Coprocessingfor a Zero Waste Future - Bombay …€¢ If the organic compound (coal or waste materials), contains chlorineorsulphur,thenacidgasessuchasHCLandSO2are produced. These

© 2014 Holcim Technology Ltd

Coprocessing for a Zero Waste Future

© 2014

Ulhas Parlikar

Dy Head, Geocycle India

ACC Limited


About Geocycle

Geocycle is the waste management brand of

Holcim. In Geocycle, the service of waste co-

processing in cement manufacturing process is

provided. Holcim is the promoter of both ACC

Limited and Ambuja Cements Limited (ACL).

• Brand was created in 2007 as the dedicated

identity used to brand waste management

solutions in the Holcim Group

• We apply the highest health, environment

and safety standards in all our operation

complying to relevant regulation

For a zero-waste future


Technical Characteristics of Cement Kiln

Preheater

cyclones

Act like a dry

scrubber for

acid gases

and metals

Clinker: Thermal, macro-molecular immobilization of metals

Mineral wastes:CaO, SiO2, Al2O3, Fe2O3

Kiln main burner

Flame: 1800 - 2000 °C

Combustion gases: >1100 °C

Retention time > 10 s

Material : 1450°C > 15 min.

(Non)-hazardous waste:

liquid, fine solid particles,

readily combustible

(Non)-hazardous

waste: lump fuel

Mineral by -products

PrecalcinerGases: > 900 °C Retention time > 3 sRaw meal: 700 °C

(Non)-hazardous waste: liquid,

solid, coarse particles


What is Co-processing?

• Co-processing is…

� …based on the principles of industrial ecology and stands for the usage/disposal of waste material (as raw

materials, as a source of energy or both) in energy intensive industries to…

� …replace natural mineral resources (material recycling) and fossil fuels such as coal, petroleum and gas

(energy recovery) by ‘processed waste’

• Benefit of co-processing to the industry & community are………

� Provides a permanent solution to waste management problems

� Reduces emissions and greenhouse gases

� Lessens reliance on fossil fuels

� Preserves natural resources

• Benefit of co-processing to the cement industry are……

� Service charges towards co-processing/tipping fees

� Reduces cost of Fuel and Raw material

In short, co-processing is the environmentally-friendly

alternative business model for responsible industries


Coprocessing and Sustainability

• In a world of diverse industries, a

range of waste material is resulted in

the process of manufacturing goods

and services

• Waste generation is an inadvertent

outcome of economic growth and it

becomes necessary to deal with its

resulting

• Landfill and incineration are

considered as necessary disposal

options in some cases, but are less

preferable in the waste management

hierarchy

Incineration

Coprocessing100% Material

Recovery100% Energy

Recovery

Prevention / Reduction

Reuse

Recycling

Waste to Energy

Land filling

Beneficial

use of

Material

and

Energy

Waste

Disposal

Co-processing recovers energy, recycles and conserves materials and contributes to reduced

environmental footprint. It represents a sustainable solution for many waste streams which can’t be

recycled and shouldn’t be land filled. It offers significant potential for reducing pollution and landfill

space caused by the waste disposal. Co-processing is thus a preferred solution in the waste

management hierarchy


What happens to the waste in the Cement Kiln ?

• Organic constituents are completely destroyed due to the high

temperatures, long residence time and oxidizing conditions in

the kiln. Combustion of an organic compound composed only

of carbon and hydrogen produces CO2 and water.

• If the organic compound (coal or waste materials), contains

chlorine or sulphur, then acid gases such as HCL and SO2 are

produced. These gases are absorbed and neutralized by the

freshly formed lime and other alkaline materials within the kiln.

• The inorganic constituents including heavy metals reacts with

the raw materials in the kiln and are included in the clinker

matrix leaving the process as part of the cement.


100

150

200

250

300

Thousands

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999(es t )

T/y

haz. A

.F.R

.T

/y h

az.

A.F

.R.

