Significance, Achievements & Benefits of Co-processing

Significance, Achievements &Benefits of Co-processing

Gujarat Pollution Control BoardHardik Shah, IASMember Secretary

Gujarat Pollution Control Board1

Content

Concept and history of co-processing

Role of GPCB

Benefits of co-processing

Pre-processing facility

Initiatives by GPCB

Current scenario

Barriers

Mile Stones

Way forward

2

Concept and history of co-processing

Role of GPCB

Benefits of co-processing

Pre-processing facility

Initiatives by GPCB

Current scenario

Barriers

Mile Stones

Way forward

• Definition: Co-processing is the use of waste as raw material, or asa source of energy or both to replace natural mineral resourcesand fossil fuels such as coal, petroleum, gas mainly in energyintensive industries like cement, lime, steel, glass and powergeneration.

• Waste materials used for co-processing are referred as AFR i.e.Alternative Fuel and Raw material

Co-processing• Definition: Co-processing is the use of waste as raw material, or as

a source of energy or both to replace natural mineral resourcesand fossil fuels such as coal, petroleum, gas mainly in energyintensive industries like cement, lime, steel, glass and powergeneration.

• Waste materials used for co-processing are referred as AFR i.e.Alternative Fuel and Raw material

3

Cement kiln co-processing technology is accepted by Basel

convention for disposal of hazardous wastes

The cement kiln co-processing technology is accepted by Montreal

protocol for disposal of POPs. Cement kiln co-processing of POPs,

hazardous and non hazardous wastes is practiced widely and

successfully in many countries around the world

A regulatory forum (RF) consisting of Member Secretary of AP, RJ,

OR, TN, Karnataka along with representative of MoEF, CPCB, CMA

and IIP have been constituted under the Chairmanship of MS, GPCB

and published 5 nos. of WHITE PAPERS

History Cement kiln co-processing technology is accepted by Basel

convention for disposal of hazardous wastes

The cement kiln co-processing technology is accepted by Montreal

protocol for disposal of POPs. Cement kiln co-processing of POPs,

hazardous and non hazardous wastes is practiced widely and

successfully in many countries around the world

A regulatory forum (RF) consisting of Member Secretary of AP, RJ,

OR, TN, Karnataka along with representative of MoEF, CPCB, CMA

and IIP have been constituted under the Chairmanship of MS, GPCB

and published 5 nos. of WHITE PAPERS4

Benefits of co-processing :

Reduces demand on natural resources

Contributes towards lowering of emissions such as greenhouse

gases

Reduce requirement of land required for land fills

Maximizes the recovery of resources present in the waste

Reduces the economical burden on the industry

Reduces demand on natural resources

Contributes towards lowering of emissions such as greenhouse

gases

Reduce requirement of land required for land fills

Maximizes the recovery of resources present in the waste

Reduces the economical burden on the industry

* SRS Data5

Reduces the Health hazard associated with disposal of Hazardous

waste by other pathways i.e. land disposal & incineration of the

hazardous waste

In order to set an integrated waste management strategy and an

appropriate technical infrastructure for disposing of waste in a

controlled and environmentally sound manner

Benefits of co-processing :

Reduces the Health hazard associated with disposal of Hazardous

waste by other pathways i.e. land disposal & incineration of the

hazardous waste

In order to set an integrated waste management strategy and an

appropriate technical infrastructure for disposing of waste in a

controlled and environmentally sound manner

6

GPCB adopted a proactive approach

Facilitator instead of a Regulator

“Team work and collaboration with stack holders” instead of

“Command and Control”

To set an integrated waste management strategy and an

appropriate technical infrastructure for utilization of waste in a

cement kiln

GPCB’s Approach

GPCB adopted a proactive approach

Facilitator instead of a Regulator

“Team work and collaboration with stack holders” instead of

“Command and Control”

To set an integrated waste management strategy and an

appropriate technical infrastructure for utilization of waste in a

cement kiln

7

Partners of Co-Processing

(A) Cement Mills :

