Dr Karstensen - Final Basel & Stockholm 21 June 13

7/29/2019 Dr Karstensen - Final Basel & Stockholm 21 June 13

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Technology for a better society

Experiences from other international processes;Basel and Stockholm convention

Dr. Kre Helge Karstensen ([email protected])Chief scientist, Foundation for Scientific and Industrial Research

(SINTEF), Norway, Asian Institute of Technology, Thailand.

Launching of Cement Industry Sector Partnership underthe UNEP Global Mercury Partnership.18-19 June 2013, Geneva, Switzerland1


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UN chemicals and waste conventionsChemicals contribute to many advantages to today'sworld; however their use can also pose risks to humanhealth and the environment. To reduce this harmful

global impact, three conventions have beenestablished that regulate chemicals and hazardouswaste at global level; the Basel, Rotterdam and

Stockholm convention.

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Origin of the UN chemicals and waste conventions Movements of hazardous wastes from industrialised to

industrialising countries for treatment or disposal.

Hazardous waste disposal costs in industrialised

countries were high, regulations becoming stricter. Disposal costs in developing economies were low, few

regulations, low standards.

No legal framework to control dumping.

Lack of awareness and lack of technical knowledge.


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Rotterdam ConventionRotterdam Convention on the Prior InformedConsent Procedure for Certain Hazardous Chemicalsand Pesticides in International Trade currentlyregulates information about the export/import of 43hazardous chemicals listed in the Conventions Annex

III, 32 of which are pesticides (including 4 severelyhazardous pesticide formulations) and 11 of which areindustrial chemicals.

The Convention was adopted in 1998 and enteredinto force in 2004. It currently has 152 Parties.

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Stockholm ConventionThe Stockholm Convention on Persistent OrganicPollutants currently regulates 22 toxic substances thatare persistent, travel long distances, bio-accumulate

in organisms and are toxic.

The Convention was adopted in 2001 and entered

into force in 2004. It currently has 179 Parties.

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Endocrine disrupting

chemicals have probably

worse impacts than earlieranticipated.


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elimination or restriction of production and use ofall intentionally produced POPs, disposal of

stockpiles and wastes, and the continuingminimization and, where feasible, ultimateelimination of releases of unintentionally produced

POPs such as dioxins and furans

Objectives of the Stockholm Convention onPersistent Organic Pollutants (POPs)

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Basel ConventionBasel Convention on the Control of TransboundaryMovements of Hazardous Wastes and theirDisposal regulates the export/import of hazardouswaste and waste containing hazardous chemicals.

The Convention was adopted in 1989 and entered

into force in 1992. It currently has 180 Parties.

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Objectives of the Basel Convention To protect human health and the environmentagainst adverse effects of hazardous wastes.

Reduction of transboundary movements of

hazardous wastes. Minimisation of generation - quantity and degree

of hazard.

Promotion of local solutions and environmentallysound management of hazardous wastes.

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The problem is that most

emerging economies have

limited or no disposal

capacity for hazardous

wastes


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Mozambique

1997-2001


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"Perceptions" about cement kilns treating hazardouswastes treatment ten years ago two examples

1. A cement kiln project was stopped in Mozambique in

2001 due to a combination of fear, active opposition,inferior preparation, lack of communication,improper technical knowledge and the absence of

internationally accepted guidance documents.

2. The Stockholm Convention mention cement kilns

firing hazardous was to be an industry source havingthe potential for comparatively high formation andrelease of dioxins to the environment.

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We wanted to explore the feasibility of using localcement kilns for treatment of organic hazardouschemicals especially in emerging economies wereother treatment options were absent.

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Co-processing in cement kilns shall primarily be about

recovery of energy and recycling of materials in wastes,i.e. substitution of fossil fuel and virgin raw materials.

However, in lack of available treatment options and

urgent needs, a feasible cement kiln can be used for

treatment of organic hazardous constituents providedthat this is done under strict Government control and

guidance.

Policy principles vs. waste treatment in cementkilns


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...more complex organichalogens such as PCB

requires 1200oC and 2

seconds residence time

US EPA Toxic Substances Control

Act (TSCA) PCB Incineration Criteria

A DRE of 99.9999% is required by TSCA for the incinerationof PCBs


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...if more than 1 % of halogenated

organic substances, expressed as

chlorine, are incinerated, the

temperature has to be raised to

minimum 1100

C during atleast two seconds.

EU Directive 2000/76/EC on Incineration of Waste regulates

Co-incineration of Hazardous Waste in Cement Kilns


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Environmental aspectsnvironmental aspectsCo- processing of wastes should only be

performed if the cement kiln operates accordingto the best available techniques and bestenvironmental practice.

If certain provisions for waste quality and wastefeeding are met, co-processing of waste will notchange the emissions from a cement kiln stacksignificantly.


