The Preferred option of Co-processing for greening the ... tools and tech- Mr Ulhas...Calciner (ILC or SLC) Kiln Inlet Mid kiln Waste materials should be fed with raw materials or

© 2014 Holcim Technology Ltd

Sharmistha Nandi

Geocycle India

The Preferred option of Co-processing for greening the nations backyard

© 2014 Holcim Technology Ltd 2

About Geocycle

Geocycle is the waste management brand of

LafargeHolcim. In Geocycle, the service ofwaste co-processing in cement manufacturing

process is provided. LafargeHolcim is thepromoter of both Ambuja Cements Limited

(ACL) and ACC Limited.

• Brand was created in 2007 as the dedicatedidentity used to brand waste management

solutions in the LafargeHolcim Group

• We apply the highest health, environment andsafety standards in all our operation

complying to relevant regulation

For a zero-waste future


Problems with earlier mandated options for

management of non-recyclable waste streams

• Disposal based - Incineration and Landfill

� NIMBY concerns

� Large waste foot print and liability is left behind� Ever increasing backyard volumes and

associated environmental hazards� Resource value present in the waste does not

get utilised Hence, opportunity to conserve

large quantity of natural resources is lost.

� High level of carbon footprint on account of increase in the GHG emissions.

3


• New Waste Management Rules (2016) are based on the principle of

sustainability rather than disposal

• New HOWM Rules, PWM Rules, SWM Rules notified in 2016 with co-

processing as the preferred option

• Guidelines on pre-processing and co-processing published by CPCB on

July 7, 2017

• Emission norms for undertaking co-processing in cement kilns notified in

May 2016

• CPCB released the monitoring protocol for ascertaining compliance to the notified emission standards

New Waste Management Rules notified in 2016


HOWM Rules 2016 & Solid Waste Management Rules

2016 –Our Permitting Process is globally aligned now• Waste generator is required to manage his waste

respecting the Waste Management Hierarchy and

SPCBs are required to authorize the same. (Rule 4)

• A facility is required to obtain authorization from SPCB for

transportation, receiving, storing and pre-processing of wastes based on the availability of compliant infrastructure to handle them safely. (Rule 6)

• Co-processing of Hazardous or Non-hazardous wastes in cement plant is to be implemented while complying to prescribed emission standards. Trials

are not required anymore. (Rule 9)

• Interstate movement of wastes for recycling or co-processing to be implemented by intimation to the respective SPCBs. (Rule 18)


HOWM Rules 2016 & Solid Waste Management Rules

2016 – Our Permitting Process is globally aligned now

• Authorization for transportation to be obtained from SPCB by waste generator or receiver. Responsibility of safe transportation lies with them

• Transport agency to have registration under the Motor Vehicle Act and vehicle to meet the specifications mentioned in the HOWM Rules / guidelines

• For Co-processing authorization, cement plant to have valid CTE / CTO

• Pre-processing centers to be developed convert SCF into RDF and wastes into AFRs rather than building incineration and landfill sites.


Co-processing – The Preferred option

• SPCBs can directly grant authorisation to cement plants

for co-processing of wastes listed in Schedule I, II & III of HOWM Rules 2016 without mandating any demonstration co-processing trial

• Waste generators currently implementing landfill or

incineration options for disposing their co-process able

wastes need to include the option of co-processing

• Waste generators intending to send their hazardous

wastes for recycling/pre-processing/co-processing to a facility located in another state need to send an

intimation letter to the PCBs. Thereafter the receiving

states and shall utiilise seven page manifest system

• Cement plants undertaking co-processing of every new waste sream shall be sending letter of intimation to the

SPCBs in Annexure 5 of the CPCB guidelines

mentioning the name of waste and the waste generator.


• Promotes Circular Economy

• Reduces � required number of landfills

� pollution caused by dumping

� greenhouse-gas emissions � environmental impact of extraction through

mining� dependence on primary resource markets� cost of production of Cement

• Mitigates Climate Change Impacts

• Conserves Energy and Material resources

• Involves highly organised industrial sector

Why is co-processing in cement kilns the preferred

choice for waste management?


Co-processing is higher in the waste management

hierarchy over WTE, incineration & Landfill options

9


What is CoWhat is Co--processing?processing?

Co-processing...

• Completely destroys waste materials through high

temperatures and long residence time.