1.Ambuja Cement Ltd – Gir Somnath

2.Ultratech Cement Ltd – Kovaya Works

3.Ultratech Cement Ltd – Jafrabad Works

4.Ultratech Cement Ltd – Sevagram, Kutch

5.Gujarat Sidhee Cement Ltd – Junagadh

6.Sanghi Industries Ltd – Kutch

7.Shree Digvijay Cement Co. Ltd – Jamnagar

8.Saurashtra Cement Ltd – Porbandar

9. Hi- Bond Cement Ltd. – Rajkot

(A) Cement Mills :

1.Ambuja Cement Ltd – Gir Somnath

2.Ultratech Cement Ltd – Kovaya Works

3.Ultratech Cement Ltd – Jafrabad Works

4.Ultratech Cement Ltd – Sevagram, Kutch

5.Gujarat Sidhee Cement Ltd – Junagadh

6.Sanghi Industries Ltd – Kutch

7.Shree Digvijay Cement Co. Ltd – Jamnagar

8.Saurashtra Cement Ltd – Porbandar

9. Hi- Bond Cement Ltd. – Rajkot

8

Partners of Co-Processing

(B) Major Waste Generators :1.Pulp & Paper Industry ,2.Dyes & Dyes Intermediates,3.Pharmaceutical Industry,4.Pesticides,5.Ceramic units having coal gassifiers,6.Automobile,7.Petrochemical refinery

(C) Preprocessing Facility :1. Ambuja Cement Ltd – Gir Somnath

(Capacity : 1,50,000 MTPA).2. Recycling Solutions Pvt. Ltd.(RSPL), Panoli

(Capacity :29200 MTPA).3. Bharuch Enviro Infrastructure Ltd (BEIL)., Ankleshwar

(Capacity : 16000 MTPA)

(B) Major Waste Generators :1.Pulp & Paper Industry ,2.Dyes & Dyes Intermediates,3.Pharmaceutical Industry,4.Pesticides,5.Ceramic units having coal gassifiers,6.Automobile,7.Petrochemical refinery

(C) Preprocessing Facility :1. Ambuja Cement Ltd – Gir Somnath

(Capacity : 1,50,000 MTPA).2. Recycling Solutions Pvt. Ltd.(RSPL), Panoli

(Capacity :29200 MTPA).3. Bharuch Enviro Infrastructure Ltd (BEIL)., Ankleshwar

(Capacity : 16000 MTPA)9

Pre-processing Facility

Provides platform to preparewaste mix liquid/ solid fromvarious wastes generated inindustries that can be use for co-processing.

Magnetic Separator

Primary Shredder

10

Magnetic Separator


Arm Handler Impregnation shredder

11


Grab Crane Closed Conveyor

12

Initiatives by GPCB

Organized series of meetings with cement plants andwaste generators to enhance co-processingOrganized series of meetings with cement plants andwaste generators to enhance co-processing

Directions were issued to cement plants foraugmenting TSR up to 10 % within 3 yearsDirections were issued to cement plants foraugmenting TSR up to 10 % within 3 years

Arranged One to One Meet with stack holdersArranged One to One Meet with stack holders

* SRS Data

Directions were issued to cement plants foraugmenting TSR up to 10 % within 3 yearsDirections were issued to cement plants foraugmenting TSR up to 10 % within 3 years

GPCB has conducted series of meetings with localUrban bodies to enhance the rate of co-processing ofMSW in various Cement Plants

GPCB has conducted series of meetings with localUrban bodies to enhance the rate of co-processing ofMSW in various Cement Plants

Sensitizing the top level management of cementindustriesSensitizing the top level management of cementindustries

13

Initiatives by GPCB

Constituted a committee for permission for co-processing of hazardous wastes and other wastes incement plants


Expediting trial runs/ regular permissions at variouslevelsExpediting trial runs/ regular permissions at variouslevels

* SRS Data



Regular monthly Review at MS & Chairman levelRegular monthly Review at MS & Chairman level

Three pre processing facilities are setup in industrialclustersThree pre processing facilities are setup in industrialclusters

14

Initiatives by GPCB

Availability of Waste Characterization reportAvailability of Waste Characterization report

Acceptance criteria as per the guideline of CPCB aremade available to hazardous waste generatorsAcceptance criteria as per the guideline of CPCB aremade available to hazardous waste generators

