Post on 12-Mar-2020
transcript
Significance, Achievements &Benefits of Co-processing
Gujarat Pollution Control BoardHardik Shah, IASMember Secretary
Gujarat Pollution Control Board1
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
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
• Definition: Co-processing is the use of waste as raw material, or asa source of energy or both to replace natural mineral resourcesand fossil fuels such as coal, petroleum, gas mainly in energyintensive industries like cement, lime, steel, glass and powergeneration.
• Waste materials used for co-processing are referred as AFR i.e.Alternative Fuel and Raw material
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 resourcesand fossil fuels such as coal, petroleum, gas mainly in energyintensive industries like cement, lime, steel, glass and powergeneration.
• Waste materials used for co-processing are referred as AFR i.e.Alternative Fuel and Raw material
3
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
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 PAPERS4
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
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
* SRS Data5
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
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
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
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
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
(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
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 : 16000 MTPA)
(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 : 16000 MTPA)9
Pre-processing Facility
Provides platform to preparewaste mix liquid/ solid fromvarious wastes generated inindustries that can be use for co-processing.
Magnetic Separator
Primary Shredder
10
Magnetic Separator
Pre-processing Facility
Arm Handler Impregnation shredder
11
Pre-processing Facility
Grab Crane Closed Conveyor
12
Initiatives by GPCB
Organized series of meetings with cement plants andwaste generators to enhance co-processingOrganized series of meetings with cement plants andwaste generators to enhance co-processing
Directions were issued to cement plants foraugmenting TSR up to 10 % within 3 yearsDirections were issued to cement plants foraugmenting TSR up to 10 % within 3 years
Arranged One to One Meet with stack holdersArranged One to One Meet with stack holders
* SRS Data
Directions were issued to cement plants foraugmenting TSR up to 10 % within 3 yearsDirections were issued to cement plants foraugmenting TSR up to 10 % within 3 years
GPCB has conducted series of meetings with localUrban bodies to enhance the rate of co-processing ofMSW in various Cement Plants
GPCB has conducted series of meetings with localUrban bodies to enhance the rate of co-processing ofMSW in various Cement Plants
Sensitizing the top level management of cementindustriesSensitizing the top level management of cementindustries
13
Initiatives by GPCB
Constituted a committee for permission for co-processing of hazardous wastes and other wastes incement plants
Constituted a committee for permission for co-processing of hazardous wastes and other wastes incement plants
Expediting trial runs/ regular permissions at variouslevelsExpediting trial runs/ regular permissions at variouslevels
* SRS Data
Constituted a committee for permission for co-processing of hazardous wastes and other wastes incement plants
Constituted a committee for permission for co-processing of hazardous wastes and other wastes incement plants
Regular monthly Review at MS & Chairman levelRegular monthly Review at MS & Chairman level
Three pre processing facilities are setup in industrialclustersThree pre processing facilities are setup in industrialclusters
14
Initiatives by GPCB
Availability of Waste Characterization reportAvailability of Waste Characterization report
Acceptance criteria as per the guideline of CPCB aremade available to hazardous waste generatorsAcceptance criteria as per the guideline of CPCB aremade available to hazardous waste generators
Identification of waste disposal problems of clustersIdentification of waste disposal problems of clusters
* SRS Data
Acceptance criteria as per the guideline of CPCB aremade available to hazardous waste generatorsAcceptance criteria as per the guideline of CPCB aremade available to hazardous waste generators
On-line tracking system is developed for movement ofhazardous and other wastesOn-line tracking system is developed for movement ofhazardous and other wastes
A web based portal (xgn) has been developed foridentifying suitable waste for co-processing to thecement industry
A web based portal (xgn) has been developed foridentifying suitable waste for co-processing to thecement industry
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Acceptance Criteria as per CPCB guidelineSpecification of HW for use as Alternative Raw
Material
Parameter Limit
Volatile organic Hydrocarbon < 5000 ppm
Total organic Carbon (TOC) < 1000 ppm
CaO + SiO2 + A1203 + Fe203 + SO3
(In Ash)
> 80 %
* SRS Data
CaO + SiO2 + A1203 + Fe203 + SO3
(In Ash)
Chloride < 1.5 %
Sulphur < 1.5 %
PCB/PCT (ppm) < 5.0
Heavy Metals (ppm) Hg
Cd+Tl+Hg
As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V
< 10
< 100
< 10,00016
Specification of HW for use ofenergy recovery
Parameter LimitCalorific Value As received basis >2500 k Cal/Kg
Ash-Liquid-Solid
< 5%< 20%
Chloride < 1.5 %Halogens (F+Br+I) < 1.0 %
* SRS Data
Halogens (F+Br+I) < 1.0 %Sulphur < 1.5 %
PCB/PCT (ppm) < 50
Heavy Metals (ppm) HgCd+Tl+Hg
As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V
< 10< 100
< 25,00pH 4 to 12
Viscosity (cSt) for Liquid < 100Flash point (Deg Centigrade) (for Liquid) > 60
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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
Type of waste Co-processed
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/cottonwaste
Pet coke
Paint Sludge & ETP Sludge18
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, groundnuthusk, saw dust.
