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CO-PROCESSING OF WASTE INCEMENT PLANTS

STATUS AND OPTIONS TO PROMOTECO-PROCESSING FOR

WASTE MANAGEMENT

Presented at International Conference Wastech, 2014 organised by

GSPCB at Mahatma Mandir, Gandhi Nagar on November 21, 2014

r B Sengupta,

Member EAC (Industry), MoEF

Former Member Secretary,

Central Pollution Control board

bsg!"gmail#com


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Co-processing The use of suitable waste

materials in manufacturing processes for thepurpose of energy and/or resource recovery and

resultant reduction in the use of conventional

fuels and/or raw materials through substitution.

CO-PROCESSING


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CO-PROCESSING OF WASTE IN CEMENT KILN

AGREEMENT IN INTERNATIONAL CONVENTION

Cement kiln co-processing technology isaccepted by Basel convention for disposal of

hazardous wastes

The cement kiln co-processing technology isaccepted by Montreal protocol for disposal of

POPs. Cement kiln co-processing of POPs,

hazardous and non hazardous wastes ispracticed widely and successfully in manycountries around the world


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INITIATING POLICY REFORMS FORSUSTAINABLE WASTE MANAGEMENT

THROUGH CO-PROCESSINGImportant Recommendations of Basel ConventionGuidelines :

1. The waste management hierarchy needs to be respected.2. Additional emissions and negative impacts on human health

must be avoided

3. The quality of the cement must remain unchanged4. Companies that co process must be qualified with appropriateinfrastructure. Assure compliance with all laws and regulations Have good environmental and safety compliance records Have personnel, processes, and systems in place committed to

protecting the environment, health, and safety Safe and sound receiving, storage, processing and feeding of

hazardous wastes

Systems for the provision and analysis of waste representativesamples should be in place Contd


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INITIATING POLICY REFORMS FORSUSTAINABLE WASTE MANAGEMENT

THROUGH CO-PROCESSINGImportant Recommendations of Basel ConventionGuidelines :

5. For optimal performance , AFRs should be fed to the cementkiln through appropriate feed points, in adequate proportions

and with proper waste quality and emission control systems.

6. Due to the heterogeneity of waste, pre-processing is requiredto produce a relatively uniform waste stream for co-processing in cement kilns. To be carried out in a purpose-

made facility, which may be located outside or inside thecement plant

Contd


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Alternatie F!el" #$i%$ %an &e !"e' t( in%rea"et$er)al "!&"tit!ti(n rate *TSR+ in %e)ent

in'!"tr,*!"e ( CV ( #a"te a" !el in %e)ent .iln+

S.

NO.

Fuel Calorific Value

(kcal / kg)

1. R! from "unicipal #olid $aste %&''-(&''

%. )sed Tires *+''-++''

(. ,aardous $aste '''-0''

. ndustrial 2lastic $aste '+'-**%'

0. 3iomass %0''-(&''

*. #laughter ,ouse $aste +''-1''

+. 2oultry 4itter %+''-(&''

&. ried #ewage #ludge 1+''-1''

Source : Holtech & CPCB


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Alternatie Ra# Material" #$i%$ %an &e!"e' a" &len'in/ )aterial

S.No. Alternative Raw Material Available Quantit

in !illion tonne"

#er annu!

1. !ly 5sh 6cement blending material7 %''.'

%. 3last !urnace #lag from #teel ndustry 1'.'

(. 4ime #ludge 62aper8 Carbide8 #ugar ndustry#ludge7

.0

. Red "ud from 5luminum ndustry (.+0

0. !oundry #ludge / #and -*. Chrome #ludge as mineraliser -

+. 4ead 9inc #lag '.0

&. 2hosphate Chal: -

Source : Holtech


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POTENTIAL AVAILABILITY OF WASTE FOR

CO-PROCESSING IN INDIA

A.Fuel

B. Alternate Raw Material

,aardous $aste '.*0 "T5

3iomass 10' "T5

)sed Tyre '.&( "T5

ndustrial 2lastic $aste '.%' "T5

R! from "#$ *.&& "T5

!lyash %'' "T5

3last !urnace #lag 1' "T5

Source : CPCB & Holtec


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GENERAL PRINCIPLE FOR CO-PROCESSING

