Co-processing - A preferred option for management of non-recyclable Hazardous and other wastes Ulhas Parlikar Dy. Head, Geocycle India ulhas.parlikar@geocycle.com 2014 Holcim Technology 2014 Ltd
About Geocycle For a zero-waste future Geocycle is the waste management brand of LafargeHolcim. In India, both ACC Limited and Ambuja Cements Limited, extend waste management services using this brand.
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
Waste Management Hierarchy
What is Co-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
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 Emissions in ng I-TEQ/m 3 0.14 0.12 0.10 0.08 0.06 0.04 0.02 regular fuel with secondary fuel (0,29) with secon-dary raw material 0.00 0 20 40 60 80 100 120 140 160 Source VDZ Measurement No.
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
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 receiving, storing and pre-processing of wastes based on the availability of compliant infrastructure to handle them safely. (Rule 6) Co-processing in cement plant is to be implemented based on the compliance to prescribed emission standards. (Rule 9) Interstate movement of wastes for recycling or coprocessing to be implemented by intimation to the respective SPCBs. (Rule 18)
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
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. All these trials have confirmed that wastes do not impact the cement kiln emissions or the product in any adverse manner.
Can wastes be transported over large distances for pre & co-processing? Is it economically viable? Volumes of the Industrial waste transported over large distances 10000 Tonnages T 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 2010 2011 2012 2013 2014 (Source :Database Geocycle India) 250 500 750 1000 1250 1500 KM
Can cement kilns manage wastes having large variation in their characteristics Cement kiln co-processing has been successfully demonstrated for wastes having following characteristics variations 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 VOC (mg/kg) 4.20 207.0 SVOC (mg/kg) BDL 0.2 PCB (mg/kg) 0.00 0.5 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 PCP (mg/kg) BDL 1.4 TOC (%) 0.00 66.0
Amount of Wastes used in cement kilns TSR (%) 72 64 60 60 49 48 47 32 30 29 27 25 22 18 16 14 13 12 10 7 4 Opportunity exists for utilising large quantum of wastes as AFRS in the Indian Cement Industry
Co-processing network of geocycle across India Geocycle has access to 14 facilities across India North North central Geocycle has made more than 60 trial burns in India with various types of Industrial waste streams East The wide spread presence across the country gives the flexibility to provide seamless solutions to our customers West Business cells with one platform each and sometimes delimited South by state Central borders due to limitations in free waste transportation. South * Depending on way forward