0, 0 00 1

0 , 00 1

0 ,0 1

0, 1

1

mg

r/N

m3

- d

ry -

11

% O

2

19 9 0 1 9 91 1 9 92 1 9 9 3 19 9 4 19 9 5 1 99 6 1 99 7 1 9 98 1 9 9 9(e s t )

Sb+Cr+Cu+Pb+VSb+Cr+Cu+Pb+V

As+Co+Ni+Se+TeAs+Co+Ni+Se+Te

Cd+Hg+TlCd+Hg+Tl

Zero Impact of Co-processing On Emissions

0,1

1

10

100

1000

pp

m

1990 1991 1992 1993 1994 1995 1996 1997 1998 es t 1999

Sb+Cr+Cu+Pb+VSb+Cr+Cu+Pb+V

As+Co+Ni+Se+TeAs+Co+Ni+Se+Te

Cd+Hg+TlCd+Hg+Tl

pp

mp

pm

On final products

On emissions

Output

products

Cement Quality


Zero Impact On PCDD/PCDF Emissions

(0,29)

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0 20 40 60 80 100 120 140 160

Measurement No.

Em

issio

ns in

ng

I-T

EQ

/m3

regular fuel with secondary fuel

with secon-dary raw material

Source VDZ


No Leaching of Pollutants from Concrete

Doped mixing

water

Lime-dissolving

carbonic acid

Trough tests on mortars

Concentrations in the eluate are

significantly below the limit values


The Geocycle Approach

1

Waste assessment

We can provide a

complete survey of your

waste and a full

assessment of its

suitability for co-

processing.

2

Waste analysis

We offer dedicated

laboratory testing to

analyze your waste to

ensure it is suitable. We

at Geocycle are able to

manage waste such as

solids, sludge and liquids

3

Waste transportation

We provide a seamless

service – ensuring the

waste is transported in

appropriate packaging with

required labelling and

documentation. The waste

is carried by operators with

required skills,

qualifications and permits.

4

Pre-processing

Further analysis of waste

is conducted in our

laboratories if required.

We have extensive

facilities to blend liquids,

shred solid materials and

homogenise waste prior to

its usage in kilns.

5

Co-processing

Waste is then safely co-

processed in cement

kilns. Our cement kilns

operate at temperatures

of up to 2000°C – which

leaves no residue or

waste after co-

processing is complete.

© 2014 Holcim Technology Ltd11

Examples of Waste Pre-Processed and Co-Processed

• Diaper trimmings

• Expired corn seed

• Damaged beans

• Plastics

• Expired products

• Packaging materials

• Rubber wastes

• Textile waste

• Refinery wastes

• Bleaching earth

• Lime sludge

• Fly ash & bottom ash

• Mill scale

• Blasting grit

• Diatomaceous earth

• Paint wastes

• Used oil & grease

• Scrap tires

• Wood chips

• Solvents

• Carbon fines

• Oil filter fluffs

• Coking wastes

• Shipping wastes

• RDF fluff & pellets

• Sorted MSW

• Filter cake

• Refinery catalyst

• Calcium fluoride

• Foundry sand

• Contaminated soil

• Aluminium production waste


Waste Pre -Processing Processed

Waste

Large scale coprocessing - Pre-Processing Activities


Pre- and Co-Processing Facilities (PCPFs)

• Geocycle India has setup international standard Waste co-processing and Pre–

processing facilities (PCPFs) at Wadi, Kymore, Bhatapara, Rabriayas, Maratha

Ambujanagar and Madukkarai to manage the wastes from the respective states.

• Pre-processing is done by techniques such as size reduction, screening,

impregnation, blending etc.

• In the PCPFs, different kinds of

wastes from industrial, biological

and municipal sources are

converted into uniform quality

materials for using them as

Alternative Fuel and Raw

Materials (AFRs) in cement plant.


