Africa’s flaring problem is less waste, more watts, according to Hesham Tawfik Elshamy head of commercial AMEAPAC at Aggreko, who unpacks how the continent can translate its flaring problem into a power solution

In 2024, Africa flared nearly 40 billion cubic metres (bcm) of gas, with Nigeria, Algeria and Libya as the largest contributors. This volume represents more than 25% of global flaring and is nearly the equivalent of Africa’s entire annual gas consumption.

This data, from the World Bank’s Global Gas Flaring Tracker 2024, also found that the global total has now reached 151bcm, which is the highest level since 2007 and is releasing 389 million tonnes of CO2 into the environment. It is a climate tragedy.

It is also a missed opportunity. This flared gas can be used to generate electricity, cut emissions and provide affordable power where it is most needed, particularly in these African regions.

Nigeria, for example, is one of the largest producers of flaring and is also struggling with poor grid reliability, which is affecting national productivity and the economy. Over the course of 2024, the country experienced at least six national grid collapses and prolonged blackouts. According to the World Bank, Nigeria’s flaring has continued at the same intensity despite its oil production dropping by almost 50% between 2012 and 2022, with more than 174 individual flare sites as of 2022.

Africa is the only region in the world where the number of people without electricity is increasing, even though globally, access to electricity is becoming more advanced and capable. The sub-Saharan Africa region accounts for 85% of the world’s population without power. Yet vast volumes of flare gas are being wasted on the continent, often at oilfields located near communities that remain entirely off-grid.

The environmental and economic cost of this trend is significant. Based on European import gas prices, for example, the global value of flared gas in 2024 exceeded US$63bn, and much of this value is wasted in countries with low electricity access. And while countries like Angola and Libya reported modest improvements in flaring in 2024, the broader pattern of burned-off value remains consistent.

Fortunately, this is a story that can have a different ending. Flare-to-power solutions can transform the narrative in Africa, converting waste gas into electricity using modular on-site systems that don’t demand extensive spending into infrastructure, but do add value and deliver immediate return on investment.

Using flared gas as fuel is cheaper than diesel, grid tariffs or compressed natural gas (CNG) and for oilfield operators, it can lead to significant operational savings. Flaring also releases methane, a greenhouse gas that is 84 times more potent than CO2 over 20 years. Capturing and using this gas reduces overall emissions and supports sustainability goals across both the organisation and the country.

This also taps into regulatory compliance requirements, which are becoming increasingly onerous and challenging to navigate. Governments across the continent are cracking down on flaring – Nigeria’s Upstream Petroleum Regulatory Commission imposed higher penalties in 2023, including a US$2 per 1,000 scf fine for routine flaring. The World Bank’s Zero Routine Flaring by 2030 Initiative now includes Nigeria, Angola, Gabon, Cameroon and the Republic of Congo.

Treated gas can be used on-site or it can be monetised. Natural gas liquids, for example, can be extracted and sold, which opens new income streams for smaller operators previously unable to justify gas recovery infrastructure. In addition, flare-to-power systems can energise isolated oilfields and industrial hubs without access to grids or pipelines.

There are, however, challenges. In Africa, insufficient pipelines and gas treatment plants, capital access constraints, fragmented regulation, and market access limitations are affecting the move to monetise or transport this gas. Although capturing flare gas across Africa could yield 10GW of power generation capacity – more than double the total installed capacity of Kenya and capable of electrifying millions of households – it isn’t being harnessed to its full potential yet.

The ’yet’ is important. Flare-to-power solutions are available and capable. Aggreko has deployed more than 500 MW of APG-fuelled systems globally, including projects that support zero-flaring operations in the Middle East and Africa. In one recent case, an operator eliminated routine flaring while powering remote oilfield infrastructure off-grid. It is possible.

Change means developing legislation and providing support to companies to ensure that gas flaring is transformed into usable power and a way of providing electricity to millions across Africa. It is a clean technology that can provide access, cut costs and mitigate emissions, and in Africa, it is a smart way to capture the energy it is burning into the sky.