Identification of waste disposal problems of clustersIdentification of waste disposal problems of clusters

* SRS Data

Acceptance criteria as per the guideline of CPCB aremade available to hazardous waste generatorsAcceptance criteria as per the guideline of CPCB aremade available to hazardous waste generators

On-line tracking system is developed for movement ofhazardous and other wastesOn-line tracking system is developed for movement ofhazardous and other wastes

A web based portal (xgn) has been developed foridentifying suitable waste for co-processing to thecement industry

A web based portal (xgn) has been developed foridentifying suitable waste for co-processing to thecement industry

15

Acceptance Criteria as per CPCB guidelineSpecification of HW for use as Alternative Raw

Material

Parameter Limit

Volatile organic Hydrocarbon < 5000 ppm

Total organic Carbon (TOC) < 1000 ppm

CaO + SiO2 + A1203 + Fe203 + SO3

(In Ash)

> 80 %

* SRS Data

CaO + SiO2 + A1203 + Fe203 + SO3

(In Ash)

Chloride < 1.5 %

Sulphur < 1.5 %

PCB/PCT (ppm) < 5.0

Heavy Metals (ppm) Hg

Cd+Tl+Hg

As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V

< 10

< 100

< 10,00016

Specification of HW for use ofenergy recovery

Parameter LimitCalorific Value As received basis >2500 k Cal/Kg

Ash-Liquid-Solid

< 5%< 20%

Chloride < 1.5 %Halogens (F+Br+I) < 1.0 %

* SRS Data

Halogens (F+Br+I) < 1.0 %Sulphur < 1.5 %

PCB/PCT (ppm) < 50

Heavy Metals (ppm) HgCd+Tl+Hg

As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V

< 10< 100

< 25,00pH 4 to 12

Viscosity (cSt) for Liquid < 100Flash point (Deg Centigrade) (for Liquid) > 60

17

FUEL INCINARABLE Fuel Landfillable RAW MATERIAL

Plastic Waste Tyre Chips Chemical Gypsum

Spent carbon Agri Waste Iron Sludge

White Coal Expired off spec drugs Copper Slag

Organic Sludge(Solid) MSW Phopho Gypsum

Distillery Residue(Liquid) Embroidery Waste Fly Ash

Type of waste Co-processed

Distillery Residue(Liquid) Embroidery Waste Fly Ash

TDI Tar Solid Waste/ FMCG Mould Gypsum

Mixed Waste Liquid Rub Waste Pond Ash/ foundry sand

Mixed Waste Solid Wooden Dust

Resin Waste Sugarcane Bagas

Process Residue pharma ind Glycerin Foot

Agro Chemical RDF

Pharma Waste Wooden Chips

Waste Oil & Oily Rags/cottonwaste

Pet coke

Paint Sludge & ETP Sludge18

Type of waste Co-processed

• Incinerable waste: Plastic, spent carbon, white coal,organic sludge(solid), distillery residue(liquid), TDI tar,mixed waste liquid, resin, process residue, agro chemicals,pharma, waste oil, paint sludge, ETP sludge, groundnuthusk, saw dust.

• Landfillable waste: Tyre chips, agro waste, expired offdrugs, MSW, embroidery waste, solid waste, municipalwaste, wooden dust, sugarcan bagas, glycerin foot, RDF,wooden chips, pet coke.

• Waste used as raw material: Chemical gypsum, Iron sludge,Coper sludge, Phospo gypsum, Fly ash, Mould gypsum,Pond ash.

19

• Incinerable waste: Plastic, spent carbon, white coal,organic sludge(solid), distillery residue(liquid), TDI tar,mixed waste liquid, resin, process residue, agro chemicals,pharma, waste oil, paint sludge, ETP sludge, groundnuthusk, saw dust.

• Landfillable waste: Tyre chips, agro waste, expired offdrugs, MSW, embroidery waste, solid waste, municipalwaste, wooden dust, sugarcan bagas, glycerin foot, RDF,wooden chips, pet coke.

• Waste used as raw material: Chemical gypsum, Iron sludge,Coper sludge, Phospo gypsum, Fly ash, Mould gypsum,Pond ash.