ACC’s Geocycle Initiative was awarded the 2013 Parivartan

Sustainability Innovation Challenge Award at the Annual Summit of the

Sustainable Business Leadership Forum in October 2013

Awards


Clean India Drive - How cement plants can contribute

• Coprocessing can manage Industrial Hazardous wastes, Industrial

Non-hazardous wastes, Segregated MSW, agro wastes, POPs etc. in

large quantities and an environmentally sound manner.

• The infrastructure available to manage all the waste generated in the

country by land filling and incineration is highly inadequate and

inappropriate.

• Cement plants already exist and are well spread out through out the

country to provide coprocessing solutions locally to the local waste

problems.

• There is no need to set up additional landfill and incineration facilities.

• Coprocessing is environmentally a superior technology than

incineration and land filling.

• All cement plants are developing necessary coprocessing capability

and capacity in the country to extend the environmental solution in the

“Clean India” drive.


Incineration v/s Co-processing

Characteristics Incineration Co-processing

Temperature 850oC – 1200

oC 1400

oC – 2000

oC

Residence Time > 2 sec @ >1200oC 4-6 sec @ >1800

oC

Turbulence Induced in SCC Induced in kiln

Gas cleaning Alkaline scrubbing Alkaline Environment in kiln

Residues Ash / fly ash In clinker product

• The higher temperature in co-processing results in efficient thermal destruction

• Residence time is 2 times higher in co-processing which helps in complete

destruction of the waste

• Turbulence when induced in cement kiln helps in complete combustion

• The Alkaline environment in kiln acts as natural gas cleaning

• Co-processing leaves no residue to be land-filled


Reduction of Green House Gases

Co-processing and

IncinerationReduction in GHG Emissions

Co-processing and

LandfillPrevention of Methane*

Emissions* Methane has 21 times more global

warming potential than CO2

The same argument is valid for all other emissions too.


Ways to treat MSW

Incinerator

MSW Pre-

Processing

Facility

MSW

Cement Plant

Power Plant WtE

AFR

Controlled Landfill

Hi tech Treatment

Open Dumping

Recycling

STAAR_Bhatapara, HTS-Geocycle, Rondobio, 2014-10-28 18

Composting


MSW fractions and feasible disposal options

19

Recyclable Plastics

Segregated Combustible

Fraction (SCF)

Composting/RDF/Biomethantion

Kitchen waste/organics

Glass

Metals

MSW

Construction and

Demolition waste

Recycling

RDF / Coprocessing/ WTE

Inert Material Land fill


MSW is garbage and cannot be directly co-processed!

20


21

Current MSW Model in India

21

RecyclingSorting

(manual+me

chanical)

Landfill

Co-Processing

25%

25%

10%

Combustible Fraction40%

++CURRENT

Considered

as Fuel for

cement

plant/WTE

© 2014 Holcim Technology Ltd 22

Adaptable Business Model in India

(integration with existing option)

RecyclingSorting

(manual+me

chanical)

Landfill

-

Pre-processing shredding and

blendingCo-Processing

25%

25%

10%

Combustible Fraction40%

INR/T

Capex: 20Cr

(shredding+storage)

OPEX: 1500/T

-Avg 500/T

CURRENT

Considered

as Fuel for

cement

plant/WTE

Key driver in the market is the appropriate

tipping fee to make the economics work


Different Models of integration

23

QA / QC

MSW from

Source

Collection

from Source

Segregation

Bio-degradable

fraction

Composting

Combustible fraction

Pre-processing

plant

RDF Fluff

Pre-

Processing

Co-processing

Third Party with support from ULB’s Third Party /cement

Plants

Cement Plants

Recyclables

Model 1

Model 2

Model 3


Holcim and GTZ through a Strategic alliance

� Proposed international guidelines for the co-processing

of waste materials in the cement production

� Secured the public acceptance of these guidelines

� Finalized them in July 2006

Regulatory framework – Global scenariio

� From those guidelines, specific legal frames on co-

processing are under implementation in around 15

countries

Coprocessing, being a technology that leaves zero waste for future concern, is practiced

on large scales in many EU and other developed countries.