• Avoids formation of dioxins and furans

• Leaves no residue to be landfilled, as ash reacts

with other components to produce cement

• Reduces overall greenhouse gas emission byreducing dependency on fossil fuels as calorific

value of the waste is recovered

• Reduces dependency on primary resources asmineral value of the waste is recovered

Therefore, it relieves the waste generator of any future liability which may accrue due to

waste disposal by processes like land filling and incineration


What happens to the waste in the Cement Kiln ?

• Organic constituents are completely destroyed into

CO2 and water.

• Chlorine, Fluorine or sulfur acids are neutralized by

the alkaline materials within the kiln.

• The inorganic constituents including heavy metals

react with the raw materials and become part of

the clinker matrix.


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

-TE

Q/m

3

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 assessmentWe can provide acomplete survey of yourwaste and a fullassessment of itssuitability for co-processing.

2

Waste analysisWe offer dedicatedlaboratory testing toanalyze your waste toensure it is suitable. Weat Geocycle are able tomanage waste such assolids, sludge and liquids

3

Waste transportationWe provide a seamlessservice – ensuring thewaste is transported inappropriate packaging withrequired labelling anddocumentation. The wasteis carried by operators withrequired skills,qualifications and permits.

4

Pre-processingFurther analysis of wasteis conducted in ourlaboratories if required.We have extensivefacilities to blend liquids,shred solid materials andhomogenise waste prior toits usage in kilns.

5

Co-processingWaste is then safely co-processed in cementkilns. Our cement kilnsoperate at temperaturesof up to 2000°C – whichleaves no residue orwaste after co-processing is complete.


Waste Waste Pre Pre --Processing Processing Processed Processed WasteWaste

Pre-Processing required for larger scale co-processing


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 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


1. Power generation through Waste to Energy (WTE)

<30% energy recovery;

0% Material Recovery

Resource Recovery Efficiency WTE vs Co-processing

2. Co-processing in cement kilns by converting SCF to RDF>80% energy recovery 100% material recovery


Is co-processing a proven technology for Waste

management? Is it proven in India?

• Co-processing evaluated globally for more than 40 years

• There are cement kilns operating at TSR levels of >90%

• It is an approved technology by Basel convention for disposal of all kinds of Hazardous and Other Wastes

• It is recommended for the destruction of POPs and ODS under Stockholm convention

• There have been >90 co-processing trials in India� Simple waste streams to complex ODS materials� Waste materials had large variation in the characteristics.� Trials were conducted in cement kilns spread across country

• All these trials have confirmed that wastes do not impact the cement kiln emissions or the product in any adverse manner.


Is co-processing a viable business model in India?

• Co-processing business model is operating for the past 10 years in India

• Volumes co-processed are increasing year on year

• Almost all the cement plants are implementing co-processing in their kilns

• National Task Force on co-processing constituted by CPCB has evaluated and concurred with the co-processing business model for

Waste management.


� Main Burner

� Calciner (ILC or SLC)

� Kiln Inlet� Mid kiln

Waste materials should be fed with raw materials or with coal only when the environmentally sound management is ensured through appropriate

evaluation through trial in consultation with CPCB

What are the appropriate feed points for co-

processing in the kiln?


� Appropriate Laboratory for waste qualification

� Adequate waste storage facility

� Environmentally sound facilities for waste Handling, pre-processing and feeding into kilns.

� Proper facilities to control fires and spillages.

� Skilled and trained manpower that understands wastes� Adequate systems for EHS and Medical Surveillance� Emergency Response Plan.

� Online emission monitoring to ascertain environmental compliance to prescribed emission standards.

What infrastructure ascertains proper Pre & Co-

processing of wastes?


All non-recyclable non-hazardous wastes, All non-recyclable H&OWs belonging

to Schedule I, II & III wastes & All non-cattle feed agro-wastes can be pre & co-processed depending upon the availability of the suitable infrastructure to handle & manage them.

Co-processing trial is not required for authorization

“Banned wastes" not to be pre-processed or co-processed

• Radioactive waste

• Asbestos-containing waste

• Explosives and ammunition / weapons

• Anatomical medical waste

“Banned wastes“ not to be co-processed

• Electronic fraction of electrical and electronic waste (e-waste)

• Whole batteries as a targeted material stream

• Waste of unknown or unpredictable composition, including unsorted municipal waste

These wastes however can be co-processed after pre-processing to remove the banned portion of the waste

Which wastes can be Pre & Co-processed?

Documents

The Preferred option of Co-processing for greening the ... tools and tech- Mr Ulhas...Calciner (ILC or SLC) Kiln Inlet Mid kiln Waste materials should be fed with raw materials or