The important general principles in co-processing are :

1. Additional emissions and negative impacts on humanhealth must be avoided

2. The quality of the clinker/cement must remain unchanged.

3. Companies that co process must be qualified

Assure compliance with all laws and regulations Have good environmental and safety compliance

records

Have personnel, processes, and systems in place

committed to protecting the environment, health, andsafety

Be capable of controlling inputs to the production

process

Contd


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Requirements for undertaking co-processing are

1. Best available technology for air pollution prevention andcontrol with continuous emission monitoring

2. Exit gas conditioning/cooling and temperature less than200C in control devices to prevent dioxin formation.

3. Adequate emergency and safety equipment andprocedures, and regular training

4. Safe and sound receiving, storage, processing and

feeding of hazardous wastes5. The operator of the co-processing plant should develop a

waste evaluation procedure to assess health and safety ofworkers and public, plant emissions, operations and

product quality, variables that should be considered whenselecting waste include:

(a) Kiln operation

(b) Emissions(c) Clinker, cement and final product quality


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AVAILABLE HA0ARDOUS WASTEWHICH CAN BE USED AS PARTIAL FUEL IN

CEMENT KILN

Organic residue from Pharmaceuticals and Pesticide

industry

Spent solvent

Sludge from petrochemical / oil refinery

Slaughter House Waste

Waste Oil

Paint sludge

Effluent Treatment Plant Sludge

Spent Pot Lining from Aluminum Industry

Spent Carbon


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$. A!en%!ent of t&e 'aar%ou" a"te Manage!ent Rule"*

$+,+* un%er t&e -nviron!ent rotection Act* $+,* to

inclu%e co0#roce""ing in ce!ent #lant" a" a %i"#o"al o#tion.

1. re#aration of tec&nical gui%eline" for "etting u#

environ!entall "oun% #re0#roce""ing facilitie" to #re#are

&o!ogenou" wa"te !i2e" "uitable for co0#roce""ing in

ce!ent kiln".

3. 4evelo#ing e!i""ion "tan%ar%" for co0#roce""ing alternate

fuel an% raw (AFR) !aterial in ce!ent kiln" inclu%ing

&aar%ou" wa"te".5. 6ncrea"ing t&e u"e of fl a"& generate% b coal ba"e% #ower

#lant" an% refu"e0%erive% fuel" (R4F) in ce!ent #lant".

7. 4evelo#ing gui%eline" for t&e tran"#ort an% "torage of&aar%ou" wa"te

Li"t ( W$ite-1a1er" 1re1are' &, Re/!lat(r, F(r!)%(n"i"tin/ ( Me)&er Se%retarie" ( 2 SPCB" !n'er

t$e C$air)an"$i1 ( MS3 GSPCB


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M("t Pr()i"in/ Alternate F!el"

RDF from municipal solid waste [ MSW ]

Used tyres

Hazardous waste

Industrial plastic waste

Biomass


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RDF r() MSW


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Barrier"

Technical Barriers Poor quality MSW due to high recycling Presence of high moisture, chlorine and heavy metals in

RDF, limiting TSR

Customization of technology for MSW to cement gradeRDF conversion units Financial Barriers

Financial Barriers

High investment cost for setting up pre-processing unit

High collection and transportation cost of MSW Policy &Regulatory Barriers

Policy and Regulatory Barriers Non availability of clean, transparent and detailed

information on MSW availability in Public domain

No clear policy that encourages conversion of MSW to

RDF and its co-processing in Cement Plants as preferredalternative


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Re%())en'e' A%ti(n Plan

Setting up a demonstration project in a public privatepartnership mode that addresses all the pillars of

sustainability namely technical, institutional andfinancial

RDF co-processing inclusion by MNRE under theirwaste to energy scheme

RDF use for co-processing to be acknowledged as a

CSR activity, which would unlock finances for thisaction that will have major societal benefits by partlysolving themenace ofMSW