Document Number UNEP/CHW.10/6/Add.3

Available in: www.basel.int

•To offer objective information about co-

processing of waste in the cement

industry

•To offer links to organizations,

institutions, and companies active in the

field of co-processing and to propose

ways and means for capacity building.

Basal Convention has reviewed and approved technical guidelines on coprocessing

Global regulatory framework – Basal Convention

� For facilitating governmental authorities globally in formulating guidelines for co-

processing of wastes

• To offer objective information about co-processing of waste in the cement industry


Global regulatory framework – Indian Scenario

The HWM rules recognized co-processing under chapter III, Rule 11. It states the following: “The Utilization of

Hazardous Wastes as a Supplementary Resource or for Energy Recovery, or after processing shall be

carried out by the units only after obtaining approval from the Central Pollution Control Board”

Trial Run for new HW stream

Approval from CPCB for regular co-

processing

Authorization from SPCB for regular co-

processing

Current Framework for Hazardous Waste Co-

processing in Cement Kilns

• CPCB Guidelines on Co-processing in Energy Intensive Industries was

published in February 2010

• On similar lines, Guidelines for Co-processing of Spent Wash generated from

Distillery Units was also published


Relevant Policy Documents pertaining to AFR activities

• Hazardous Waste (Management, Handling and

Transboundary Moveent) Rules 2008

(http://www.cpcb.nic.in/divisionsofheadoffice/hwmd/mhtrule

s2008.pdf)

• Municipal Solid Waste Management Rules 2000

(http://www.moef.nic.in/legis/hsm/mswmhr.html) and

• http://envfor.nic.in/sites/default/files/so-1978-e.pdf (Draft

of 2013)

• CPCB Guidelines on Coprocessing in Cement, Steel and

Power Plants – Feb (2010)

(http://cpcb.nic.in/upload/Latest/Latest_51_GUIDELINES-

ON_CO-ProcessinginCement.pdf)


Typical Process for Coprocessing related Permits

Regional

SPCB Office

SPCB Head

Office

CPCB SPCB Head

Office

Cement Plant

ApplicationRecommendation

Recommendation

Permit Application

Authorisation


Operating Process Based on Current Legal Policy Framework

Apply to Regional SPCB

Office for trial permit

Annexure 7

SPCB Head Office to

recommend to CPCB

Undertake

coprocessing trial

Identify Waste Stream

CPCB to grant trial

permission

Submit report to SPCB

Regional Office

SPCB Head Office to

recommend to CPCB

CPCB to grant Regular

coprocessing permission

Apply for authorisation in Form 1 to

Regional SPCB office to regularly

coprocess the permitted waste stream

SPCB Head office to authorise

regular coprocessing of the permitted

waste stream

Start regular coprocessing of

the identified Waste Stream

Submit returns in Form IV to

SPCB


Important Stakeholders to address the Policy framework

issues

Advocacy

Consultants

Rules,

Guidelines &

Policies

Industry

AssociationsNGOsNGOs

CommunityEmployees


What needs to be done to ensure large scale use of environmentally

friendly coprocessing technology in Clean India Drive.

• The regulatory framework in India provides generic permit to manage the

waste through land fill and incineration process.

• Although coprocessing technology has superior environmental performance

over incineration or landfill operations, cement plant has to obtain

coprocessing permit per waste stream. That too after demonstrating the

suitability of each one of them in the cement kiln through an elaborate

coprocessing trial.

• This waste by waste permitting process is a very slow permitting process

requiring about one year for each of the waste stream.

• There is need therefore to modify the existing waste management rules in

favor of coprocessing so that cement kilns can have generic permit to

coprocess all kinds of suitable wastes.

• Since coprocessing leaves zero waste for future concern, in the current

“Clean India” drive in the country, cement kilns can contribute substantially

in treating large amounts of hazardous and non-hazardous wastes in safe

and environmentally sound manner.