T h u r s d a y , 0 1 M a r c h 2 0 1 8

Water e f f ic iency and innovat ion a t PPC's De Hoek plant

W a t e r S e c u r i t y i n C o n s t r u c t i o n

T s h i l i d z i D l a m i n i & J a c o J o u b e r t

Introduction

• Background

• History of PPC De Hoek

• Integrated water management approach

• Initiatives

• Results

• Opportunities

Background

• PPC’s sustainability vision is ensure the sustainability of operations by

reducing our environmental footprint and providing energy and resource

efficient products

• As part of our sustainability programme we implemented systems to

minimize environmental footprint using ISO 14001 model

• Together with our stakeholder's we identified energy, air quality, carbon

footprint, environmental legal framework and water as our material issues

• Due to the scarcity of water in South Africa, water has been one of

environmental material risk to the business for many years

• The current water challenge in the Western Cape placed water on top of

business’s priority list

• De Hoek was founded in 1919 with the

discovery of limestone at Pieketberg and

today PPC De Hoek is the most

significant cement manufacturing plant

in the Western Cape.

• The Plant consist of mining,

manufacturing, village and recreation

facilities. De Hoek is a home to 80

families.

History of PPC De Hoek

•

Water

Water Use Identification

Monitoring regime

GN704

WUL Internal & External

Audit Reporting

Management: ISO 14001

WCDM

IWWMP

Innovation and Change

Management

PPC De Hoek Integrated Water Management Programme

• With looming day zero innovation and change management becomes more critical

• Meeting compliance targets

• Conservation, demand and supply

People

• Awareness sessions for employees and PPC village residents

• Awareness sessions at local schools

• Water use penalties for high consumers - De Hoek residence

• Utilise security personnel to detect leaks and monitor unauthorized

consumption during patrols

• Provided containers/ drums to employees to enable them to store grey water

for re-use.

Our Water Management Initiatives

Innovation

• Increased temperature control limits on kiln

• Temperature control change reduced water consumption by 23 m3 per day.

• Continuous reduction in irrigation volumes

• Changes in irrigation schedules

• Use of dirty water from the mine for process and dust suppression

• Enhanced water monitor regime to assess consumption at all levels

• Innovative ideas from employees

Technology-related changes

• Conversion of Electro Static Precipitators (ESPs) to Bag filters

• Apart from improved emission levels it also resulted in reduced water consumption

• Future projects will consider technology that are water efficient

Our Water Management Initiatives

• As part of our sustainability journey PPC accelerated its water savings initiatives

since 2013 with a significantly increased effort in 2015 even more in 2017 to

comply with legislated water consumption due to the drought.

• The combined water consumption for the mine, village (80 houses), recreation

facilities and manufacturing reduced since 2013 from 1 Kl/ ton of clinker to 0.5 Kl/

ton of clinker in 2017

Results

Results

• The Western Cape consumes 1.4 M tons of cement per annum of which 1.2M is

produced locally.

• On average construction uses about 1 Kl of water per 1 ton of cement for

various mixing activities.

• Thus the total water consumption related to cement manufacturing is 2.06M Kl

per annum.

• Cape Town (Metro) recently targeted a water consumption of 600 000 Kl per

day. i.e. 219M Kl per annum

• Manufacturing of cement and construction consumes less than 1%.

Water consumption in the construction industry

Opportunities for construction sector

• In its vision 2050 the WBCSD highlighted the following:-

• Competition between domestic consumption, mining, agriculture and

resource extraction by 2050

Proposed following:-

• Supply side innovation and solutions

• Desalination plants

• Storm water type infrastructure

• Rainwater collection systems

• Reducing and leveraging of waste water

• Efficiency, conservation and recycling on the demand side