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U"e' T,re"


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Barrier"Technical Barriers

Possibility of coating formation at kiln inlet due to highsulphur content

Poor availability near cement plants

Financial Barriers High Price due to other uses, high transportation and

collection cost

High financial risk of setting up co-processing system due

to uncertainty of availability at targeted price

Policy and Regulatory Barriers

Lack of information on used tyre inventory, district &

sector wise break-up of waste in public domain No clear policy that prefers co-processing of tyres to other

modes of disposal

Cumbersome import permit process

Requirement of emission trials by MoEF for ever newsource of imported tyres


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Recommend ban on current practices of disposingused tyres that create huge environment pollution

Recommend free import of tyre chips and rubberwaste for co-processing


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Ha4ar'(!" Wa"te


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Barrier"

Technical Barriers

Non uniform quality due to varying sources Presence of high moisture and Chlorine Lack of pre-processing facilities

Limited technical knowledge and skilled manpower

Financial Barriers

Time consuming and expensive trial runs needed for each

new stream High capital cost for setting pre-processing platforms Huge competition for HW, impacting gate fee


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Barrier"


Unclear emission norms, cement industry required to

demonstrate no change in emissions before and after HWuse

Incinerator standards to be followed for co-processing asthere are no specific emission standards for cement kilns

Interstate transfer of HW is restricted by some state PCBs Non availability of clear and transparent information on

sources of HW, details on state wise / sector wisegeneration of wastes in public domain

Outdated Classification of HW

Preference to TSDFs


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Developing emission standards for Cement Industryusing HW

Recommend exemption of emission trials for selected

categories of HW Suggest steps to increase availability of HW for co

processing by including some part of land-fillable HW Develop guidelines for HW pre-processing units for

cement industry Facilitate availability of HW Inventory data base on

software platform in all relevant states Suggest amendments to existing HW rules to include

co-processing of HW in Cement plants as a 4th optionof HW disposal

For HW Pre processing units for cement Industry,

central/ state subsidy be encouraged based onviability gap funding


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In'!"trial Pla"ti% Wa"te


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Barrier"

Technical Barriers High moisture content and impurities

Lack of pre-processing facilities for Industrial Plasticwaste

Financial Barriers Lower charges motivating industry for land filling High transportation cost as cement plants are far off

Availability inconsistent to justify installation of co-processing facility


Unclear Policy at Central and state level about the need forenvironmental permits for co-processing

Non uniform policy at state level regarding classification ofplastic waste as hazardous or non-hazardous


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Replicate Gujarat model of encouraging plastic wasteco processing in cement plants in other states of India

Normalization of policy with regard to categorizationof plastic waste that facilitates its transportationacross states


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S!r1l!" Bi()a""

B i


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Barrier"

Technical Barriers

Low bulk density, bailing required for straws Used in boilers, furnaces, brick kilns making availability

difficult for cement plants Requirement of shredders/ chippers for size reduction

High Potassium and Sodium in some crop residues maycause kiln operational issues

Financial Barriers High costs of handling, bailing & transportation over long

distances Uncertainty of regular availability of biomass makes

investment decision on co-processing system difficult. Requirement of huge land area for cultivating energy crops

Policy and Regulatory Barriers Restricted usage of biomass only for power generation by

some states, encouragement of biomass based power plantsby state nodal agencies

Practice of burning rice straw to clear fields, ban on suchpractices not enforced rigorously


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Represent to MNRE for including biomass co-processing in cement industry in their action agenda

for utilizing surplus biomass as green fuel

Captive/ neighborhood energy crop plantation shouldbe carried out by the cement industry as CSR activity


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USE OF WASTE FOR CO-PROCESSING ININDIA

*RECOMMENDED REGULATORY REFORMS+

PROPOSED AMENDMENT IN HA0ARDOUS


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PROPOSED AMENDMENT IN HA0ARDOUSWASTE MANAGEMENT RULES TO BOOST

UP CO-PROCESSING OF WASTE INCEMENT PLANT

$. 6n C&a#ter 6* Section 3* 4efinition"* t&e following !a be

inclu%e%8

(e) 9Co0#roce""ing: ;&e u"e of "uitable wa"te !aterial"

in !anufacturing #roce""e" for t&e #ur#o"e of energ an%/or

re"ource recover an% re"ultant re%uction in t&e u"e of

conventional fuel" an%/or raw !aterial" t&roug& "ub"titution.

