Co-fueling of Plastic Waste in

Cement Industry: Lessons Learned in

Thailand

C. VisvanathanEnvironmental Engineering and Management

Asian Institute of Technology

Email: visu@ait.asia

Webpage: http://www.faculty.ait.ac.th/visu/

Plastic Waste in Thailand

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 3

Coastal population directly

dump their waste in ocean

Dumpsites cause

secondary pollution

E.g., Leachate runoff

Cause of Marine Plastic Pollution

Marine Pollution caused by two main sources:

Dumpsites located at river watershed

Direct dumping by coastal population

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 4

Plastic Waste Flow in Thailand in 2018

Fresh MSW

Paper

8 %

Others

10 %

Plastic

18 % Organic

and Soil

64 %

Waste Generation

25.24 MT Managed Waste

5.80 MT

• Landfill

• Control Dumping

• WTE Plants

• Uncontrolled

Dumping

• Marine Dumping

Mismanaged Waste

19.43 MT Paper

2 %

Others

14 %

Plastic

42 %

Organic and

Soil

42 %

Source: Jarusutthirak, 2018; PCD, 2019; UNEP, 2017, Current Study

Dumpsite Composition

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 5

0

200

400

600

800

1,000

1,200

1,400

1,600

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Import

Valu

e (

Mill

ion B

aht)

Import

Volu

me (

mill

ion tonnes)

0.70

0.60

0.50

0.40

0.30

0.20

0.10

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

0

20

40

60

80

100

120

140

Num

ber

of

com

pan

ies

utiliz

ing w

aste

pla

stic im

port

Plastic Waste Import to Thailand

Source – Leungsakul, 2018

Volume (tonnes) Value (Million Baht)

China bans plastic waste import in 2017, displacing

it to other countries including Thailand

Plastic Waste Recycling

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 7

Approaches for Plastic Waste Recycling

Plastic Waste Recycling

Waste to Material

Waste to Energy

Quality of segregated plastic is

important

Not suitable for plastic waste

recovered from landfills

Needs purification technologies for

pre-treatment

Segregation from other streams of

waste necessary

Quality of segregated plastic

does not play a significant role

Better suited for plastic waste

recovered from landfills

Relatively less purification

technologies required

Segregation from other

streams not necessary…

Deposition at

landfills

Disposal

Use

Production

Raw Material

Extraction

Waste to EnergyWaste to

Material

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 8

‘Waste to Material’ and ‘Waste to Energy’

Waste to Material:

Thermoplastics are recyclable, after sorting out based on

the type of distinct polymer such as PE, PET and PVC.

Can be remelted back into a liquid

Can be made into many useful products like furniture,

building materials etc.,

Successes have also been achieved in using the plastic

waste for laying roads

Waste to Energy:

Thermosetting plastics are only incinerable and non-

recyclable

Always remain in a permanent solid state

Suitable for generating energy

Used as co-fuel in cement kilns

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 9

Cement Production with Co-Fuelling

Homogenizing

Hall

Raw Mill

Storage

Silo

Raw material

crusher

Cement Silos

Cement Mills

Preheater

Stack SiloESP

Clinker Storage

Additive Silos

Rotary Kiln

Co-Fuelling

(Coal + Plastic)

Plastic to Coal ratio = 5%

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 10

Co-Fuelling vs WTE

Technical Superiority• Ash from waste utilised in clinker production – No solid waste (ash) generation

• No need to install emission control systems – Lime used in pre-heater acts as “Scrubber” for heavy metals

Waste to Energy MSW to SRF for Cement Production

Production Production

• Electricity: 138 GWh/year • 0.12 million tonnes/year cement production

• Heat: 320-400 GWh/year • Producing 15 GJ/tonnes of energy

• Investment -100 million euro • Investment - 36 million euro

• Energy Recovered - 83% • Energy Recovered - 90%

Incentives from Government Incentives from Government

• 32,000 euro/GWh electricity generation

• FIT’s 4.4 million euro/year (12 years)• Zero subsidy

Source: Heidelberg Cement

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 11

Policy Drivers for WTE

• Expected to reach 30% renewable energy consumption 2036

• Support for WTE:

1. FiT (Feed in Tariff) for electricity from wastes

2. Financial Support - Energy service company fund (ESCO)

3. Project Subsidy

• Adder Program replaced by FiT in 2014

FiT = FiT(F) + FiT(V) + FiT (Premium)

Source: Ministry

of Energy,

Thailand

Capacity FiT (Baht/kWh) Period

(year)

FiT Premium (Baht/kWh)

FiT (F) – FixedFiT(F) FiT(V) FiT (Total) 3 Southern Border Provinces

Very Small Power Provider (VSPP)

≤ 1 MW 3.31 3.21 6.43 20 0.50

> 1-3 MW 2.61 3.21 5.82 20 0.50

Fit (V) – Variable

according to inflation

> 3-10 MW 2.39 2.69 5.08 20 0.50

Small Power Provider (SPP)

> 10 MW 1.81 1.85 3.66 20 -

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 12

Waste Processing at Dumpsite

Dumpsite Waste

Rejected Waste

Processed Waste

Trommel Screen

Nong-Khae

Organic Waste – 39.83%

Plastic Waste – 45.25%

Nakhon-Nayok

Organic Waste – 44.87%

Plastic Waste – 39.12%

Nong-Khae

Organic Waste – 83.46%

Plastic Waste – 12.22%

Nakhon-Nayok

Organic Waste – 60.90%

Plastic Waste - 26.28%

Nong-Khae

Organic Waste – 31.66%

Plastic Waste – 58.84%

Nakhon-Nayok

Organic Waste – 26.67%

Plastic Waste – 60.44%

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 13

Saraburi (Nong-Khae) Dumpsite features

No. of years of operation … 10 years

Capacity … 50,000 tonnes

Processing capacity … 1000 tonnes/month

Incoming waste … 15 tonnes/day

Screens … 80 mm trommel screen × 2

Operation period … 8 hours

Nong Chorakhe, Nong Khae District, Saraburi

Saraburi Case Study

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 14

Nong Khae Dump Site

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 15

Saraburi Case Study

Waste Type Dumpsite Waste (%) Amount (tonnes) Rejected Waste (%) Processed Waste (%)

Organic +

Soil39.83 19,916.20 83.46 31.66

Paper 1.45 726.25 0.00 0.31

Plastic 45.25 22,625.69 12.22 58.84

Glass 1.68 837.98 3.20 1.02

Metal 2.23 1,117.31 0.00 0.20

Rubber 1.12 558.65 0.07 0.00

Textile 5.08 2,541.89 0.46 2.66

Yard 1.62 810.05 0.00 3.98

Ceramic 1.73 865.92 0.59 1.33

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 16

Nakhon-Nayok Dumpsite features

No. of years of operation … 20 years

Capacity … 175,000 tonnes

Processing capacity … 500 tonnes/month

Incoming waste … 24 tonnes/day

Screen … 80 mm trommel screen

Operation period … 8 hours

Phrommani, Mueang Nakhon Nayok District, Nakhon Nayok

Nakhon-Nayok Case Study

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 17

Nakhon Nayok Dumpsite

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 18

Nakhon-Nayok Case Study

Waste Type Dumpsite Waste (%) Amount (tonnes) Rejected Waste (%) Processed Waste (%)

