© 2014 Holcim Technology Ltd
Co-processing for environmentally sound management of wastes
© 2014
Ulhas Parlikar
Dy. Head, Geocycle India
© 2014 Holcim Technology Ltd
About Geocycle
Geocycle is the waste management brand of
Holcim. In Geocycle, the service of waste co-processing in cement manufacturing process is
provided. Holcim is the promoter of both ACCLimited and Ambuja Cements Limited .
• Brand was created in 2007 as the dedicatedidentity used to brand waste management
solutions in the Holcim Group• We apply the highest health, environment
and safety standards in all our operationcomplying to relevant regulation
For a zero-waste future
© 2014 Holcim Technology Ltd
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
© 2014 Holcim Technology Ltd
We should strive for a circular economy
Circular Economy...
• Leads to fewer landfills and reduces
pollution caused by dumping
• Reduces greenhouse-gas emissions,
thereby fighting global warming
• Reduces the environmental impact of extraction (mining/quarrying),
transporting and processing of raw material
• Reduces dependence on primary
resource markets
• Conserves natural (non-renewable) energy and material resources
Technology
Recycling
Technology
Industry
Society
waste Product
© 2014 Holcim Technology Ltd
Waste Management Hierarchy
© 2014 Holcim Technology Ltd
What is CoWhat is Co--processing?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
© 2014 Holcim Technology Ltd
Typical Features of Cement Kiln Typical Features of Cement Kiln
© 2014 Holcim Technology Ltd
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.
© 2014 Holcim Technology Ltd
Zero Impact On PCDD/PCDF EmissionsZero Impact On PCDD/PCDF Emissions
(0,29)
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0 20 40 60 80 100 120 140 160
Measurement No.
Em
issio
ns in
ng I
-TE
Q/m
3
regular fuel with secondary fuel
with secon-dary raw material
Source VDZ
© 2014 Holcim Technology Ltd
No Leaching of Pollutants from ConcreteNo Leaching of Pollutants from Concrete
Doped mixing
water
Lime-dissolving
carbonic acid
Trough tests on mortars
Concentrations in the eluate are
significantly below the limit values
© 2014 Holcim Technology Ltd
Waste Pre-processed and Co-processing
“Banned wastes" will not be processed
• Radioactive waste
• Asbestos-containing waste
• Explosives and ammunition / weapons
• Anatomical medical waste
“Banned wastes" will not 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
© 2014 Holcim Technology Ltd
Reduction of Green House Gases Reduction of Green House Gases
Co-processing and
IncinerationReduction in GHG Emissions
Co-processing and
LandfillPrevention of Methane* Emissions* Methane has 21 times more global warming potential than CO2
The same argument is valid for all other emissions too.
© 2014 Holcim Technology Ltd
Coprocessing demonstrated as a sustainable solution for waste management in India
• More than 50 demonstration trials implemented with the involvement of SPCBs and CPCB
• Emission monitoring conducted through approved third parties
• More than 50 different types wastes were coprocessed
• Each waste had different physico-chemical characteristics
• These consisted of Solids, Liquids, sludges and Gases
• Their hazard nature varied from simple expired products to
plastics to complex POPs (Ozone Depleting Substances)
• All these trials demonstrated that, when proper controls are
implemented, co processing activity in cement kilns does not influence the cement kiln emissions or the cement product.
• A large scale utilisation of plastic waste and properly prepared
RDF is getting co processed in the country.
13
© 2014 Holcim Technology Ltd
Key Partners for Sustainable Waste Management
14
© 2014 Holcim Technology Ltd
MSW components and co-processability
15
Plastics, wood, paper, cloth,
rubber and other combustibles
Composting/RDF/Biomethantion
Kitchen
waste/organics
Glass
Metals
Street Sweepings
Recycling/Trading/Land filling
Major Area of concern
Solution co-processing√
© 2014 Holcim Technology Ltd
Geocycle pioneer in Co-processing non-recyclable Plastic & other Waste from MSW
• Non recyclable plastic waste from Jabalpur,
Katni and Bhopal MSW at ACC Kymore.
• Non-recyclable plastics of Kulu
and Shimla Municipality at ACC
Gagal and ACL Darlaghat.
• Non-recyclable plastic waste of 7
other municipalities from HP in
ACC Gagal
• Partner with Goa Municipality in
solving their plastic waste
problem at ACC Wadi works.