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The Usahihi Nairobi–Mombasa Expressway, Africa’s largest road public–private partnership (PPP), has officially welcomed Turner & Townsend, a global leader in programme and project management, as a strategic delivery partner

The addition of Turner & Townsend reinforces the consortium’s capacity to execute the transformative US$3.6bn, 459 km expressway, which aims to reduce travel time between Nairobi and Mombasa from over ten hours to just 4–5 hours.

Designed to alleviate congestion along the A8 highway, the new transport corridor will enhance mobility for both passengers and cargo while improving safety standards. The expressway also represents a new model for sustainable infrastructure in Africa, integrating intelligent transport systems, electric vehicle charging stations, wildlife crossings, and climate-resilient design features.

Turner & Townsend will bring its global expertise in programme management, governance, cost control, risk oversight, and project assurance, ensuring that the Usahihi Expressway is delivered efficiently, transparently, and to the highest international standards.

The company’s appointment builds on its extensive track record in large-scale infrastructure delivery, having supported governments and private sector partners across East Africa on major initiatives such as Kabalega International Airport and key components of the Tilenga Project. These experiences, involving complex budgets, multi-stakeholder coordination, and performance management, have prepared Turner & Townsend to manage the scope and intricacies of the expressway project.

Kyle McCarter, partner at Everstrong Capital and chairman of the Usahihi Nairobi–Mombasa Expressway, said, “Turner & Townsend’s track record across Africa speaks for itself. Their expertise in large-scale, complex projects ensures that the Usahihi Expressway will not only be delivered successfully but will also set a new benchmark for infrastructure delivery on the continent.”

John Rogers, regional director, East Africa, at Turner & Townsend, added, “The Nairobi – Mombasa Expressway is a game-changing landmark project in Kenya which will cut journey times in half greatly improving regional connectivity. The Usahihi Expressway isn’t just a road, it’s a catalyst for economic growth, regional integration and climate-smart development.

Our partnership with Everstrong Capital will allow us to deploy our world-class expertise in programme management, governance, risk oversight, cost control and project assurance to the project. We look forward to delivering this complex infrastructure programme that will support transformational growth across Kenya and East Africa.”

Turner & Townsend joins Everstrong Capital and the broader Usahihi consortium, which includes TRAC, Lotz to Develop, Ashitiva Advocates, Rebel, Andersen, CPF Group, and Kurrent, in delivering this landmark project.

The partnership underscores a shared commitment to global best practices in PPP delivery, guided by transparency, accountability, and collaboration. As the Kenya National Highways Authority (KeNHA) reviews the project’s feasibility study, the strengthened consortium is preparing to move into the next phase of development for this critical transport infrastructure initiative.

DP World has initiated the rollout of its advanced Port Community System (PCS) in Kenya, marking a significant step forward in enhancing trade efficiency and transparency in the region

The Port of Mombasa, serving as a key gateway for over a dozen landlocked nations in East and Central Africa, handles a substantial portion of regional imports and exports. Strengthening its digital capabilities is therefore essential to boosting Africa’s trade competitiveness.

The PCS was developed in partnership with EMEA Port Logistics and implemented with support from the Kenya Ports Authority (KPA) and the Government of Kenya. While DP World does not operate the port, the system provides all port users, public and private, with improved cargo visibility, enhanced operational efficiency, and faster clearance processes.

“Digitisation is no longer optional; it’s essential for unlocking the full potential of African trade. By introducing this platform in Kenya, we are connecting Africa’s ports to the digital economy and setting a new regional benchmark for digital integration and transparency,” stated Mahmood Albastaki, chief operating officer of Digital Trade Solutions at DP World. 

The PCS offers importers, exporters, freight forwarders, transport companies, and customs agents access to a comprehensive suite of digital tools, including cargo tracking, gate booking, billing, payments, and real-time status updates.

