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Co-fueling of Plastic Waste in
Cement Industry: Lessons Learned in
Thailand
C. VisvanathanEnvironmental Engineering and Management
Asian Institute of Technology
Email: [email protected]
Webpage: http://www.faculty.ait.ac.th/visu/
Plastic Waste in Thailand
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 3
Coastal population directly
dump their waste in ocean
Dumpsites cause
secondary pollution
E.g., Leachate runoff
Cause of Marine Plastic Pollution
Marine Pollution caused by two main sources:
Dumpsites located at river watershed
Direct dumping by coastal population
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 4
Plastic Waste Flow in Thailand in 2018
Fresh MSW
Paper
8 %
Others
10 %
Plastic
18 % Organic
and Soil
64 %
Waste Generation
25.24 MT Managed Waste
5.80 MT
• Landfill
• Control Dumping
• WTE Plants
• Uncontrolled
Dumping
• Marine Dumping
Mismanaged Waste
19.43 MT Paper
2 %
Others
14 %
Plastic
42 %
Organic and
Soil
42 %
Source: Jarusutthirak, 2018; PCD, 2019; UNEP, 2017, Current Study
Dumpsite Composition
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 5
0
200
400
600
800
1,000
1,200
1,400
1,600
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
Import
Valu
e (
Mill
ion B
aht)
Import
Volu
me (
mill
ion tonnes)
0.70
0.60
0.50
0.40
0.30
0.20
0.10
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
0
20
40
60
80
100
120
140
Num
ber
of
com
pan
ies
utiliz
ing w
aste
pla
stic im
port
Plastic Waste Import to Thailand
Source – Leungsakul, 2018
Volume (tonnes) Value (Million Baht)
China bans plastic waste import in 2017, displacing
it to other countries including Thailand
Plastic Waste Recycling
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 7
Approaches for Plastic Waste Recycling
Plastic Waste Recycling
Waste to Material
Waste to Energy
Quality of segregated plastic is
important
Not suitable for plastic waste
recovered from landfills
Needs purification technologies for
pre-treatment
Segregation from other streams of
waste necessary
Quality of segregated plastic
does not play a significant role
Better suited for plastic waste
recovered from landfills
Relatively less purification
technologies required
Segregation from other
streams not necessary…
Deposition at
landfills
Disposal
Use
Production
Raw Material
Extraction
Waste to EnergyWaste to
Material
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 8
‘Waste to Material’ and ‘Waste to Energy’
Waste to Material:
Thermoplastics are recyclable, after sorting out based on
the type of distinct polymer such as PE, PET and PVC.
Can be remelted back into a liquid
Can be made into many useful products like furniture,
building materials etc.,
Successes have also been achieved in using the plastic
waste for laying roads
Waste to Energy:
Thermosetting plastics are only incinerable and non-
recyclable
Always remain in a permanent solid state
Suitable for generating energy
Used as co-fuel in cement kilns
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 9
Cement Production with Co-Fuelling
Homogenizing
Hall
Raw Mill
Storage
Silo
Raw material
crusher
Cement Silos
Cement Mills
Preheater
Stack SiloESP
Clinker Storage
Additive Silos
Rotary Kiln
Co-Fuelling
(Coal + Plastic)
Plastic to Coal ratio = 5%
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 10
Co-Fuelling vs WTE