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Fuel feed point in cement kiln systems

Precalciner firingor secondary firing (SP kilns)

Main firingKiln inlet

firing


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Co-processing practiceo-processing practiceAlternative fuels have to undergo a rigorous

acceptance and inspection procedure beforebeing used. It is necessary to avoid/limit mercuryinputs into the kiln system.

Emission monitoring is obligatory in order todemonstrate compliance with existing laws,

regulations and agreements.


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Waste acceptanceaste acceptanceOperators need to ensure that only wastes

originating from trustworthy parties will beaccepted, considering the integrity of allparticipants throughout the supply chain.

The traceability of the wastes needs to be ensuredprior to reception by the facility, with deliveriesof unsuitable wastes refused.

.


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Operational aspectsperational aspectsMaterials transport, handling and storage mustbe effectively monitored, and full compliance

with existing regulatory requirements must beassured.

This includes analysis and reporting ofparameters such as the heating value, the contentof water, heavy metals, ash, sulphur andchlorine. Also retained samples should be storedfor a certain period of time.

.


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Process optimizationrocess optimizationCharacterize the parameters that correspond togood operation and use these as a basis toimprove other operational performance.

Having characterized good kiln operatingparameters, establish reference data by addingcontrolled doses of waste, and assess what are the

changes and required controls and practices tocontrol emissions.


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Manage the kiln process to achieve andmaintain stable operating conditions, i.e. byoptimizing process control (including

implementing computer-based automaticcontrol systems) and using modern,

gravimetric solid fuel feed systems.

Stable fuel feeding is importanttable fuel feeding is important


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Minimize fuel energy use by employingpreheating and pre-calcination to the extentpossible considering the existing kiln system

configuration; and use of modern clinkercoolers, enabling maximum heat recovery

from the exhaust gas.

Best available techniquesest available techniques


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Monitoring and stabilisation of critical

process parameters, i.e. homogenous rawmix and fuel feed, regular dosage and excess

oxygen, stable kiln operation andmonitoring of CO.

Ensure rapid cooling of exhaust gases to atemperature lower than 200 C.

Stable operating conditions is crucialtable operating conditions is crucial


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Consistent long-term supply of a given waste oralternative fuel (e.g. a supply of a month or more)

is required in order to maintain stable conditionsduring operation.

Substances entering the kiln should be carefullyselected and controlled; specifications should be

set based on product/process or emissionconsiderations and monitored.

Supply of wastesupply of wastes


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Pre-treatment of waste, including hazardouswaste, for the purpose of providing a morehomogeneous feed and thus more stable

combustion conditions may, depending onthe nature of the waste-derived fuel,involve drying, shredding, mixing orgrinding.

Pre-treatment of heterogeneous wastesre-treatment of heterogeneous wastes


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The feeding of raw mix containing waste withorganic compounds that could act as precursorshould be avoided.

Halogenated waste should preferably be fedthrough the main burner.

Waste-derived fuel should never be used duringstart-up and shutdown.

Halogenated wastesalogenated wastes


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In general, organic waste should be fed through

either the main burner or the secondary burnerfor pre-heater/pre-calciner kilns.

For the secondary burner it should be ensuredthat the combustion zone temperature ismaintained > 850 C for a sufficient residence

time (>3 s).

Waste feedingaste feeding


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Consistency in fuel characteristics (both alternativeand fossil).

Consistency in fuel supply rate or frequency ofintroduction of batch-charged materials.

Keeping adequate excess oxygen to achieve goodcombustion.

Keeping CO concentrations of in exhaust gasesstable .

Combustion and process stability can be ensured by:ombustion and process stability can be ensured by:


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The destruction and removal efficiency forhazardous compounds should be at least 99.99%.

Chlorinated aromatic compounds should bechosen as a test compound if available because

they are generally difficult to destroy.

For POPs, a DRE/DE of99.9999% should bedemonstrated.

The following should be fulfilled in a test burn:


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The cement kiln should meet an emissionslimit for PCDD/PCDFs of 0.1 ng TEQ/Nm3

both under baseline and co-processing

conditions and needs to be in compliancewith national emission limit values.

Normal performance


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Material control (product quality &health/safety).

Auditing of waste generators/collectors.

Occupational health and safety.

Design safety (installation design &equipment).

Scope of safety audits


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Cement manufacturing is a sensitive processAll materials (in the form of AFRs) introducedinto a cement production process should ideallyresemble the homogeneity, particle sizedistribution, heat and water content and

chemical composition as normal fine coal andraw meal used in cement manufacturing.

As waste materials often are heterogeneous, pre-treatment and pre-processing are often necessary.


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Cement manufacturers are vulnerableCo-processing is still controversial among

some stakeholders and one accident mayunder worst case conditions undermineco-processing acceptance in the entireindustry, i.e. all players have theresponsibility to minimize risks and strive

towards excellence and best practice toprotect the reputation.


