Waste Co-processing in the Scheme of Industrial...

Waste Co-processing in the Scheme of Industrial Ecology

Pavel Cech, October 2013, Kuala Lumpur

Presentation Flow

Brief introduction of Lafarge

• Group

• Malaysia

Industrial Ecology Concept

Co-processing Fundamentals

Lafarge IE Activities in Malaysia

Possible Opportunities

Closing Remark

Brief Introduction of Lafarge

Profile 2012

World leader in building materials

Major player in the cement, aggregates and concrete industries

We contribute to the construction of cities throughout the world

with innovative solutions, providing cities with more housing, and

make them more compact, more durable, more beautiful and

better connected

Operating in 64 countries

65,000 employees

€15.8 billion of annual sales

1,570 production sites

Listed on the Paris Stock Exchange

4

Sustainable development is rooted in Lafarge’s history and values

More than 170 years of history and experience to build on

Principles of Action since 1977, updated in 2003

Participation in the Rio Earth Summits in 1992 and 2012

Founding member of the World Business Council for

Sustainable Development (WBCSD) in 1992

First industrial partner of WWF in 2000

CO2 emissions reduction commitments since 2001

Business Code of Conduct since 2004

We have been a pioneer and intend to remain so

Lafarge Malaysia

Cement

• 1,120 employees

• 3 integrated cement plants

• 1 clinker grinding plant

• >12.0 million tonnes p.a.

Malaysia is one of Lafarge’s key markets in South-East Asia. It became a part of Lafarge in 2001

through the acquisition of Blue Circle.

Industrial and sales activities in Cement, Aggregates & Concrete.

Lafarge Malaysia Berhad is the largest cement manufacturer in Malaysia serving local and export

market

Lafarge Malaysia Berhad is listed on Bursa Malaysia and as at1 March 2013, it was ranked 35th

by market capitalization worth RM8.3 billion with 2012 revenue at RM2.74 billion.

Aggregates

• 97 employees

• 5 quarries

• > 2.0 million tonnes p.a.

Concrete

• 375 employees

• 29 ready-mix plants

• 2.0 million m3 p.a.

Singapore Operations held via Alliance Concrete Singapore

• 11 ready-mix plants

• >1.5 million m3 concrete p.a.

• 1 cement terminal

Lafarge industrial network in Malaysia

Integrated Cement Plants

Grinding Station

Ready-Mix Plants

Aggregates Quarries

Industrial Ecology Concept

Lower

consumption

of natural

resources

Minimum

of rejects

Someone’s waste becomes resources for others

Energetic Surplus = Energy sources

Logistic improvement (supply + collection)…

Minimization of waste disposal capacities

Industrial Ecology is scientific approach which consists of mimicking the low consumption

equilibrium of ecosystems

Inspired by the efficiency of natural ecosystems

9

Bending the line…

In the traditional manufacturing concept the life of material is a

line which by applying Industrial Ecology we can turn into a cycle.

Material Extraction Logistics Manufacturing Distribution Usage Disposal x

Lo

gis

tics

Usa

ge

Innovative

Know-How

Process & Technology

Industrial Ecology

Co-processing Fundamentals

What is Co-processing?

Thermal or material recovery (or

combination of both) in a cement

manufacturing process generating

no residual waste.

Why do we co-process Waste?

Cost reduction

Reduction of emissions

Environmental protection (sound and safe

disposal solutions for industries and

communities)

Conservation of non-renewable resources

Co-processing in the waste management hierarchy

Co-processing prerequisites

Cement manufacturing process

Raw mix preparation

Burning

Cement grinding

Alternative Raw Materials

Chemical Flexibility of the raw mix

Alternative Fuels

Very High temperature

Long residence time

Gas cleaning inherent to

the process

Additive to

Cement

Fly Ashes

Blast Furnace

Slag

Silica Fumes

A closed cycle process without residual or waste/byproduct.

Co-processing of waste reduces pollution!

Emission reduction

Hazardous

Waste

Hydro-

carbons

Municipal

Solid Waste

Biomass

Industrial

and

Commercial

Waste

Co-processing

solutions

Rubber

Waste

What can be co-processed?

Lafarge IE Activities in Malaysia

Industrial Ecology in Malaysia

Lafarge Industrial Ecology is locally present COPROCEM

Malaysia which organizes waste management services to the

customers (waste generators) for waste co-processing in cement

kilns of Lafarge Malaysia.

Lean, versatile and agile team from diverse backgrounds

With about 400 kt/y of co-processed waste a leading player in

AFR

Catering to a wide range of customers from sectors such as:

heavy industry (metallurgy, mining, chemical…), light industrial

manufacturing (FMCG, electronics, food…), agriculture or even

government

No customer is a small customer but a responsibility (moral and

financial) for waste generation strictly lies with the waste

generator.

Co-processed waste streams in Malaysia

Agricultural biomass

Industrial biomass

Processed C&D waste

Tires and tire residues

RDF

Bleaching media

Solid non-combustible SW

Semisolid non-combustible SW

Combustible industrial solid waste

22

Waste Code Examples

SW104 Spent blasting media, dross, PFA

SW204 Metal hydroxide sludge containing heavy metals

SW205 Waste containing calcium sulfate from power plant

or chemical industry

SW207 Sludge containing fluoride

SW313 Spent filter earth

SW320 Phenolic resin waste

DOE approved hazardous waste streams

SW207

SW104

SW204

SW205

Orbis pictus…

Information

• Customer’s manufacturing process inquiry

• Waste description (physical, qualitative and quantitative)

• Sampling of waste

Assessment

• Review of chemical analysis and it’s comparison with internal WAC

• Process impact computation

• Technical evaluation with the cement plant

Commercials

• Commercial proposal to the waste generator

• Waste disposal agreement

Permitting

• Approval application at DOE

• Transporter registation

Operation

• Disposal logistics, disposal and billing

• Regulatory compliance (emission monitoring, manifests…)

Standard process for Customer On-boarding

Closing Remark

Cement industry provides an existing

infrastructure for safe, sound and cost

effective disposal of many waste streams.

How can we place this proposition into the

broader framework?

Thank YOU!

Pavel Cech

VP Industrial Ecology SW&E Asia

pavel.cech@lafarge.com

+60126857189

Contact