Dangote Cement reduces water consumption by 70% with biological dust control

Only one year earlier, Dangote was experiencing several operational challenges:

• Excessive dust reduced visibility across the site, creating safety concerns
• Water trucks were constantly running at maximum capacity
• Significant resources were dedicated to road maintenance and grading
• Vehicles and equipment required frequent cleaning and maintenance
• Environmental impact was a growing concern

“That place was extremely dusty. Even outside the plant, there was a dust cloud hanging everywhere. Visibility was poor,” recalls JC Le Roux, Head of Business Development Africa, Bind-X, who visited the site.

While the plant management had previously explored bitumen-based dust control options, they found these solutions too expensive. This left them continuing to rely on water alone, despite its clear limitations and resource intensity.

The mine’s Operational Sustainability Manager at Dangote was looking for a better way to cut water usage and manage dust, while also keeping cost in mind. 

When he heard about a new and proven biological dust control product, and looked at the cost analysis, he was keen to run a trial on site. 

They began a trial of Terrabind Max on a stretch of road at the facility a few kilometers long. As a spray-on application, it was ideal for their well-established roads and didn’t need to be built in with a grader.

The implementation process was straightforward:

1. The team received on-site technical assistance and training on product mixing and application
2. An initial higher dose was applied to establish the road treatment over 2-3 days
3. After the initial application, the team transitioned to a lower maintenance dose applied once daily

The trial demonstrated immediate and substantial benefits — a 70% reduction in water usage for dust control — leading Dangote to continue using the method, and now expanding it across their operations.

The most significant outcomes included:

• Dramatically improved visibility and safety across the site
• Reduced frequency of road grading and maintenance
• Lower fuel consumption for both water trucks and graders
• Decreased wear on vehicles and equipment
• Recognition from environmental authorities

“Suddenly, buses, trucks, and other vehicles could drive over the road without kicking up dust. That was a game-changer for the operation,” JC noted.

Perhaps most unexpectedly, the Ministry of Environmental Affairs witnessed the results during a site visit. “When they drove on that road, they were surprised at the lack of dust. They stopped and asked what was being used. They were impressed when they learned it was a biological dust suppression method, which is 100% environmentally safe, and they praised the initiative.”

Based on the success of the initial results, Dangote now:

• Continues to use biological dust control at their current site
• Expanded the approach to additional roads within their operation
• Implemented the same solution at another facility

“The two biggest benefits for Dangote were water savings and reduced road maintenance,” JC explained. “The team should be commended for their competence and excellent teamwork in executing the project.”

The combined benefits of water conservation, improved safety, reduced maintenance, and environmental recognition have made biological dust control an essential part of Dangote’s operational strategy going forward.

By implementing Bind-X’s biological dust control method, Dangote has addressed critical dust control challenges while significantly reducing their environmental footprint and operational costs.