Once fully operational, the system is expected to reduce cargo clearance times by up to 30%, improving turnaround for more than 3,000 port users annually. For the Kenya Ports Authority, the PCS will facilitate smarter gate management, better control over cargo movements, and shorter dwell times, reinforcing Mombasa’s status as a leading maritime hub connecting East and Central Africa to global markets.

Jack Rono, Director of EMEA Port Logistics, added, “This partnership with DP World marks an important step in advancing Kenya’s logistics capabilities. Together, we’re creating a connected and transparent ecosystem that benefits all players in the trade chain.”

The Kenya PCS complements DP World’s expanding digital trade network across Africa, linking key corridors from the Indian and Atlantic Oceans to inland logistics hubs. It also supports Kenya’s Vision 2030 objectives to modernise trade infrastructure and foster a digitally enabled economy.

The PCS builds on DP World’s recent collaboration with the Government of Kenya via the eCitizen platform, which promotes the digitalisation of customs and government services, driving a more efficient, transparent, and data-driven trade environment.

The African Export-Import Bank (Afreximbank) has announced the signing of a US$1.35bn financing facility for Dangote Industries Limited (DIL)

This forms part of a larger approximately US$4bn syndicated financing arrangement for DIL, Africa’s largest industrial conglomerate, with Afreximbank acting as the Mandated Lead Arranger for the syndication.

This transaction — one of the largest syndicated loans in recent African financial markets — will be used to refinance capital invested in the construction of the Dangote Petroleum Refinery and Petrochemicals Complex, the world’s largest single-train refinery with a capacity of 650,000 barrels per day. The financing will reduce initial operational expenditures, strengthen DIL’s balance sheet, and support its ongoing growth.

Afreximbank’s contribution of US$1.35bn, the largest share among participating banks, highlights its commitment to major infrastructure projects that drive Africa’s industrialisation, energy security, and intra-African trade.

Since the refinery complex commenced operations in February 2024, Afreximbank has continued to provide financial support for crude supply and product offtake, ensuring smooth operations and reinforcing its role in Africa’s most significant refining project.

Commenting on the deal, Benedict Oramah, president & chairman of the board of directors at Afreximbank, said, “With this landmark deal, we once again demonstrate that Africa’s development can only be meaningfully financed from within. It is only when African institutions lead the way that others can follow. The journey to utilise African resources for its own economic transformation is well underway. Through the Bank’s funding support, we are enhancing the capacity of the Dangote Refinery and Petrochemical Industries Ltd to produce and supply high quality refined petroleum products to the Nigerian market, as well as for export to the entire continent and the world. Our energy security is in sight.”

Aliko Dangote, CEO, Dangote Industries Limited, added, “Afreximbank’s contribution to this milestone financing underscores our shared vision to industrialise Africa from within. This refinancing strengthens our balance sheet and accelerates with ease the refinery’s suppy of high-quality refined petroleum products across Africa.”

The syndicated facility attracted strong interest from major African and international financial institutions, reflecting confidence in Africa’s industrial growth and in Dangote’s vision for transforming the continent.

FLS has completed a significant upgrade to its polyurethane manufacturing facility in Delmas, Mpumalanga, positioning the site as a key global hub for the production of its advanced NexGen wear-resistant material

This development forms part of a wider modernisation programme by FLS, aimed at strengthening supply chains, increasing manufacturing efficiency and enhancing
sustainability across its global footprint.

Brad Shepherd, director service line - screen and feeder consumables at FLS, said the investment at Delmas aligns with the company’s global strategy to standardise and optimise production processes.

“This is a milestone for us,” commented Shepherd. “We are integrating cutting edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way. The upgrade enables us to respond more quickly and reliably to customer needs across Africa, the Middle East and Europe.”