1. 6n C&a#ter 6* Section 3* 4efinition"* t&e #re"ent clau"e (e)

!a be !o%ifie% a" un%er8

(f) 9%i"#o"al: !ean" an o#eration w&ic& %oe" not lea%

to reccling* or reu"e an% inclu%e" #&"icoc&e!ical* biological

treat!ent* incineration* co0#roce""ing an% %i"#o"al in lan% fill.

Contd

3 it& t& b t % t ( ) t


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3. it& t&e above two a!en%!ent" a co0#roce""or (e.g.) a ce!ent

kiln owner beco!e" 9o#erator of %i"#o"al facilit: un%er clau"e


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. Con"e>uent to t&e above* Section $+($)* C&a#ter V6 !a be

a!en%e% a" un%er to inclu%e co0#roce""or at #ar wit& ;S4F o#eratorin re"#ect of ackaging an% labeling of '.

;&e occu#ier or o#erator of t&e ;reat!ent Storage An%

4i"#o"al Facilit or Co0roce""ing facilit or reccler "&all en"ure t&att&e &aar%ou" wa"te are #ackage%* labele% an% tran"#orte%* ba"e%on t&e co!#o"ition in a !anner "uitable for "afe &an%ling* "toragean% tran"#ort a" #er t&e gui%eline" i""ue% b t&e Central ollutionControl ?oar% fro! ti!e to ti!e.


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PROPOSED EMISSION STANDARD FOR CO-PROCESSING OF ALTERNATE FUEL

INCLUDING HA0ARDOUS WASTE INCEMENT KILN

5t present no emission standard e;ist for co-

processing of alternate fuel / ,$ in cement

:iln. The emission standard e;ist for common

haardous waste incinerator under


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PROCESSING ALTERNATE FUEL5RAW MATERIAL *AFR+ INCLUDINGHA0ARDOUS WASTE

EFFECTIVE FROM 01.08.2015Units at 760mm Hg, dry air, 10 percent oxygen, 273 K

Parameter, Unit Not to exceed Notes

1. Particulate Matter

mg/Nm3 50 A,Bkg/t of clinker 0.125=

2. Sulphur-di-oxide

mg/Nm3 100 A,Crelaxable upto1000* mg/Nm3 by concerned

SPCB in special cases

3. Oxides of Nitrogen, expressed as NO2 A,C,D

mg/Nm3 new - 600Existing 800

> C2C3 recommend 1''' mg/Nm3

Parameter, Unit Not to exceed Notes


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4. Metals

Bmg/Nm3 Mercury and its compounds 0.05Cadmium and Thallium and their 0.05compoundsSb+As+Pb+Co+Cr+Cu+Mn+Ni+V - 0.5

5. Acid Gases A,B

mg/Nm3 Hydrogen Chloride - 10Hydrogen Fluoride - 1

6. Dioxins and Furans ng ITEQ/m3 - 0.1 B

Notes:A: Continuous monitor is required to be installed. Momentary emission levelswill not be considered for conformity check instead not exceeding 72 hours shall be

considered as the averaging period.B: Method of analysis as prescribed in Methods and Standards operatingpractices of Emission Testing in Hazardous Waste incinerators, LATS, CPCB,September, 2007.

C: Method of analysis as prescribed in Emission Regulation Part-III, publishedby CPCB

D: New Cement Plants Commissioned after 01.08.2015=Existing Cement Plants Commissioned before 01.08.2015.=

Contd


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t is recommended that the proposed standard may be

notified under


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iv.