Wastes can be co-processed.(Industrial Sectors)

• Pharmaceuticals ind.,• Dyes And Dye-

Intermediates,• Beverages ind.,• Mining And Ore,• Fine Chem,

• Textile Industries,• Paint manufacturing.,• Petrochem,• Synthetic oil,• Rubber Ind.,• Org. Chemicals,

• Pharmaceuticals ind.,• Dyes And Dye-

Intermediates,• Beverages ind.,• Mining And Ore,• Fine Chem,

* SRS Data

• Textile Industries,• Paint manufacturing.,• Petrochem,• Synthetic oil,• Rubber Ind.,• Org. Chemicals,

20

Total Waste Co-processed (MT)

79,14,295

5000000

6000000

7000000

8000000

9000000

Co-procesed Waste (MT)

* SRS Data

15,693 22,3451,71,605

1,81,220,549,424

28,23,305

38,15,053

3,35,650

0

1000000

2000000

3000000

4000000

5000000

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17* Total

Year wise status is from April to march

21

Total Plastic WasteCo-processed (MT)

120000

140000

160000

180000

1,71,565

* SRS Data

0

20000

40000

60000

80000

100000

120000

2009-'10 2010-'11 2011-'12 2012-'13 2013-'14 2014-'15 2015-'16 2016-'17* Total

0 0515

29,716

51,687

31,990

52,747

4,910

Yearwise status is from April to March

22

Total Waste Co-processed (MT)as Alternative Raw Material and

As Alternative Fuel

6000000

7000000

8000000

61,22,598

79,15,556From 2009 to April. 2016

* SRS Data

0

1000000

2000000

3000000

4000000

5000000

6000000

Alternate RawMaterial

Alternate Fuel Total (MT)

17,92,958

23

Industry wise status

4000000

5000000

6000000

7000000

8000000

27,11,235

79,14,293

* SRS Data

0

1000000

2000000

3000000 21,63,337

2,61,430 4,12,3077,62,736 7,58,784

2,08,336 25,1826,09,484

1,463

2009 to April 2016

24

Hazardous and Other Wastes(M&TM) Rules 2016

• As per Rule 6To obtain authorization for handling, generation, collection,storage, packaging, Transportation, use, treatment, processing,recycling, recovery, pre-processing, co-processing, Utilization,offering for sale, transfer or disposal of the hazardous and otherwastes.

• Rule 9To obtain authorization and passbook for utilization of hazardousand other wastes as a resource or after pre-processing either forco-processing or for any other use, including within the premises ofthe generator (if it is not part of process)

• As per Rule 6To obtain authorization for handling, generation, collection,storage, packaging, Transportation, use, treatment, processing,recycling, recovery, pre-processing, co-processing, Utilization,offering for sale, transfer or disposal of the hazardous and otherwastes.

• Rule 9To obtain authorization and passbook for utilization of hazardousand other wastes as a resource or after pre-processing either forco-processing or for any other use, including within the premises ofthe generator (if it is not part of process)

* SRS Data25

Provisions for co processing/pre-processing under HWM Rules 2016

• SPCBs/PCCS may grant authorisation to cement industry for utilisation ofHazardous wastes as prescribed in Rule 9

• No trial run permission is required once regular permission is accorded byCPCB

• The standards for co processing have been are notified by MoEF& CCdated 9/5/2016 and 10/5/2016.

• Passbook shall be issued by SPCB along with authorisation• Records of waste co processed/pre-processed shall be maintained by the

cement industry– Cement industry/pre processing facility shall provide– adequate lab facility,– waste handling and storage facilities,– Contineous Emission Monitoring– Fire and spillage control system

• SPCBs/PCCS may grant authorisation to cement industry for utilisation ofHazardous wastes as prescribed in Rule 9

• No trial run permission is required once regular permission is accorded byCPCB

• The standards for co processing have been are notified by MoEF& CCdated 9/5/2016 and 10/5/2016.

• Passbook shall be issued by SPCB along with authorisation• Records of waste co processed/pre-processed shall be maintained by the

cement industry– Cement industry/pre processing facility shall provide– adequate lab facility,– waste handling and storage facilities,– Contineous Emission Monitoring– Fire and spillage control system

* SRS Data26

Provision for transportationunder HWM Rules 2016

Final disposal of hazardous and other waste in to TSDF and CHWIF,

Interstate NOC from both the state is required.

