Coprocessing solution for environmentally sound management ... · recycling) and fossil fuels such...

© 2014 Holcim Technology Ltd

Co-processing for environmentally sound management of wastes

© 2014

Ulhas Parlikar

Dy. Head, Geocycle India


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 ACCLimited and Ambuja Cements Limited .

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

solutions in the Holcim Group• We apply the highest health, environment

and safety standards in all our operationcomplying to relevant regulation

For a zero-waste future


Problems with existing Waste treatment systems

• Ever increasing backyard volumes and associated

environmental hazards

• We are missing an opportunity to conserve large

quantity of natural resources.

• High level of carbon footprint on account of

increase in the GHG emissions.

3


We should strive for a circular economy

Circular Economy...

• Leads to fewer landfills and reduces

pollution caused by dumping

• Reduces greenhouse-gas emissions,

thereby fighting global warming

• Reduces the environmental impact of extraction (mining/quarrying),

transporting and processing of raw material

• Reduces dependence on primary

resource markets

• Conserves natural (non-renewable) energy and material resources

Technology

Recycling

Technology

Industry

Society

waste Product


Waste Management Hierarchy


What is CoWhat is Co--processing?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’

In short, co-processing is an environmentally friendly alternative business model for responsible management of wastes


Typical Features of Cement Kiln Typical Features of Cement Kiln


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 EmissionsZero 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 ConcreteNo 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


Waste Pre-processed and Co-processing

“Banned wastes" will not be processed

• Radioactive waste

• Asbestos-containing waste

• Explosives and ammunition / weapons

• Anatomical medical waste

“Banned wastes" will not 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


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.


Coprocessing demonstrated as a sustainable solution for waste management in India

• More than 50 demonstration trials implemented with the involvement of SPCBs and CPCB

• Emission monitoring conducted through approved third parties

• More than 50 different types wastes were coprocessed

• Each waste had different physico-chemical characteristics

• These consisted of Solids, Liquids, sludges and Gases

• Their hazard nature varied from simple expired products to

plastics to complex POPs (Ozone Depleting Substances)

• All these trials demonstrated that, when proper controls are

implemented, co processing activity in cement kilns does not influence the cement kiln emissions or the cement product.

• A large scale utilisation of plastic waste and properly prepared

RDF is getting co processed in the country.

13


Key Partners for Sustainable Waste Management

14


MSW components and co-processability

15

Plastics, wood, paper, cloth,

rubber and other combustibles

Composting/RDF/Biomethantion

Kitchen

waste/organics

Glass

Metals

Street Sweepings

Recycling/Trading/Land filling

Major Area of concern

Solution co-processing√


Geocycle pioneer in Co-processing non-recyclable Plastic & other Waste from MSW

• Non recyclable plastic waste from Jabalpur,

Katni and Bhopal MSW at ACC Kymore.

• Non-recyclable plastics of Kulu

and Shimla Municipality at ACC

Gagal and ACL Darlaghat.

• Non-recyclable plastic waste of 7

other municipalities from HP in

ACC Gagal

• Partner with Goa Municipality in

solving their plastic waste

problem at ACC Wadi works.

• Large scale co-processing of

SCF from MSW of Hyderabac

after converting it into RDF


Challenges during waste co-processing

• Increasing volumes

• Varying quality

• Many kinds of packaging

• Risk mitigation of each waste stream

• Varying infrastructure for handling

• Large storage space requirement

• Kiln adaptability constraints

• Traceability of problem materials


Waste Waste Pre Pre --Processing Processing Processed Processed WasteWaste

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.


Co-processing network of geocycle across India

Business cells with one platform each

and sometimes delimited by state

borders due to limitations in free waste

transportation.

* Depending on way forward

North North central North central

West

South

South Central

East

• Geocycle has access to 14 facilities

across India

• Geocycle has made more than 60 trial

burns in India with various types ofIndustrial waste streams

• The wide spread presence across the

country gives the flexibility to provideseamless solutions to our customers


Why wastes need to be managed sustainably?

• Environmental damage is getting out of control.

• Climate change is impacting us all.

• Communities are objecting to implementation of landfills

and incineration facilities for waste management.

• Landfill is building liabilities for the business & society.

• Industries are required to shift to Green practices.

• Importing countries are demanding compliance to

sustainable waste management practices.