• Landfillable waste: Tyre chips, agro waste, expired offdrugs, MSW, embroidery waste, solid waste, municipalwaste, 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.
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• 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, groundnuthusk, saw dust.
• Landfillable waste: Tyre chips, agro waste, expired offdrugs, MSW, embroidery waste, solid waste, municipalwaste, 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.
Wastes can be co-processed.(Industrial Sectors)
• Pharmaceuticals ind.,• Dyes And Dye-
Intermediates,• Beverages ind.,• Mining And Ore,• Fine Chem,
• Textile Industries,• Paint manufacturing.,• Petrochem,• Synthetic oil,• Rubber Ind.,• Org. Chemicals,
• Pharmaceuticals ind.,• Dyes And Dye-
Intermediates,• Beverages ind.,• Mining And Ore,• Fine Chem,
* SRS Data
• Textile Industries,• Paint manufacturing.,• Petrochem,• Synthetic oil,• Rubber Ind.,• Org. Chemicals,
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Total Waste Co-processed (MT)
79,14,295
5000000
6000000
7000000
8000000
9000000
Co-procesed Waste (MT)
* SRS Data
15,693 22,3451,71,605
1,81,220,549,424
28,23,305
38,15,053
3,35,650
0
1000000
2000000
3000000
4000000
5000000
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17* Total
Year wise status is from April to march
21
Total Plastic WasteCo-processed (MT)
120000
140000
160000
180000
1,71,565
* SRS Data
0
20000
40000
60000
80000
100000
120000
2009-'10 2010-'11 2011-'12 2012-'13 2013-'14 2014-'15 2015-'16 2016-'17* Total
0 0515
29,716
51,687
31,990
52,747
4,910
Yearwise status is from April to March
22
Total Waste Co-processed (MT)as Alternative Raw Material and
As Alternative Fuel
6000000
7000000
8000000
61,22,598
79,15,556From 2009 to April. 2016
* SRS Data
0
1000000
2000000
3000000
4000000
5000000
6000000
Alternate RawMaterial
Alternate Fuel Total (MT)
17,92,958
23
Industry wise status
4000000
5000000
6000000
7000000
8000000
27,11,235
79,14,293
* SRS Data
0
1000000
2000000
3000000 21,63,337
2,61,430 4,12,3077,62,736 7,58,784
2,08,336 25,1826,09,484
1,463
2009 to April 2016
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Hazardous and Other Wastes(M&TM) Rules 2016
• As per Rule 6To 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 otherwastes.
• Rule 9To obtain authorization and passbook for utilization of hazardousand other wastes as a resource or after pre-processing either forco-processing or for any other use, including within the premises ofthe generator (if it is not part of process)
• As per Rule 6To 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 otherwastes.
• Rule 9To obtain authorization and passbook for utilization of hazardousand other wastes as a resource or after pre-processing either forco-processing or for any other use, including within the premises ofthe generator (if it is not part of process)
* SRS Data25
Provisions for co processing/pre-processing under HWM Rules 2016
• SPCBs/PCCS may grant authorisation to cement industry for utilisation ofHazardous wastes as prescribed in Rule 9
• No trial run permission is required once regular permission is accorded byCPCB
• The standards for co processing have been are notified by MoEF& CCdated 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
• SPCBs/PCCS may grant authorisation to cement industry for utilisation ofHazardous wastes as prescribed in Rule 9
• No trial run permission is required once regular permission is accorded byCPCB
• The standards for co processing have been are notified by MoEF& CCdated 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
* SRS Data26
Provision for transportationunder 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
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
* SRS Data27
Co-processing is added as preferential mechanism over disposal in
Hazardous Waste Rules 2016
The approval process for co-processing of hazardous waste is put-
up on emission norms basis rather than on trial basis
Provision for co-processing / pre-processing 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 put-
up on emission norms basis rather than on trial basis
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Procedure to obtainauthorisation (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* SRS Data
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
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 ofnotification (25.08.2014)
Anywhere in thecountry/CEPI/urban centers
30
Standards for Air Emission(for Cement Plants)
PM Before/On or after the date ofnotification (25.08.2014)
Anywhere in thecountry/CEPI/urban centers
30
SO2 Irrespective of date ofcommissioning
Anywhere in thecountry
100, 700 and 1000when pyritic sulphurin the limestone isless than 0.25%, 0.25to 0.5% and morethan 0.5%respectively.