For recycling or utilization including co-processing, of hazardous

waste, the sender shall intimate both the SPCB

The responsibility of safe transport shall be either of the sender or

the receiver whosoever arranges the transport

Final disposal of hazardous and other waste in to TSDF and CHWIF,

Interstate NOC from both the state is required.

For recycling or utilization including co-processing, of hazardous

waste, the sender shall intimate both the SPCB

The responsibility of safe transport shall be either of the sender or

the receiver whosoever arranges the transport

* SRS Data27

Co-processing is added as preferential mechanism over disposal in

Hazardous Waste Rules 2016

The approval process for co-processing of hazardous waste is put-

up on emission norms basis rather than on trial basis

Provision for co-processing / pre-processing in HWM Rules 2016

Co-processing is added as preferential mechanism over disposal in

Hazardous Waste Rules 2016

The approval process for co-processing of hazardous waste is put-

up on emission norms basis rather than on trial basis

28

Procedure to obtainauthorisation (Rule 6)

Obtain an authorization / renewal of authorisation from the State

Pollution Control Board Form 1 along with relevant document

SPCB shall grant authorisation in Form 2 after ensuring technical

capabilities and equipment complying with the Standard

Operating Procedures or other guidelines specified by CPCB

through site inspection.

Receive HW only after making entry into the passbook.

Authorization shall be valid for 5 years

Includes Authorization for recycling of Other wastes listed in

Schedule - III* SRS Data

Obtain an authorization / renewal of authorisation from the State

Pollution Control Board Form 1 along with relevant document

SPCB shall grant authorisation in Form 2 after ensuring technical

capabilities and equipment complying with the Standard

Operating Procedures or other guidelines specified by CPCB

through site inspection.

Receive HW only after making entry into the passbook.

Authorization shall be valid for 5 years

Includes Authorization for recycling of Other wastes listed in

Schedule - III 29

Parameter Standards

(i) Rotary kiln –with co-Processing (ii) Rotary kiln –without co-processing

Date of commissioning Location Concentration not to exceed, (mg/Nm3)

PM Before/On or after the date ofnotification (25.08.2014)

Anywhere in thecountry/CEPI/urban centers

30

Standards for Air Emission(for Cement Plants)

PM Before/On or after the date ofnotification (25.08.2014)

Anywhere in thecountry/CEPI/urban centers

30

SO2 Irrespective of date ofcommissioning

Anywhere in thecountry

100, 700 and 1000when pyritic sulphurin the limestone isless than 0.25%, 0.25to 0.5% and morethan 0.5%respectively.

100, 700 and 1000when pyriticsulphur in thelimestone is lessthan 0.25%, 0.25 to0.5% and morethan 0.5%respectively.

30

Parameter Standards

(i) Rotary kiln –with co-Processing (ii) Rotary kiln –without co-processing

Date ofcommissioning

Location Concentration not to exceed, (mg/Nm3)

Nox After the date ofnotification(25.08.2014)

Anywhere inthe country

(1) 600 (1) 600


After the date ofnotification(25.08.2014)


Before the date ofnotification(25.08.2014)


(2) 800 for rotary kilnwith In Line calcinertechnology (ILC)

(3) 1000 for rotary kilnusing mixed stream ofILC, Separate LineCalciner (SLC) andsuspension pre-heatertechnology or SLCtechnology alone orwithout calciner.

(2) 800 for rotary kilnwith In Line calcinertechnology (ILC)

(3) 1000 for rotary kilnusing mixed stream ofILC, Separate LineCalciner (SLC) andsuspension pre-heatertechnology or SLCtechnology alone orwithout calciner. 31

Parameter Standards

(i) Rotary kiln –with co-Processing

Concentration not to exceed, (mg/Nm3)

HCL 10

HF 1


HF 1

TOC 10

Hg and its compounds 0.05

Cd + Ti and their compounds 0.05

Sb + As + Pb + Co + Cu + Mn + Ni + Vand their compounds

0.5

Dioxins and Furans 0.1 ngTEQ/Nm3

32

Barriers

Unorganized handling of the Hazardous & Other Wastes.

