Significance, Achievements & Benefits of Co-processing

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1 Significance, Achievements & Benefits of Co-processing Gujarat Pollution Control Board Hardik Shah, IAS Member Secretary Gujarat Pollution Control Board 1

2 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

3 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 resources and fossil fuels such as coal, petroleum, gas mainly in energy intensive industries like cement, lime, steel, glass and power generation. Waste materials used for co-processing are referred as AFR i.e. Alternative Fuel and Raw material 3

4 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 PAPERS 4

5 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 5 * SRS Data

6 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

7 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

8 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 8

9 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 : MTPA) 9

10 Pre-processing Facility Provides platform to prepare waste mix liquid/ solid from various wastes generated in industries that can be use for coprocessing. Magnetic Separator Primary Shredder 10

11 Pre-processing Facility Arm Handler Impregnation shredder 11

12 Pre-processing Facility Grab Crane Closed Conveyor 12

within 3 years for Sensitizing the top level management of cement industries GPCB has conducted series of

13 Initiatives by GPCB Arranged One to One Meet with stack holders Organized series of meetings with cement plants and waste generators to enhance co-processing Directions were issued to cement plants augmenting TSR up to 10 % within 3 years for Sensitizing the top level management of cement industries GPCB has conducted series of meetings with local Urban bodies to enhance the rate of co-processing of MSW in various Cement Plants 13 * SRS Data

wastes and other wastes in cement plants Regular monthly Review at MS &

14 Initiatives by GPCB Expediting trial runs/ regular permissions at various levels Constituted a committee for permission for coprocessing of hazardous wastes and other wastes in cement plants Regular monthly Review at MS & Chairman level Three pre processing facilities are setup in industrial clusters 14 * SRS Data

15 Initiatives by GPCB Identification of waste disposal problems of clusters Availability of Waste Characterization report Acceptance criteria as per the guideline of CPCB are made available to hazardous waste generators A web based portal (xgn) has been developed for identifying suitable waste for co-processing to the cement industry On-line tracking system is developed for movement of hazardous and other wastes 15 * SRS Data

16 Acceptance Criteria as per CPCB guideline Specification of HW for use as Alternative Raw Material Parameter Limit Volatile organic Hydrocarbon < 5000 ppm Total organic Carbon (TOC) < 1000 ppm CaO + SiO2 + A Fe203 + SO3 > 80 % (In Ash) Chloride < 1.5 % Sulphur < 1.5 % PCB/PCT (ppm) < 5.0 Heavy Metals (ppm) Hg < 10 Cd+Tl+Hg < 100 As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V < 10, * SRS Data

17 Specification of HW for use of energy recovery Parameter Calorific Value As received basis Ash -Liquid -Solid Chloride Halogens (F+Br+I) Sulphur PCB/PCT (ppm) Heavy Metals (ppm) Hg Cd+Tl+Hg As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V ph Viscosity (cst) for Liquid Flash point (Deg Centigrade) (for Liquid) Limit >2500 k Cal/Kg < 5% < 20% < 1.5 % < 1.0 % < 1.5 % < 50 < 10 < 100 < 25,00 4 to 12 < 100 > * SRS Data

18 Type of waste Co-processed 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 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/cotton waste Paint Sludge & ETP Sludge Pet coke 18

19 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, groundnut husk, saw dust. Landfillable waste: Tyre chips, agro waste, expired off drugs, MSW, embroidery waste, solid waste, municipal waste, 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

20 Wastes can be co-processed. (Industrial Sectors) Textile Industries, Paint manufacturing., Petrochem, Synthetic oil, Rubber Ind., Org. Chemicals, Pharmaceuticals ind., Dyes And DyeIntermediates, Beverages ind., Mining And Ore, Fine Chem, 20 * SRS Data

Total Waste Co-processed (MT) 9000000 79,14,295 Co-procesed Waste (MT) 8000000 7000000 6000000 5000000 38,15,053 4000000 28,23,305 3000000 2000000 1000000 0 15,693

21 Total Waste Co-processed (MT) ,14,295 Co-procesed Waste (MT) ,15, ,23, , , ,71, ,81,220,549,424 3,35, * Total Year wise status is from April to march 21 * SRS Data

Total Plastic Waste Co-processed (MT) 1,71,565 180000 160000 140000 120000 100000 80000 52,747 51,687 60000 31,990 29,716 40000 20000 0 0

22 Total Plastic Waste Co-processed (MT) 1,71, ,747 51, ,990 29, , ' ' ' ' ' ' ' '17* Total Yearwise status is from April to March 22 * SRS Data