What are the benefits of co-processing technology?

• There is no subsequent waste - hence zero waste future.

• It helps mitigate global warming.

• It lessens the use of fossil fuels and raw materials.

• It reduces pollution and negative health impacts.

• It reduces cost of production of cement

• It conserves natural resources

• It generates additional employment and opportunity for sustainable livelihood.


Wastes can cause obnoxious or toxic emissions?Co-processing is not a proven technology in India?

• Wastes do not impact the cement kiln emissions

• Co-processing evaluated for more than 40 years globally.

• Emission testing from >75 trials in India confirmed the same.

• Simple waste streams to complex ODS materials

• Waste materials had large variation in the characteristics.

• Trials were conducted in cement kilns spread across country

• Globally, some cement kilns operate at TSR levels of >90%

• It is an approved technology by Basel convention for disposal of HWs

• Co-processing is recommended for the destruction of POPs by Stockholm convention.


Is co-processing a viable business model in India?

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

• Volumes are increasing year on year

• Waste generators desire to grow sustainably

• The considerations involved in the costing of disposal through co-processing and landfill / incineration options are different.

• National Task Force on co-processing has evaluated the co-processing business model for Hazardous and other wastes as well as for RDF.


Wastes can not be transported over large distances

for pre & co-processing !!!!!

Volumes of the Industrial waste transported over

large distances

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

250 500 750 1000 1250 1500

Tonnages

2010 2011

2012 2013

2014

KM

T

(Source :Database – Geocycle India)


Only wastes having similar characteristics can be

approved for co-processing?

PARAMETER MIN MAX

Moisture (%) 0.60 67.4

Ash (%) 0.96 98.70

VM (%) 0.3 94.9

FC (%) 0.1 45.7

Carbon 0.4 75.6

Hydrogen 0.2 9.1

Nitrogen 0 15.5

Sulphur 0.1 22

Oxygen 0 76.3

GCV (Kcal/Kg) 80 7960

NCV (Kcal/Kg) 114.8 6042

Mineral matter 3.5 34.5

Chloride as Cl (mg/kg) 0 14200

Fluoride as F (mg/kg) 0 20.1

PARAMETER MIN MAX

Cadmium (mg/kg) 0.10 27.6

Chromium (mg/kg) 0.20 36,229.7

Copper (mg/kg) 1.00 8,848.6

Cobalt (mg/kg) 0.10 176.4

Manganese (mg/kg) 0.10 7,800.0

Nickel (mg/kg) 0.10 9,300.0

Lead (mg/kg) 0.10 633.3

Zinc (mg/Kg) 1.00 22,000.0

Arsenic (mg/kg) 0.10 8.1

Mercury (mg/kg) 0.10 3.8

Selenium (mg/kg) 0.00 8.2

Antimony (mg/kg) 0.10 9.4

Vanadium (mg/kg) 1.00 82,400.0

Thallium (mg/kg) 0.10 1.0

Tin (mg/kg) 0.00 145.6 PARAMETER MIN MAX

VOC (mg/kg) 4.20 207.0

SVOC (mg/kg) BDL 0.2

PCB (mg/kg) 0.00 0.5

PARAMETER MIN MAX

PCP (mg/Kg) BDL 1.4

TOC (%) 0.00 66.0


How much waste can be used as AFR?

72

64

60 60

49 48 47

3230 29

2725

22

1816

14 13 1210

7

1

TSR (%) achieved in cement kilns by countries


Permitting Process for Preprocessing and Co-processing of Wastes as per new WM Rules 2016

• Waste generator is required to obtain authorization from SPCBs to manage his waste respecting the Waste Management Hierarchy.

• SPCBs are required to authorize the generator to manage his waste

ensuring respect to the WM Hierarchy.

• The cement plant facility is required to obtain authorization from SPCB

for receiving, storing and pre-processing of wastes based on the availability of suitable infrastructure to handle them safely.

• Co-processing in cement plant is to be permitted based on the

compliance to prescribed emission standards and not based on demonstration trials.

• Interstate movement of wastes for co-processing to be implemented by sending intimation to the respective Pollution Control Boards.

Coprocessing solution for environmentally sound management ... · recycling) and fossil fuels such...

Documents

Transcript of Coprocessing solution for environmentally sound management ... · recycling) and fossil fuels such...