Technical Superiority• Ash from waste utilised in clinker production – No solid waste (ash) generation
• No need to install emission control systems – Lime used in pre-heater acts as “Scrubber” for heavy metals
Waste to Energy MSW to SRF for Cement Production
Production Production
• Electricity: 138 GWh/year • 0.12 million tonnes/year cement production
• Heat: 320-400 GWh/year • Producing 15 GJ/tonnes of energy
• Investment -100 million euro • Investment - 36 million euro
• Energy Recovered - 83% • Energy Recovered - 90%
Incentives from Government Incentives from Government
• 32,000 euro/GWh electricity generation
• FIT’s 4.4 million euro/year (12 years)• Zero subsidy
Source: Heidelberg Cement
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 11
Policy Drivers for WTE
• Expected to reach 30% renewable energy consumption 2036
• Support for WTE:
1. FiT (Feed in Tariff) for electricity from wastes
2. Financial Support - Energy service company fund (ESCO)
3. Project Subsidy
• Adder Program replaced by FiT in 2014
FiT = FiT(F) + FiT(V) + FiT (Premium)
Source: Ministry
of Energy,
Thailand
Capacity FiT (Baht/kWh) Period
(year)
FiT Premium (Baht/kWh)
FiT (F) – FixedFiT(F) FiT(V) FiT (Total) 3 Southern Border Provinces
Very Small Power Provider (VSPP)
≤ 1 MW 3.31 3.21 6.43 20 0.50
> 1-3 MW 2.61 3.21 5.82 20 0.50
Fit (V) – Variable
according to inflation
> 3-10 MW 2.39 2.69 5.08 20 0.50
Small Power Provider (SPP)
> 10 MW 1.81 1.85 3.66 20 -
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 12
Waste Processing at Dumpsite
Dumpsite Waste
Rejected Waste
Processed Waste
Trommel Screen
Nong-Khae
Organic Waste – 39.83%
Plastic Waste – 45.25%
Nakhon-Nayok
Organic Waste – 44.87%
Plastic Waste – 39.12%
Nong-Khae
Organic Waste – 83.46%
Plastic Waste – 12.22%
Nakhon-Nayok
Organic Waste – 60.90%
Plastic Waste - 26.28%
Nong-Khae
Organic Waste – 31.66%
Plastic Waste – 58.84%
Nakhon-Nayok
Organic Waste – 26.67%
Plastic Waste – 60.44%
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 13
Saraburi (Nong-Khae) Dumpsite features
No. of years of operation … 10 years
Capacity … 50,000 tonnes
Processing capacity … 1000 tonnes/month
Incoming waste … 15 tonnes/day
Screens … 80 mm trommel screen × 2
Operation period … 8 hours
Nong Chorakhe, Nong Khae District, Saraburi
Saraburi Case Study
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 14
Nong Khae Dump Site
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 15
Saraburi Case Study
Waste Type Dumpsite Waste (%) Amount (tonnes) Rejected Waste (%) Processed Waste (%)
Organic +
Soil39.83 19,916.20 83.46 31.66
Paper 1.45 726.25 0.00 0.31
Plastic 45.25 22,625.69 12.22 58.84
Glass 1.68 837.98 3.20 1.02
Metal 2.23 1,117.31 0.00 0.20
Rubber 1.12 558.65 0.07 0.00
Textile 5.08 2,541.89 0.46 2.66
Yard 1.62 810.05 0.00 3.98
Ceramic 1.73 865.92 0.59 1.33
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 16
Nakhon-Nayok Dumpsite features
No. of years of operation … 20 years
Capacity … 175,000 tonnes
Processing capacity … 500 tonnes/month
Incoming waste … 24 tonnes/day
Screen … 80 mm trommel screen
Operation period … 8 hours
Phrommani, Mueang Nakhon Nayok District, Nakhon Nayok
Nakhon-Nayok Case Study
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 17
Nakhon Nayok Dumpsite
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 18
Nakhon-Nayok Case Study
Waste Type Dumpsite Waste (%) Amount (tonnes) Rejected Waste (%) Processed Waste (%)