23 Total Waste Co-processed (MT) as Alternative Raw Material and As Alternative Fuel From 2009 to April ,15, ,22, ,92, Alternate Raw Material Alternate Fuel Total (MT) 23 * SRS Data

24 Industry wise status 79,14, ,11, ,63,337 7,62,736 7,58,784 6,09,484 4,12,307 2,61,430 2,08,336 25,182 1, to April * SRS Data

25 Hazardous and Other Wastes (M&TM) Rules 2016 As per Rule 6 To 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 other wastes. Rule 9 To obtain authorization and passbook for utilization of hazardous and other wastes as a resource or after pre-processing either for co-processing or for any other use, including within the premises of the generator (if it is not part of process) 25 * SRS Data

26 Provisions for co processing/preprocessing under HWM Rules 2016 SPCBs/PCCS may grant authorisation to cement industry for utilisation of Hazardous wastes as prescribed in Rule 9 No trial run permission is required once regular permission is accorded by CPCB The standards for co processing have been are notified by MoEF& CC dated 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 26 * SRS Data

27 Provision for transportation under 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 27 * SRS Data

28 Provision for co-processing / preprocessing 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 putup on emission norms basis rather than on trial basis 28

29 Procedure to obtain authorisation (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 29 * SRS Data

30 Standards for Air Emission (for Cement Plants) 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 of notification ( ) Anywhere in the country /CEPI /urban centers 30 SO2 Irrespective of date of commissioning Anywhere in the country 100, 700 and 1000 when pyritic sulphur in the limestone is less than 0.25%, 0.25 to 0.5% and more than 0.5% respectively. 100, 700 and 1000 when pyritic sulphur in the limestone is less than 0.25%, 0.25 to 0.5% and more than 0.5% respectively. 30

31 Standards for Air Emission (for Cement Plants) Parameter Nox Standards (i) Rotary kiln with co-processing (ii) Rotary kiln without co-processing Date of commissioning Location Concentration not to exceed, (mg/nm3) After the date of notification ( ) Anywhere in the country (1) 600 (1) 600 Before the date of notification ( ) Anywhere in the country (2) 800 for rotary kiln with In Line calciner technology (ILC) (2) 800 for rotary kiln with In Line calciner technology (ILC) (3) 1000 for rotary kiln using mixed stream of ILC, Separate Line Calciner (SLC) and suspension pre-heater technology or SLC technology alone or without calciner. (3) 1000 for rotary kiln using mixed stream of ILC, Separate Line Calciner (SLC) and suspension pre-heater technology or SLC technology alone or 31 without calciner.

32 Standards for Air Emission (for Cement Plants) Parameter Standards (i) Rotary kiln with co-processing Concentration not to exceed, (mg/nm3) HCL 10 HF 1 TOC 10 Hg and its compounds 0.05 Cd + Ti and their compounds 0.05 Sb + As + Pb + Co + Cu + Mn + Ni + V and their compounds 0.5 Dioxins and Furans 0.1 ngteq/nm3 32

33 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. 33 * SRS Data

34 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. 34 * SRS Data

35 Mile Stones GPCB has taken an Initiative to achieve the target of 50,00,000 MT of waste co-processed at the end of March 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 35

36 Way Forward To encourage the preprocessing facilities in hazardous waste generating industrial clusters & cement plants Supply of adequate Online Tracking system for HAZ-Waste at national level Encouraging segregation facilities of MSW for coprocessing for preparation of RDF Supply of technology to monitor online, all emission parameters Removal or reduction of frequent permissions for different wastes Way Forward 36 * SRS Data

37 Way Forward The issue of interstate movement of hazardous & other waste is now require to intimate both the SPCB before waste procurement. Technological aspects need to be promoted so as to conserve the fuel in place of utilization of waste as resource Waste exchange Banks / Collection Centers to provide information on wastes Sector wise and region wise meetings are on way to use hazardous waste for co processing To identify new sectors and their waste generators to link up with cement industries Way Forward 37 * SRS Data

38 38

STATUS OF CO-PROCESSING OF WASTE IN CEMENT PLANTS AS PER HAZARDOUS AND OTHER WASTES MANAGEMENT RULES, Dr B Sengupta,

STATUS OF CO-PROCESSING OF WASTE IN CEMENT PLANTS AS PER HAZARDOUS AND OTHER WASTES MANAGEMENT RULES, 2016 Dr B Sengupta, Former Member Secretary, Central Pollution Control board bsg161@gmail.com Presented