Sustainability

Environmental

Air Emissions

Air emissions (gases and particles released into the atmosphere through our manufacturing process) have been identified as one of PPC's material issues. The emissions are released from stacks (the point sources) and from stockpiles and transfer points (fugitive sources).

Material issues to stakeholders are dust (or particulate matter), sulphur dioxide (SO2) and oxides of nitrogen (NOX) released from the kiln stacks. SO2 emissions are caused by sulphurcontaining raw materials, while NOX emissions are caused primarily by high-temperature combustion in kilns.

PPC is dedicated to effectively managing and controlling stack and fugitive emissions. This includes actively participating in the section 21 Air Quality Act working groups in terms of setting reasonable and achievable air emission limits, and monitoring and reporting conditions.

All PPC kiln and mill stacks are fitted with continuous emission monitors for dust and have strict internal management systems. Several kilns also have continuous emission monitors (OPSIS) to quantify select gaseous emissions.

Every plant has a portable gas analyser for discrete measurement of SO2 and NOX. Controls have focused on technology upgrades, alternate air emission measurement studies, ie the mass balance project, forming closer relationships with national, provincial and local authorities, engaging with stakeholders through the environment stakeholder forums, developing best practices as well as training and capacity building among staff.

Quarterly reports are submitted to the Department of Water and Environmental Affairs, as well as to provincial and local air quality authorities. Plants are required to report on their dust, SO2 and NOX emissions. Startup monitoring results (measured from start-up to a raw meal feed rate of 50% of nominal capacity) are excluded from results. Cement kilns are allowed to deviate from the limits of dust, NOX and SO2 emissions during heat-up, for a maximum of 72 hours after start-up.

Future environmental engineering projects

The following environmentally beneficial projects are currently being investigated:

• Slurry finishing mill 4: installation of a new high-efficiency separator in the mill circuit and a bag filter for dust collection, resulting in greater energy efficiency and dust emission reduction.
• Hercules road transport tipping station: for coal and other incoming materials, resulting in environmental benefits including reduced fugitive emissions and improved water quality.
• Slurry coal handling and storage: initiatives to improve the coal storage and handling area, reducing fugitive dust emissions and improving water quality.
• De Hoek kiln 6: kiln ESP to bag house conversion, grate cooler and indirect coalfiring system installation. Benefits include reduced point-source dust emissions, reduced coal and water consumption and improved energy efficiency.
• Jupiter fly ash: improvements to storage, handling and transport system, allowing for increased cement extension. Benefits include a reduction in carbon footprint.