Organic +

Soil44.87 78,522.5 60.90 26.67

Paper 1.92 3,360 0.00 2.22

Plastic 39.12 68,460 26.28 60.44

Glass 1.58 2,765 3.42 0.89

Metal 2.71 4,742.5 2.56 1.33

Rubber 3.27 5,722.5 0.85 3.78

Textile 2.14 3,745 3.42 3.78

Yard 1.69 2,957.5 0.64 0.44

Ceramic 2.70 4,725 1.92 0.44

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 19

Landfills and WtE Plants

in Thailand

Incoming Waste

(tonnes/day)Symbol

< 10

10 – 50

50 – 100

100 – 300

300 - 500

> 500

WTE

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 20

1 Bangkok 21 Loei 1.92 41 Phayao 0.65 61 Satun 0.22

2 Amnat Charoen 22 Lopburi 5.23 42 Phetchabun 1.25 62 Sing Buri 0.40

3 Ang Thong 23 Mae Hong Son 0.39 43 Phetchaburi 63 Si Sa Ket 0.58

4 Bueng Kan 0.62 24 Maha Sarakham 0.44 44 Phichit 0.34 64 Songkhla 0.78

5 Buri Ram 1.59 25 Mukdahan 0.19 45 Phitsanulok 0.55 65 Sukhothai 0.17

6 Chachoengsao 4.13 26 Nakhon Nayok 0.65 46 Phrae 0.52 66 Suphan Buri 6.07

7 Chai Nat 0.18 27 Nakhon Pathom 2.50 47Phra Nakhon Si

Ayutthaya22.00 67 Surat Thani 2.03

8 Chaiyaphum 1.58 28 Nakhon Phanom 2.19 48 Phuket 68 Surin 0.37

9 Chanthaburi 0.17 29Nakhon

Ratchasima3.51 49 Prachin Buri 2.58 69 Tak 1.55

10 Chiang Mai 1.19 30 Nakhon Sawan 0.84 50Prachuap Khiri

Khan0.39 70 Trang 0.34

11 Chiang Rai 1.09 31Nakhon Si

Thammarat1.93 51 Ranong 1.52 71 Trat 0.59

12 Chon Buri 7.73 32 Nan 0.13 52 Ratchaburi 0.66 72Ubon

Ratchathani1.54

13 Chumphon 2.28 33 Narathiwat 0.61 53 Rayong 1.13 73 Udon Thani 2.18

14 Kalasin 1.25 34Nong Bua Lam

Phu0.50 54 Roi Et 1.92 74 Uthai Thani 0.04

15Kamphaeng

Phet0.32 35 Nong Khai 0.43 55 Sa Kaeo 2.73 75 Uttaradit 0.54

16 Kanchanaburi 2.58 36 Nonthaburi 56 Sakon Nakhon 0.70 76 Yala 0.03

17 Khon Kaen 2.84 37 Pathum Thani 0.95 57 Samut Prakan 77 Yasothon 0.87

18 Krabi 0.83 38 Pattani 0.72 58 Samut Sakhon 0.63

19 Lampang 123 39 Phangnga 0.85 59 Samut Songkhram

20 Lamphung 0.54 40 Phatthalung 0.49 60 Saraburi 0.34

1

2

3

4

5

6

7

8

9

10

11

12

13

1415

16

17

18

1920

21

22

23

24

25

2627

28

29

30

31

32

33

34

35

40

37

38

39

3

6

41

42

43

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45

46

47

4

8

49

50

5

1

52

53

54

55

56

575859

61

6062 63

64

65

66

67

68

69

70

71

73

7274

75

76

77

Dumpsites in

Thailand24

44

10

7

94

8

126

72

20

15

46

13

49

173

22

191

74

43

33

107

11

13

3

4

37

90

17

30

42

21

46

16

4

42

11

14

59

38

11

14

21

40

11

22

19

13

9

12

54

9

22

3

7

8

4

49

21

7

23

40

14

20

13

15

69

94

2

37

2

38

Amount of Waste in

Provinces (tonnes)

Number of Dumpsites

Priority Provinces

(Near Water Bodies)

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 21

Waste Type

Average Composition in dumpsites

(%)

(Current Study)

Amount of Waste in Dumpsites in

Thailand (MT)

Amount of Waste in Landfills in

Thailand (MT)

