Displaying items by tag: Water

Bolivia: SEDEM, the government’s business development agency, has refuted accusations that a new cement plant being built in Caracollo, Oruro does not have enough water or raw materials. Patricia Ballivián, the general manager of SEDEM, presented reports from PricewaterhouseCoopers and C & C Ingeniería y Procesos defending the supplies to the unit. The reports were released in response to accusations by a local politician that the project had been poorly planned.

The reports revealed that the Empresa Publica Productiva Cementos de Bolivia’s (ECEBOL) plant will recycle the industrial portion of its water supply. It will have a supply of 4l/s and a 3.5Ml reservoir. It also has limestone, gypsum and clay reserves sufficient for the production of 100Mt of cement. These are expected to last the plant 60 years.

Pakistan: Bestway Cement has promoted its environmental credentials following the Supreme Court’s mandated investigation into water usage by cement companies near the Katas Raj Temples in 2018. The cement producer says that all of its cement plants are ISO 14001:2004 Environment Management Systems certified. Specifically on the issue of water conservation, it has installed air-cooled condenser systems at two of its plants at Chakwal and Kallar Kahar respectively and it has built rain-harvesting ponds. In total the company has spent around US$14m on water conservation measures. Altogether it says that it has achieved 80% and 88% reductions in consumption of ground water for industrial use, respectively, at the two plants.

Other environmental measures the company has made include installing waste heat recovery (WHR) units at all four of its cement plants. Its total WHR capacity is 45.5MW giving it 28% of its total power needs. The company is recognised by the United Nations Framework Convention on Climate Change (UNFCCC) under its Clean Development Mechanism (CDM) Program for its initiative to reduce carbon emissions/footprint. It has also implemented tree plantation at its plants and surrounding areas, it uses drip irrigation and sewerage waste management and its head office in Islamabad has been certified as a Green Office by the World Wide Fund for Nature (WWF).

Pakistan: The Supreme Court has ordered DG Khan Cement to pay nearly US$0.6m into a dam fund in relation to falling water levels at the Katas Raj Temples in Chakwal, Punjab. The cement producer must make a deposit of US$0.5m as payment for water it used and US$0.1m as a penalty for ‘misleading’ the court, according to the Nation newspaper. The court has accused the company of pumping water from boreholes leading to water loss at a pond at the temples.

Pakistan: The Supreme Court has appointed a special committee to visit the DG Khan’s cement plant in Chakwal to investigate how it stores water. The committee will report back to the court about the capacity of the reservoirs built by the plant as well as whether they were filled by extracting water from the aquifer or from rainwater, according to the Dawn newspaper. The committee will also take samples of water from the reservoirs.

The court has been looking into how DG Khan and Bestway Cement set up cement plants in the Potohar region related to water issues at the nearby Katas Raj Temples. Previously, the court was told that the DG Khan Cement was only operating tube-wells for domestic use by its workers but a witness alleged that the plants were extracting water for industrial use from the water table.

Pakistan: The Supreme Court has ordered cement producers to pay for underground water used by cement producers near Katas Raj. Chief Justice Mian Saqib Nisar said that underground water is ‘very precious’ and added that cement factories using it near the temple at the site would no longer be able to do so for free, according to the Nation newspaper. The Chief Justice has also directed the Punjab Food Authority to audit local companies to assess how much water they are using and how much they are paying for it. The on-going case was started in response to a pond drying out at the Hindu heritage site due to water consumption by nearby cement plants.

Earlier this year South Africa’s PPC commented on the drought facing Cape Town. It said that cement manufacturing was not water intensive, that its operations were ‘totally’ self-sufficient from its own surface water sources with capacity for several months and that it was working with the local government which viewed construction as an important economic sector. Point made!

Water conservation is an established part of the sustainability toolkit for cement producers. Yet recent weather patterns in the Northern Hemisphere may also test how well companies are doing. Above average temperatures have been recorded this summer, in some places accompanied by unusually dry conditions. A news story this week about Cemex Colombia being fined for using water from a river shows one aspect of the problems that can face industrial users. Another story that we’ve covered previously has been the legal action taken against producers using water from a site near to the Katas Raj Temples in Pakistan.

Wet process cement manufacturing uses more water than dry process but even modern plants use water for cooling equipment and exhaust gases, in emission control systems such as wet scrubbers. In addition, quarrying and aggregate production may require water, and concrete production also needs water. Issues also arise with quarry dewatering and discharging water into rivers and the like. Global Cement Directory 2018 data indicates that, where known, about 10% of integrated cement plants still use a wet production method.