The centrepiece of the upgrade is the introduction of purpose-built infrastructure to produce NexGen screen media - a polyurethane material developed by FLS to deliver extended wear life, reduced maintenance and improved operational efficiency. In on-site trials, screen panels made from NexGen have demonstrated up to three times the wear life of conventional rubber and polyurethane products, making it a gamechanger for industries that rely on high performance screening solutions.

Warren Walker, head of global manufacturing - polyurethane operations at FLS, explained that Delmas is the first of the company’s five global polyurethane plants to complete this transition. “We have installed new, latest generation polyurethane machines, precision tooling and dedicated preheating ovens for inserts,” he said. “This allows us to significantly increase our output while ensuring consistent quality.”

The facility now includes two trommel screen media stations and three screen media stations, each tailored to produce NexGen products. One of the standout technologies introduced is a programmable auto- calibrating polyurethane machine capable of adjusting material hardness to suit
specific applications.

“The flexibility to produce varying hardness levels is critical,” Walker noted. “It means we can tailor our screen media precisely to the customer’s application, ensuring optimum performance and longevity.”

To complement this, a high capacity polyurethane machine capable of pouring up to 42 kg per minute is in operation at the facility. This system is particularly suited to applications requiring large volume pours, such as flotation spare parts and vertical mill components.

The Delmas facility already benefited from a significant upgrade in 2019, when a state-of-the-art six-axis machining centre was introduced for tooling precision, along with robotic welding systems for manufacturing screen media panel inserts and a CNC controlled spiral welding machine to produce wedge wire products. The latest round of investments builds on this foundation and brings the facility to the forefront of global polyurethane production capability.

Energy efficiency was a key consideration in the new layout and equipment design. “We have incorporated smart energy saving features like individual temperature control on each casting table station,” Walker remarked. “This avoids the need to heat large surface areas unnecessarily and contributes to our carbon reduction goals.”

Further supporting these goals is the installation of 300 kW of solar generation capacity at the Delmas site, completed in 2024. Plans are already in place to expand this by another 500 kW in 2026, along with the integration of a battery energy storage system (BESS), enabling greater energy independence and resilience.

FLS’s offering from Delmas extends beyond screen media manufacturing. The facility is equipped to handle the complete fabrication of vibrating screens, from raw material processing and in-house machining to assembly and factory acceptance testing. This vertical integration allows the company to deliver customised solutions with tighter control over quality and lead times.

Shepherd emphasises that FLS operates both as an original equipment manufacturer (OEM) and a screen media specialist, supplying screen panels for all types and brands of vibrating screens, feeders and trommel screens.

“We don’t just supply products,” he said. “We work closely with our customers through our network of on-the-ground specialists to assess site conditions and select the best screening media for their specific needs.”

He notes that many older processing plants are treating materials that differ from their original design specifications. In these cases, screen efficiency can often only be improved by optimising the screen media. “This is where NexGen makes a real difference,” Shepherd commented. “Combined with the correct aperture design, it allows customers to get more life and better performance from their screens.”

Unlike injection-moulded polyurethane, which can compromise the structural integrity of screen panels, FLS’s proprietary process retains superior mechanical properties, resulting in a tougher more durable product. “We have never used injection moulding because it reduces the quality of the end product,” Shepherd explained. “Our process delivers a product that stands up to the toughest operating conditions and offers lasting value.”

Walker adds that the expansion at Delmas not only supports FLS’s global operations but also contributes meaningfully to the South African economy. “Our commitment to local manufacturing is evident in the scale of our investment and the jobs we have created,” he said. “We have expanded our workforce, prioritised local recruitment and significantly grown our apprenticeship programme.”

A strong focus has also been placed on developing female artisans. In 2024, six women from the local community were recruited into a three year trade apprenticeship programme, receiving training in welding, fitting and boilermaking.

“Our investment during a period of economic uncertainty underlines FLS’s long term commitment to South Africa and to our customers in the broader EMEA region,” said Walker. “We are not just building products – we are building skills, opportunities and partnerships that will power sustainable growth for years to come.”