100, 700 and 1000when pyriticsulphur in thelimestone is lessthan 0.25%, 0.25 to0.5% and morethan 0.5%respectively.
30
Parameter Standards
(i) Rotary kiln –with co-Processing (ii) Rotary kiln –without co-processing
Date ofcommissioning
Location Concentration not to exceed, (mg/Nm3)
Nox After the date ofnotification(25.08.2014)
Anywhere inthe country
(1) 600 (1) 600
Standards for Air Emission(for Cement Plants)
After the date ofnotification(25.08.2014)
Anywhere inthe country
Before the date ofnotification(25.08.2014)
Anywhere inthe country
(2) 800 for rotary kilnwith In Line calcinertechnology (ILC)
(3) 1000 for rotary kilnusing mixed stream ofILC, Separate LineCalciner (SLC) andsuspension pre-heatertechnology or SLCtechnology alone orwithout calciner.
(2) 800 for rotary kilnwith In Line calcinertechnology (ILC)
(3) 1000 for rotary kilnusing mixed stream ofILC, Separate LineCalciner (SLC) andsuspension pre-heatertechnology or SLCtechnology alone orwithout calciner. 31
Parameter Standards
(i) Rotary kiln –with co-Processing
Concentration not to exceed, (mg/Nm3)
HCL 10
HF 1
Standards for Air Emission(for Cement Plants)
HF 1
TOC 10
Hg and its compounds 0.05
Cd + Ti and their compounds 0.05
Sb + As + Pb + Co + Cu + Mn + Ni + Vand their compounds
0.5
Dioxins and Furans 0.1 ngTEQ/Nm3
32
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.
* SRS Data
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
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.
* SRS Data
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
GPCB has taken an Initiative to achieve the target of 50,00,000
MT of waste co-processed at the end of March 2017.
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 ‘’
Mile Stones
35
GPCB has taken an Initiative to achieve the target of 50,00,000
MT of waste co-processed at the end of March 2017.
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 ‘’
Way Forward
Encouragingsegregationfacilities ofMSW for co-processingforpreparationof RDF
Toencouragethe pre-processingfacilities inhazardouswastegeneratingindustrialclusters &cementplants
Supply ofadequateOnlineTrackingsystem forHAZ-Wasteat nationallevel
Removal orreduction offrequentpermissionsfor differentwastes
Supply oftechnologyto monitoronline, allemissionparameters
* SRS Data
Encouragingsegregationfacilities ofMSW for co-processingforpreparationof RDF
Toencouragethe pre-processingfacilities inhazardouswastegeneratingindustrialclusters &cementplants
Supply ofadequateOnlineTrackingsystem forHAZ-Wasteat nationallevel
Removal orreduction offrequentpermissionsfor differentwastes
Supply oftechnologyto monitoronline, allemissionparameters
Way Forward36
Way ForwardTo identifynew sectorsand theirwastegeneratorsto link upwith cementindustries
Sector wiseand regionwisemeetings areon way tousehazardouswaste for coprocessing
WasteexchangeBanks /CollectionCenters toprovideinformationon wastes
Technologicalaspects needto bepromoted soas toconserve thefuel in placeof utilizationof waste asresource
The issue ofinterstatemovementof hazardous& otherwaste is nowrequire tointimateboth theSPCB beforewasteprocurement.
* SRS Data
To identifynew sectorsand theirwastegeneratorsto link upwith cementindustries
Sector wiseand regionwisemeetings areon way tousehazardouswaste for coprocessing
WasteexchangeBanks /CollectionCenters toprovideinformationon wastes
Technologicalaspects needto bepromoted soas toconserve thefuel in placeof utilizationof waste asresource
The issue ofinterstatemovementof hazardous& otherwaste is nowrequire tointimateboth theSPCB beforewasteprocurement. Way Forward
37
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