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CO PROCESSING OF OTHER ALTERNATE FUEL*USED TYRE3 BIOMASS3 INDUSTRIAL PLASTIC

WASTE ETC6 OTHER THAN

HA0ARDOUS WASTE IN CEMENT KILN+

)se of above waste as partial fuel in cement :iln can be dealt under

5ir 5ct8 1&1 by #2C3 / 2CC under following section of 5ir 5ct @

#ection 1+6176g7 #ection 16(7 #ection 1607

nce these wastes are notified by respective #tate Dovernment as

9a##rove% fuel: under 5ir 5ct based upon recommendation of

#2C3s / 2CCs8 consent to operate can be granted under 5ir 5ct by

#2C3 / 2CC to cement plants to use above waste as fuel sub?ect tothey meet the emission standard for co-processing as proposed .


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CO-PROCESSING OF RDF FROM MSW IN

CEMENT PLANT

f R! from "#$ is notified by #2C3 / 2CC as

approved fuel under 5ir 5ct then CT for use of thisfuel as cement :iln can be given under 5ir 5ct.

5lternatively under "#$ rules under


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CO PROCESSING OF FLY ASH GENERATEDFROM TPP IN CEMENT PLANT

2resent generation of fly as is about 1'-%'' "T5 from coal based

power station and it is going to increase rapidly as more coal based

power station are being setup in ndia.

)nder 3# code8 fly ash upto (0E are permitted to be used to

manufacture 9fl a"& #oolona ce!ent:. 3# may consider to increase

this limit to 'E for some special category uses of cement.

"o

)nder


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CO-PROCESSING BLAST FURNACE SLAGGENERATED FROM INTEGRATED STEEL

PLANTS

2resently in ndia8 more than 1' "T5 blast furnace

slag are generated from steel industry. 3last furnaceslag after granulation can be used for ma:ing slagcement.

)nder

RECOMMENDATION AND WAY FORWARD


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RECOMMENDATION AND WAY FORWARDTO BOOST-UP COPROCESSING

Co-processing of various type of waste to bepromoted

Inventory of Haz Waste available for Co-processing to be updated.

RDF from MSW to be used as partial fuel incement kiln. This may be included as a part ofCSR programme to manage the MSW disposalproblem.

Fly ash (ESP ash) should be used to produce

fly ash pozzolona cement. Thermal power plant/ cement plants should setup cement grindingunit near thermal power plant.

Blast furnace slag from steel industry should begranulated and used for cement making.

Steel melting shop (SMS) slag should be used for


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Steel melting shop (SMS) slag should be used forcement making after Iron removal.

Coke oven sludge / distillation residue / mixed wastesolvent, spent carbon etc. should be used as partialfuel in cement kiln

Oily sludge from oil refinery / petrochemical industryshould be used for co-processing in cement plant

Spent pot lining from aluminium industry should beused as partial fuel in cement kiln.

Plastic waste should be recycled and also can beused for road making and co-processing in cementplant.

Distillery units for spent wash management shouldadopt concentration cum incineration and powergeneration for disposal of waste.

Chemical gypsum to be used for cement production.


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Wa, F(r#ar'

1. Follow-up with MOEF for amendment ofhazardous waste rule 2009 as per RFrecommendation

2. Finalization of of emission standard for co-processing and follow-up with MoEF fornotification under E(P) Act, 1986

3. Follow-up with MOEF/SPCB for setting of preprocessing plants to promote co-processing ofwaste.

4. Follow-up with respective state Govt forconsideration of RDF as approved fuel for useas fuel in cement kiln.

5. Setting of RDF plant by large industries undernew CSR policy for proper MSW management.


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6. Follow-up with MOEF for proposed amendmentin EIA 2006 to promote fly ash utilization

7. Coordinate with power/cement plant to promotefly ash utilization through Task Force of CPCBon TPP

8. R&D work for SMS slag utilization in cementplant through Task force of CPCB on Steelplant

9. Calibration of CEMS in cement kiln and data

reporting at website of respective cement plant10.Organize national and regional workshop to

promote co-processing of waste in cement

plants.

Wa, F(r#ar'


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