• Large scale co-processing of
SCF from MSW of Hyderabac
after converting it into RDF
© 2014 Holcim Technology Ltd
Challenges during waste co-processing
• Increasing volumes
• Varying quality
• Many kinds of packaging
• Risk mitigation of each waste stream
• Varying infrastructure for handling
• Large storage space requirement
• Kiln adaptability constraints
• Traceability of problem materials
© 2014 Holcim Technology Ltd
Waste Waste Pre Pre --Processing Processing Processed Processed WasteWaste
Large scale coprocessing - Pre-Processing Activities
© 2014 Holcim Technology Ltd
Pre- and Co-Processing Facilities (PCPFs)
• Geocycle India has setup international standard Waste co-processing and Pre–
processing facilities (PCPFs) at Wadi, Kymore, Bhatapara, Rabriayas, Maratha
Ambujanagar and Madukkarai to manage the wastes from the respective states.
• Pre-processing is done by techniques such as size reduction, screening,
impregnation, blending etc.
• In the PCPFs, different kinds of
wastes from industrial, biological
and municipal sources are
converted into uniform quality
materials for using them as
Alternative Fuel and Raw
Materials (AFRs) in cement plant.
© 2014 Holcim Technology Ltd
Co-processing network of geocycle across India
Business cells with one platform each
and sometimes delimited by state
borders due to limitations in free waste
transportation.
* Depending on way forward
North North central North central
West
South
South Central
East
• Geocycle has access to 14 facilities
across India
• Geocycle has made more than 60 trial
burns in India with various types ofIndustrial waste streams
• The wide spread presence across the
country gives the flexibility to provideseamless solutions to our customers
© 2014 Holcim Technology Ltd
Why wastes need to be managed sustainably?
• Environmental damage is getting out of control.
• Climate change is impacting us all.
• Communities are objecting to implementation of landfills
and incineration facilities for waste management.
• Landfill is building liabilities for the business & society.
• Industries are required to shift to Green practices.
• Importing countries are demanding compliance to
sustainable waste management practices.
© 2014 Holcim Technology Ltd
What are the benefits of co-processing technology?
• There is no subsequent waste - hence zero waste future.
• It helps mitigate global warming.
• It lessens the use of fossil fuels and raw materials.
• It reduces pollution and negative health impacts.
• It reduces cost of production of cement
• It conserves natural resources
• It generates additional employment and opportunity for sustainable livelihood.
© 2014 Holcim Technology Ltd
Wastes can cause obnoxious or toxic emissions?Co-processing is not a proven technology in India?
• Wastes do not impact the cement kiln emissions
• Co-processing evaluated for more than 40 years globally.
• Emission testing from >75 trials in India confirmed the same.
• Simple waste streams to complex ODS materials
• Waste materials had large variation in the characteristics.
• Trials were conducted in cement kilns spread across country
• Globally, some cement kilns operate at TSR levels of >90%
• It is an approved technology by Basel convention for disposal of HWs
• Co-processing is recommended for the destruction of POPs by Stockholm convention.
© 2014 Holcim Technology Ltd
Is co-processing a viable business model in India?
• Co-processing business model is operating for the past 10 years.
• Volumes are increasing year on year
• Waste generators desire to grow sustainably
• The considerations involved in the costing of disposal through co-processing and landfill / incineration options are different.
• National Task Force on co-processing has evaluated the co-processing business model for Hazardous and other wastes as well as for RDF.
© 2014 Holcim Technology Ltd
Wastes can not be transported over large distances
for pre & co-processing !!!!!
Volumes of the Industrial waste transported over
large distances
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
250 500 750 1000 1250 1500
Tonnages
2010 2011
2012 2013
2014
KM
T
(Source :Database – Geocycle India)
© 2014 Holcim Technology Ltd
Only wastes having similar characteristics can be
approved for co-processing?
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
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
VOC (mg/kg) 4.20 207.0
SVOC (mg/kg) BDL 0.2
PCB (mg/kg) 0.00 0.5
PARAMETER MIN MAX
PCP (mg/Kg) BDL 1.4
TOC (%) 0.00 66.0
© 2014 Holcim Technology Ltd
How much waste can be used as AFR?
72
64
60 60
49 48 47
3230 29
2725
22
1816
14 13 1210
7
1
TSR (%) achieved in cement kilns by countries
© 2014 Holcim Technology Ltd
Permitting Process for Preprocessing and Co-processing of Wastes as per new WM Rules 2016
• Waste generator is required to obtain authorization from SPCBs to manage his waste respecting the Waste Management Hierarchy.
• SPCBs are required to authorize the generator to manage his waste
ensuring respect to the WM Hierarchy.
• The cement plant facility is required to obtain authorization from SPCB
for receiving, storing and pre-processing of wastes based on the availability of suitable infrastructure to handle them safely.
• Co-processing in cement plant is to be permitted based on the
compliance to prescribed emission standards and not based on demonstration trials.
• Interstate movement of wastes for co-processing to be implemented by sending intimation to the respective Pollution Control Boards.