Graph 1: Specific water consumption by selected cement producers in 2017. Source: Corporate sustainability reports.

As Graph 1 shows there is some variation between the major cement producers with regards to how much water they use. They all operate with different types of equipment and production methods in different geographical locations so the difference between the companies is to be expected. A cement plant in northern Europe that normally experiences high levels of rainfall will have a different approach to water conservation than one, say, in a water stressed area like the Middle East. Incidentally, the definition used to define a water-stressed or scarce area is one where there is less than 1000m³/yr per person. One other point to note here is that each of the companies has a higher consumption figure than the 100 – 200L/t that the Cement Manufacturers' Association of the Philippines (CeMAP) reckoned that an average dry-process cement plant used when it was promoting water conservation back in 2013.

Looking at specific recent success stories, India’s UltraTech Cement reported a specific water consumption of 54L/t of clinker at its Star Cement plant in Dubai, UAE in 2016 – 2017 following a dedicated initiative at the site. An another milestone that UltraTech Cement was keen to point out in its last sustainability report was that three of 13 integrated plants had achieved water sufficiency though the use of the company’s 360° Water Management Model with its use of rainwater harvesting and recharging groundwater. These plants are not dependent on any groundwater or fresh water sources. The other larger cement producers all have similar water management schemes with reduction targets in place.

Climate change models generally predict hotter and wetter weather but changing weather patterns and growing populations are likely to impact upon water management and consumption. Given the integral nature of water in the cement production process, many cement producers have realised the importance of it and treat it as an input material like fuel or limestone. Hence the highlighting of water conservation in company sustainability reports over the last decade. The test for the success of these initiatives will be how producers cope in drought situations where they may be seen as being in competition with domestic users. Thankfully in PPC’s case, Cape Town avoided having to ration water to the general public, as the rains returned in the spring.

Colombia: Cemex Colombia has been fined US$429,000 for taking groundwater from the Tunjuelo River without permission. The sanction of the District Department of the Environment of Bogotá imposed the penalty, according to the La Republica newspaper. However, the settlement exonerated Cemex of causing any environmental damage. The company says it does not plan to file any legal appeal for the sanction.

China: Anhui Conch has suspended production at three of its production lines at the cement plant run by its Tongling Conch subsidiary at Gusheng in Anhui province. The suspension has followed the temporary closure of a pier used by the plant in late May 2018 in accordance with new government regulations on drinking water supply and pollution.

Use of the pier has been suspended as it is close to the Tongling Water Treatment Plant. The pier is used to export cement and clinker products from the unit and bring in raw materials such as coal. The temporary suspension of the plant’s production lines will reduce its clinker production capacity by 58% to just under 9Mt/yr from 15Mt/yr.

The cement producer has defended its environmental record, pointing out that the pier was approved with all the necessary licences and environmental approvals in 1987. Construction of the water treatment plant started in 1992.

Clinker products produced by Tongling Conch are mainly sold to Anhui Conch’s subsidiaries, including cement grinding plants along the Yangtze River and on the coast. The company plans to source clinker from other plants to continue supporting the affected grinding plants.

UK: Hanson UK’s sustainability report for 2017 shows that its CO₂ emissions per tonne of product have fallen by 7.2% to reach the lowest level for five years. However, the subsidiary of Germany’s HeidelbergCement may face issues meeting its target of a 10% reduction by 2020 from its 2010 figures as its CO₂ emissions from production have rise by 5.7% since 2010.

Overall, the company described 2017 as a year of ‘solid’ progress. It passed its 2020 targets for reducing both mains water use and waste to landfill. The number of lost time injuries remained static at 21, but the frequency rate was down on the prior year and there was a three-month unbroken spell without a lost time injury. The building materials producer also launched HeidelbergCement’s Sustainability Commitments 2030, including a set of targets for the group to achieve by 2020.

Pakistan: Cement producers have proposed finding an alternative water source in a case about the Katas Raj Temples being adjudicated by the Supreme Court. They have also agreed to pay the Punjab government for any water they use until then, according to the Statesman newspaper. The court was investigating allegations that the pond at the Hindu heritage site was drying out due to water consumption by nearby cement plants.

Bestway Cement and DG Khan Cement proposed that they would submit up to US$17m and US$4m respectively as security deposits until they find alternative water sources. They have also proposed building a small dam in the area, the outflow of which will be maintained in a way that the pond at Katas Raj is not adversely affected. Local cement plants of the two companies are currently using water from nearby river and underground sources.