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

Transcription

1 The Preferred option of Co-processing for greening the nations backyard Sharmistha Nandi Geocycle India

2 About Geocycle For a zero-waste future Geocycle is the waste management brand of LafargeHolcim. In Geocycle, the service of waste co-processing in cement manufacturing process is provided. LafargeHolcim is the promoter of both Ambuja Cements Limited (ACL) and ACC Limited. Brand was created in 2007 as the dedicated identity used to brand waste management solutions in the LafargeHolcim Group We apply the highest health, environment and safety standards in all our operation complying to relevant regulation 2

3 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

4 New Waste Management Rules notified in 2016 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 coprocessing 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 4

5 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 coprocessing to be implemented by intimation to the respective SPCBs. (Rule 18)

6 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.

7 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.

8 Why is co-processing in cement kilns the preferred choice for waste management? 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

9 Co-processing is higher in the waste management hierarchy over WTE, incineration & Landfill options 9

10 What is Co-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 by reducing dependency on fossil fuels as calorific value of the waste is recovered Reduces dependency on primary resources as mineral 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

11 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.

12 Zero Impact On PCDD/PCDF Emissions Emissions in ng I-TEQ/m regular fuel with secondary fuel (0,29) with secon-dary raw material 0.00 Source VDZ Measurement No.

13 No Leaching of Pollutants from Concrete Trough tests on mortars Lime-dissolving carbonic acid Doped mixing water Concentrations in the eluate are significantly below the limit values

14 The Geocycle Approach Waste assessment We can provide a complete survey of your waste and a full assessment of its suitability for coprocessing. 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 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. 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. Co-processing Waste is then safely coprocessed in cement kilns. Our cement kilns operate at temperatures of up to 2000 C which leaves no residue or waste after coprocessing is complete. 14

15 Pre-Processing required for larger scale co-processing Waste Pre -Processing Processed Waste

16 Incineration v/s Co-processing 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 Characteristics Incineration Co-processing Temperature 850 o C 1200 o C 1400 o C 2000 o C Residence Time > 2 >1200 o C 4-6 >1800 o C Turbulence Induced in SCC Induced in kiln Gas cleaning Alkaline scrubbing Alkaline Environment in kiln Residues Ash / fly ash In clinker product

17 Reduction of Green House Gases Co-processing and Incineration Reduction in GHG Emissions Co-processing and Landfill Prevention of Methane* Emissions * Methane has 21 times more global warming potential than CO2 The same argument is valid for all other emissions too

18 Resource Recovery Efficiency WTE vs Co-processing 1. Power generation through Waste to Energy (WTE) <30% energy recovery; 0% Material Recovery 2. Co-processing in cement kilns by converting SCF to RDF >80% energy recovery 100% material recovery 18

19 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.

20 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.

21 What are the appropriate feed points for coprocessing in the kiln? 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 21

22 What infrastructure ascertains proper Pre & Coprocessing of wastes? 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. 22

23 Which wastes can be Pre & Co-processed? 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 & coprocessed 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 23

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