Organic + Soil 42.35 97.86 90.78

Paper 1.69 3.89 3.62

Plastic 42.19 97.48 90.42

Glass 1.63 3.76 3.49

Metal 2.47 5.71 5.30

Rubber 2.19 5.06 4.71

Textile 3.61 8.34 7.75

Yard 1.66 3.82 3.55

Ceramic 2.22 5.12 4.75

Total 231.08 214.34

Plastic Recovery Potential of Landfills in Thailand

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 22

Plastic Waste Recovery Potential in Thailand

Total Population of Thailand = 69.04 million

Coastal Population of Thailand = 26 million (37.65% of total population)

Number of Landfills = 104 Landfills

Waste in Landfills = 214.34 Million Tonnes

Plastic Waste in Landfills = 90.42 Million Tonnes

Number of Dumpsites = 2380 Dumpsites

Waste in Dumpsites = 231.08 Million Tonnes

Plastic Waste in Dumpsites = 97.48 Million Tonnes

Plastic Waste Recovery Potential = 187.9 Million Tonnes

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 23

Waste Pre-processing

Excavation

Size Selection

Dry Solid Waste

(59.64% Plastic)

Organic Waste

Dumpsite Waste

(42% Plastic)

Excavator

Trommel Screen

Excavated Waste

Excavated Waste

Waste Segregation

Wind Shifting

Heavier Waste

Lighter Waste

Waste Segregation

Magnetic Separation Ferrous Metal

Size Selection

Spinning

Dry Solid Waste

Dry Solid Waste

Dry Solid Waste

Waste Size Reduction

Shear Shredder

Lighter WasteFinal Product

(80% Plastic)

Final Product used in co-fuelling

(5%) in Kiln.

Waste processing

at dumpsite

Waste processing

at dumpsite

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 24

Calorific Value of Waste

Calorific Value of dumpsite waste

increases from 16.74 GJ/tonne to

18.84 GJ/tonne.

Trommel Reject waste mainly

comprised of soil and organic material,

hence lower calorific value.

Plastic waste without moisture and

impurities can have calorific values up

to 45 GJ/tonne.

16.74 17.58

4.18

18.84

30

0

5

10

15

20

25

30

35

DumpsiteWaste

TrommelProcessed

TrommelReject

Final Product Clean PlasticWaste

(average)

Calorific Value of Waste at

different stages (GJ/tonne)

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 25

Energy Conversion Capacity

Calorific value of 1 tonne of plastic waste (ash and moisture free) = 15 - 45

GJ/tonne (2)

Calorific value of 1 tonne of final waste from Ecocycle = 18.84 GJ/tonne

Plastic to Electricity production conversion efficiency = 22% (avg) (1)

Plastic to Heat (Cement Kiln) conversion efficiency = 75% (avg) (1)

1 – World Bank Technical Guidance, Municipal Solid Waste

Incineration, 1999

2 - Towards a better exploitation of the technical potential of

waste-to-energy, 2016

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 26

Challenges of Plastic Co-fueling

• Cement production from plastic waste is a double-edged

sword with benefits of recovery as well as challenges

• Policies pushing WTE Plants, drives the provincial

authorities to support WTE Plants

• Lack of co-fuelling regulations can lead to uncontrolled

emissions

• Lack of well segregated waste decreases the quality of

SRF

• Costs versus benefits of using SRF are way out of

balance

• Centralised collection and production takes waste

management away from the source

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 27

Key Takeaways

• Plastic waste generation along with marine dumping causes

serious impacts

• Efforts such as bans or reduction in single use plastics offers

solution for future, however the stock of plastic waste in landfills

need to be addressed to control marine plastic pollution

• The characteristics of plastic waste in landfills makes it attractive for

recovery. Higher plastic waste recovery potential from landfills are

estimated through this study

• ‘Waste to Energy’ approach through co-fueling of plastic waste in

cement industry reduces the need for high quality segregation or

purification

• Policy intervention is needed to encourage plastic co-fueling in

cement industry owing to its engineering superiority

• The study recommends to prioritise plastic waste recovery from 41

provinces located at coastal area, Chao Phraya and Mae khlong

river basin.

C .Visvanathan / Asian Institute of Technology, Thailand Co-fueling of Plastic Waste in Cement Industry 28

Thank You!