Transcript Driving Green Manufacturing & Energy Efficiency in Dangote

Green Manufacturing:
Adopting Energy Efficiency in
Manufacturing Supply Chains
-Dangote Cement Strategy
By Pabby Paramjit
Director, Dangote Academy
SCOPE
This Presentation addresses 3 key Areas
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• Cursory view
of
environmental
impact of
cement
manufacturing
• Opportunities
for green
manufacturing
in the cement
industry and
trends
• Green
Manufacturing
strategies in
Dangote
Cement
Cursory view of environmental impact of
cement manufacturing
The cement industry impacts the
environment in different ways
• Air and Dust Emissions
• Like most energy intensive
industries, cement plants generate
air emissions like CO2, NOx and SOx
• According to the recent publication
of the Cement Sustainability
Initiative (CSI), cement industry is
responsible for about 5% of all manmade CO2 emissions.
• Dust emission is also associated
with material handling in cement
plants
…Environmental impact of Cement
Manufacturing
• Consumption of raw
materials and fuels
• Large amounts of
energy and materials
are consumed in
producing millions of
tons of cement
annually. This has some
environmental
consequences which
must be addressed
…Environmental impact of Cement
Manufacturing
• Impact on land and
communities
• Quarrying of limestone, the
main cement raw material has
impact on land and
settlements around the
quarry
• Dust, noise and vehicular
movements are all
unavoidable consequences of
large scale limestone
quarrying
• Quarrying activities may
sometimes affect biodiversity
and the ecosystem
Opportunities for green manufacturing in the cement
industry
Environmentally friendly products &
emission control technologies
• Climate Protection & Emission
Reduction
• Emission reduction products like
low carbon cements (blended)
are produced to reduce the
environmental impact of
cement manufacturing.
• Dust emission prevention
equipment like electrostatic
precipitators and bag house
filters have been designed with
improved efficiency to control
dust
Electrostatic Precipitator for Dust
Control
Green manufacturing in cement
industry
• Fuels & Waste Material
Recycling
• The cement kiln provides
opportunities for
disposing many waste
materials as alternative
energy sources.
• This has the advantages of
waste reduction,
conservation of fossil fuels
and emission reduction.
…Green manufacturing in cement
industry
• Blended Cement and use of
Clinker Replacement Materials
(CRM)
• Production of blended cement
using the CRM option has
provided a remarkable avenue
for green manufacturing in the
cement industry
• Materials like slag, fly ash,
pozzolans, limestone and others
are used as CRM in cement
• This has led to reduced specific
energy consumption, utilization
of waste materials and
environmental protection
Green Manufacturing Strategy in
Dangote Cement
• Technology Options
• Dangote Cement plants
are new, hence provides
us with the opportunity to
select “state of art”
technologies
• We specifically select
technologies and
equipment based on
energy efficiencies and
environmental
consideration
• Our scale of production
has added advantage of
energy optimization in our
plants
Robotic process control lab
…Green Manufacturing Strategy
in Dangote Cement
• Energy Efficiency in our
plants
• Our kiln system is
equipped with
Mechanical Flow
Regulator for optimal
heat recovery in the
clinker cooler
…Green Manufacturing Strategy
in Dangote Cement
• The pre-calciner Kiln
technology is designed for
energy efficiency. This also
provides opportunity to
use Alternative Fuels
Resources (AFR) in the precalciner
Preheater
String without
calciner
Calciner
Rotary Kiln
…Green Manufacturing Strategy
in Dangote Cement
• All our grinding operations are
done with Vertical Roller Mills
using grinding aids, this come
with high output and low
specific energy consumption in
comparison with older plants
using ball mills.
• Adoption of CRM option (L/S
cement) results in lower energy
consumption per ton of cement.
• All these help in environmental
preservation
Energy efficient grinding technology of
Vertical Roller Mills
Environmental Initiatives in
Dangote Cement
• Robust Environmental
Management System
• Environmental Policy
Targeted at
Efficient Emission Control
• Designed particulate emission limit: 30mg/ Nm3
• Actual values: 15-20mg/Nm3
• Nigerian standard: 100mg/Nm3
• Prevention of pollution
• Compliance to legal &
other requirements/
Standards
• Conducive environment
• NIS ISO 14001:2014
Certified
High Efficiency Electrostatic
precipitator for dust control
…Environmental Initiatives in
Dangote Cement
• Other Specific Environmental Initiative
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Tree Planting
Water spraying to suppress dust emission
Environmental monitoring & reporting
Community resettlement
Quarry rehabilitation plan
Aligning future leaders of the company to green
manufacturing
..Environmental Initiatives in
Dangote Cement
Tree planting activities & grassing
…Environmental Initiatives in
Dangote Cement
Dust Suppression in the Mines
Environmental Monitoring & Reporting
Dust Monitor
Lux meter
Gas Analyzer
Ambient Gas
Analyzer
Noise level
meter
…Environmental Initiatives in
Dangote Cement
Mining Community Resettlement to avoid noise
pollution
New Oyo
Community After
Re-settlement
Old Oyo
Community
…Environmental Initiatives in
Dangote Cement
• Our Dangote Academy
enables us to align the
future leaders of the
Company to Environmental
preservation
Thank you.