Organic +
Soil44.87 78,522.5 60.90 26.67
Paper 1.92 3,360 0.00 2.22
Plastic 39.12 68,460 26.28 60.44
Glass 1.58 2,765 3.42 0.89
Metal 2.71 4,742.5 2.56 1.33
Rubber 3.27 5,722.5 0.85 3.78
Textile 2.14 3,745 3.42 3.78
Yard 1.69 2,957.5 0.64 0.44
Ceramic 2.70 4,725 1.92 0.44
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 19
Landfills and WtE Plants
in Thailand
Incoming Waste
(tonnes/day)Symbol
< 10
10 – 50
50 – 100
100 – 300
300 - 500
> 500
WTE
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 20
1 Bangkok 21 Loei 1.92 41 Phayao 0.65 61 Satun 0.22
2 Amnat Charoen 22 Lopburi 5.23 42 Phetchabun 1.25 62 Sing Buri 0.40
3 Ang Thong 23 Mae Hong Son 0.39 43 Phetchaburi 63 Si Sa Ket 0.58
4 Bueng Kan 0.62 24 Maha Sarakham 0.44 44 Phichit 0.34 64 Songkhla 0.78
5 Buri Ram 1.59 25 Mukdahan 0.19 45 Phitsanulok 0.55 65 Sukhothai 0.17
6 Chachoengsao 4.13 26 Nakhon Nayok 0.65 46 Phrae 0.52 66 Suphan Buri 6.07
7 Chai Nat 0.18 27 Nakhon Pathom 2.50 47Phra Nakhon Si
Ayutthaya22.00 67 Surat Thani 2.03
8 Chaiyaphum 1.58 28 Nakhon Phanom 2.19 48 Phuket 68 Surin 0.37
9 Chanthaburi 0.17 29Nakhon
Ratchasima3.51 49 Prachin Buri 2.58 69 Tak 1.55
10 Chiang Mai 1.19 30 Nakhon Sawan 0.84 50Prachuap Khiri
Khan0.39 70 Trang 0.34
11 Chiang Rai 1.09 31Nakhon Si
Thammarat1.93 51 Ranong 1.52 71 Trat 0.59
12 Chon Buri 7.73 32 Nan 0.13 52 Ratchaburi 0.66 72Ubon
Ratchathani1.54
13 Chumphon 2.28 33 Narathiwat 0.61 53 Rayong 1.13 73 Udon Thani 2.18
14 Kalasin 1.25 34Nong Bua Lam
Phu0.50 54 Roi Et 1.92 74 Uthai Thani 0.04
15Kamphaeng
Phet0.32 35 Nong Khai 0.43 55 Sa Kaeo 2.73 75 Uttaradit 0.54
16 Kanchanaburi 2.58 36 Nonthaburi 56 Sakon Nakhon 0.70 76 Yala 0.03
17 Khon Kaen 2.84 37 Pathum Thani 0.95 57 Samut Prakan 77 Yasothon 0.87
18 Krabi 0.83 38 Pattani 0.72 58 Samut Sakhon 0.63
19 Lampang 123 39 Phangnga 0.85 59 Samut Songkhram
20 Lamphung 0.54 40 Phatthalung 0.49 60 Saraburi 0.34
1
2
3
4
5
6
7
8
9
10
11
12
13
1415
16
17
18
1920
21
22
23
24
25
2627
28
29
30
31
32
33
34
35
40
37
38
39
3
6
41
42
43
44
45
46
47
4
8
49
50
5
1
52
53
54
55
56
575859
61
6062 63
64
65
66
67
68
69
70
71
73
7274
75
76
77
Dumpsites in
Thailand24
44
10
7
94
8
126
72
20
15
46
13
49
173
22
191
74
43
33
107
11
13
3
4
37
90
17
30
42
21
46
16
4
42
11
14
59
38
11
14
21
40
11
22
19
13
9
12
54
9
22
3
7
8
4
49
21
7
23
40
14
20
13
15
69
94
2
37
2
38
Amount of Waste in
Provinces (tonnes)
Number of Dumpsites
Priority Provinces
(Near Water Bodies)
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 21
Waste Type
Average Composition in dumpsites
(%)
(Current Study)
Amount of Waste in Dumpsites in
Thailand (MT)
Amount of Waste in Landfills in
Thailand (MT)
Organic + Soil 42.35 97.86 90.78
Paper 1.69 3.89 3.62
Plastic 42.19 97.48 90.42
Glass 1.63 3.76 3.49
Metal 2.47 5.71 5.30
Rubber 2.19 5.06 4.71
Textile 3.61 8.34 7.75
Yard 1.66 3.82 3.55
Ceramic 2.22 5.12 4.75
Total 231.08 214.34
Plastic Recovery Potential of Landfills in Thailand
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 22
Plastic Waste Recovery Potential in Thailand
Total Population of Thailand = 69.04 million
Coastal Population of Thailand = 26 million (37.65% of total population)
Number of Landfills = 104 Landfills
Waste in Landfills = 214.34 Million Tonnes
Plastic Waste in Landfills = 90.42 Million Tonnes
Number of Dumpsites = 2380 Dumpsites
Waste in Dumpsites = 231.08 Million Tonnes
