amounts of power. Overall 110kwh required to make 1 ton of cement Transportation of the product to market using heavy trucks adds to the carbon footprint.
Challenges and Successes… Challenges Mined lands are scars on the landscape and present hazards to human and wildlife. Local eco- systems often destroyed Alternative use of mined land without rehabilitation is limited The cost of rehabilitating mined land is prohibitive Government support for such activities is almost nil.
Challenges and Successes… Emissions of carbon dioxide into the atmosphere running into millions of tons per annum mainly from limestone processing Air pollution through dust emissions present health hazard to surrounding populations and workers Large consumption of power often generated by fossil fuels in the recurrent dry season. Underdeveloped regulation
Challenges and Successes… Successes Environmental management agenda is a major priority in the cement industry. Adoption of clean production practices and improving efficiencies in the production of cement exemplified by falling prices of the product Rehabilitation of quarries and ecological restoration has been successful in some of the cement companies in EA. E.g. Bamburi nature trail. Use of alternative fuels is actively pursued by members. E.g. substitution with biofuels such as biomass from sugar cane industry, coffee, rice and macadamia husks etc.
Challenges and Successes… Use of more modern technology of controlling dust emissions, e.g. Bag House in place ESP. Developments in solar energy feasible for industrial use now a reality. Improved road infrastructure will cut fuel consumption Expected development of efficient rail transport will cut transport cost and reduce carbon footprint
Challenges and Successes… Ongoing development of emission standards through collaboration of the industry and regulators (e.g. NEMA) As we develop further the use of recycled concrete from demolitions will be useful in landfills of disused quarries. Further clinker reducing additives can be used such as fly ash, slag and silica fume which are byproducts of other industries.