Limited area of storage for H&OW in Small and Medium

Enterprises.

Higher rate of H&OW generation.

Non suitability of waste for disposal to TSDF

Source Segregation of Municipal Solid Waste

Utilization of RDF as an AFR in Cement Kilns is not economically

viable for cement industries.

Transportation fees for transporting RDF are very high.

* SRS Data

Unorganized handling of the Hazardous & Other Wastes.

Limited area of storage for H&OW in Small and Medium

Enterprises.

Higher rate of H&OW generation.

Non suitability of waste for disposal to TSDF

Source Segregation of Municipal Solid Waste

Utilization of RDF as an AFR in Cement Kilns is not economically

viable for cement industries.

Transportation fees for transporting RDF are very high.33

Barriers

Variation in wastes characteristics leads to frequent change in

operational parameters &blend ratio

Limitation on chloride & fluoride contents in wastes needs to be

addressed. Waste can be co- processed after giving adequate

treatment from Chlorine removal.

Installation of adequate feeding system for different wastes.

Health aspect of workers.

Lack of adequate facility for pre-processing in major industrial

cluster.

* SRS Data

Variation in wastes characteristics leads to frequent change in

operational parameters &blend ratio

Limitation on chloride & fluoride contents in wastes needs to be

addressed. Waste can be co- processed after giving adequate

treatment from Chlorine removal.

Installation of adequate feeding system for different wastes.

Health aspect of workers.

Lack of adequate facility for pre-processing in major industrial

cluster.34

GPCB has taken an Initiative to achieve the target of 50,00,000

MT of waste co-processed at the end of March 2017.

Under the “Gatisheel Gujarat”- a program launched by Hon’ble

CM Smt. Anandiben Patel, the forests and environment

department has targeted 28 lack MT of waste co –processing

under concept of “waste to wealth ‘’

Mile Stones

35

GPCB has taken an Initiative to achieve the target of 50,00,000

MT of waste co-processed at the end of March 2017.

Under the “Gatisheel Gujarat”- a program launched by Hon’ble

CM Smt. Anandiben Patel, the forests and environment

department has targeted 28 lack MT of waste co –processing

under concept of “waste to wealth ‘’

Way Forward

Encouragingsegregationfacilities ofMSW for co-processingforpreparationof RDF

Toencouragethe pre-processingfacilities inhazardouswastegeneratingindustrialclusters &cementplants

Supply ofadequateOnlineTrackingsystem forHAZ-Wasteat nationallevel

Removal orreduction offrequentpermissionsfor differentwastes

Supply oftechnologyto monitoronline, allemissionparameters

* SRS Data

Encouragingsegregationfacilities ofMSW for co-processingforpreparationof RDF

Toencouragethe pre-processingfacilities inhazardouswastegeneratingindustrialclusters &cementplants

Supply ofadequateOnlineTrackingsystem forHAZ-Wasteat nationallevel

Removal orreduction offrequentpermissionsfor differentwastes

Supply oftechnologyto monitoronline, allemissionparameters

Way Forward36

Way ForwardTo identifynew sectorsand theirwastegeneratorsto link upwith cementindustries

Sector wiseand regionwisemeetings areon way tousehazardouswaste for coprocessing

WasteexchangeBanks /CollectionCenters toprovideinformationon wastes

Technologicalaspects needto bepromoted soas toconserve thefuel in placeof utilizationof waste asresource

The issue ofinterstatemovementof hazardous& otherwaste is nowrequire tointimateboth theSPCB beforewasteprocurement.

* SRS Data

To identifynew sectorsand theirwastegeneratorsto link upwith cementindustries

Sector wiseand regionwisemeetings areon way tousehazardouswaste for coprocessing

WasteexchangeBanks /CollectionCenters toprovideinformationon wastes

Technologicalaspects needto bepromoted soas toconserve thefuel in placeof utilizationof waste asresource

The issue ofinterstatemovementof hazardous& otherwaste is nowrequire tointimateboth theSPCB beforewasteprocurement. Way Forward

37

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Documents

Significance, Achievements & Benefits of Co-processing