Plastic Waste in Dumpsites = 97.48 Million Tonnes
Plastic Waste Recovery Potential = 187.9 Million Tonnes
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 23
Waste Pre-processing
Excavation
Size Selection
Dry Solid Waste
(59.64% Plastic)
Organic Waste
Dumpsite Waste
(42% Plastic)
Excavator
Trommel Screen
Excavated Waste
Excavated Waste
Waste Segregation
Wind Shifting
Heavier Waste
Lighter Waste
Waste Segregation
Magnetic Separation Ferrous Metal
Size Selection
Spinning
Dry Solid Waste
Dry Solid Waste
Dry Solid Waste
Waste Size Reduction
Shear Shredder
Lighter WasteFinal Product
(80% Plastic)
Final Product used in co-fuelling
(5%) in Kiln.
Waste processing
at dumpsite
Waste processing
at dumpsite
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 24
Calorific Value of Waste
Calorific Value of dumpsite waste
increases from 16.74 GJ/tonne to
18.84 GJ/tonne.
Trommel Reject waste mainly
comprised of soil and organic material,
hence lower calorific value.
Plastic waste without moisture and
impurities can have calorific values up
to 45 GJ/tonne.
16.74 17.58
4.18
18.84
30
0
5
10
15
20
25
30
35
DumpsiteWaste
TrommelProcessed
TrommelReject
Final Product Clean PlasticWaste
(average)
Calorific Value of Waste at
different stages (GJ/tonne)
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 25
Energy Conversion Capacity
Calorific value of 1 tonne of plastic waste (ash and moisture free) = 15 - 45
GJ/tonne (2)
Calorific value of 1 tonne of final waste from Ecocycle = 18.84 GJ/tonne
Plastic to Electricity production conversion efficiency = 22% (avg) (1)
Plastic to Heat (Cement Kiln) conversion efficiency = 75% (avg) (1)
1 – World Bank Technical Guidance, Municipal Solid Waste
Incineration, 1999
2 - Towards a better exploitation of the technical potential of
waste-to-energy, 2016
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 26
Challenges of Plastic Co-fueling
• Cement production from plastic waste is a double-edged
sword with benefits of recovery as well as challenges
• Policies pushing WTE Plants, drives the provincial
authorities to support WTE Plants
• Lack of co-fuelling regulations can lead to uncontrolled
emissions
• Lack of well segregated waste decreases the quality of
SRF
• Costs versus benefits of using SRF are way out of
balance
• Centralised collection and production takes waste
management away from the source
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 27
Key Takeaways
• Plastic waste generation along with marine dumping causes
serious impacts
• Efforts such as bans or reduction in single use plastics offers
solution for future, however the stock of plastic waste in landfills
need to be addressed to control marine plastic pollution
• The characteristics of plastic waste in landfills makes it attractive for
recovery. Higher plastic waste recovery potential from landfills are
estimated through this study
• ‘Waste to Energy’ approach through co-fueling of plastic waste in
cement industry reduces the need for high quality segregation or
purification
• Policy intervention is needed to encourage plastic co-fueling in
cement industry owing to its engineering superiority
• The study recommends to prioritise plastic waste recovery from 41
provinces located at coastal area, Chao Phraya and Mae khlong
river basin.
C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 28
Thank You!