Challenges and Successes of Creating…

1. The Challenges and Successes of Creating an Environmentally Sustainable Cement Industry in East AfricaPresented by: Kephar L TandeChair, EA Cement Producers Association

2. 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

3. 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

4. Challenges and Successes… • Cement is an extractive Industry • Natural materials mined include: • Limestone & kunkur • Bauxite • Iron ore • Pozzolana • Gypsum

5. 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.

6. 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.

7. 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.

8. 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

9. 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.

10. 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

11. 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.