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Technology for a better society 36

1. A systematic and comprehensive investigation of the

feasibility of using cement kilns in developingcountries for destruction of POPs and other hazardouswastes thorough documentation.

2. A project with WBCSD CSI to gather and evaluateformation, release and control of U-POPs from thecement industry.

3. Preparation and testing of best-practice Guidelines onenvironmentally sound co-processing and treatmentof hazardous wastes in cement kilns.

"Investigations" were initiated


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The global dioxin emission inventoryfor 1996 applies an emission factor forhazardous waste burning cement kilns

of 2,600 g TEQ/t and 200 g TEQ/tfor non-hazardous waste burningcement kilns

. implying an exit gas concentrationof >1800 ng TEQ/Nm3 and 87 ng

TEQ/Nm3 for hazardous waste burningand non-hazardous waste burningcement kilns respectively.

Outdated Emission Factors?


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More than 2200 PCDD/PCDF

measurements, many PCB and some HCBmeasurements were compiled from cementcompanies around the world.

The data showed that most modern cementkilns can meet an emission level of 0.1 ngTEQ/Nm3, or an average flue gasconcentration of 0.021 ng I-TEQ/m3, alsowhen co-processing wastes and treatinghazardous wastes.

http://www.pops.int/documents/meetings/bat_bep/2nd_session/egb2_followup/

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Using the Emission factors cement made by Brzuzy and Hites(1996) of 4160 g TEQ/ton would imply that the cement industryreleased 1420 kg PCDD/PCDF per year, or 60% of estimated totalglobal emissions.

Assuming a global cement production of approximately 2 billiontons and using the emission factors of the UNEP Toolkit, 0.05 g

TEQ/ton, would imply a cement industry contribution of 100 g/y.

Using the average flue gas concentration of 0.021 ng I-TEQ/m3

from the 500 latest measurements, and assuming a global clinker

production of 1.6 billion t/y and an exhaust-gas volume of 2300Nm3/ton clinker, implies that the contribution from the globalcement industry would constitute 77 grams per year.

From 1420 kg to 77 grams


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Findings confirmed by the UNEP StandardizedToolkit", 2005

In the USA, earlier tests indicated that higher

emissions were found for some wet kilns wherehazardous wastes were fired"

"More detailed investigation suggested that

provided combustion is good - the maincontrolling factor is the temperature of the dustcollection device in the gas cleaning system

The plants equipped with low temperatureelectrostatic precipitators appear to have wellcontrolled emissions with or without waste fuels

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UNEP Toolkit emission factors for cementproduction, 2005

No differentiation on firing hazardous wastes; onlyon technology and the temperature in the APCD!


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1. Recent test burns have revealed several benefits of using cementkilns compared to other treatment techniques, e.g. superiordestruction performance, low and controlled emissions of POPs,large treatment capacity, availability, affordability, local jobcreation and sustainability provided responsible operation.

2. The data gathering of POPs from the cement industry showed

that the contribution from the industry was significantly lessthan anticipated and showed that most modern cement kilns canmeet an emission level of 0.1 ng TEQ/Nm3, also when co-processing wastes and treating hazardous wastes.

3. Guidelines for co-processing of wastes in cement kilns are todaywidely adopted and continuously amended.

Results of the "investigations"


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Cement manufacturers can contributeCement manufacturers can contribute to a successfulimplementation of the Basel and the StockholmConvention by solving hazardous waste problems infeasible local kilns; by substitution of fossil fuels andvirgin raw materials with wastes and biomass, andthereby reduce their carbon footprint; by minimizingrisks and strive towards excellence and best practice; byreducing their over-all emissions proactively.

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A Cement Industry Partnership with UNEP on


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Accountable for 10% of anthropogenic mercury emissions,a partnership with UNEP represents an uniqueopportunity for the cement industry to address a seriousthreat to health and environment.

A successful cooperation will require dedication,transparency, willingness to conduct testing, documentand share information, and to address possible challenges

in a responsible and proactive manner.A successful partnership will contribute to improve theindustry's reputation and to reduce its ecological footprint.

Mercury

Co-processing alternative fuels and raw materials and


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treatment of organic hazardous wastes in cement kilns Cement kilns are in operation in "all" countries;

Facilities and infrastructure are already in place;

Recovers energy & recycle materials; conserves non-renewable resources;

Inherent features, e.g. time & temperatures, are excellent for

organic hazardous waste destruction; Usually no residues to dispose of compared to 30% in DI;

Emissions will normally be unaffected if properly operated;

Reduces disposal costs and CO2 emissions compared tolandfilling and incineration;

New cement kilns in DCs are always BAT.

Summary of recommendations and best practice for co-processing


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An approved EIA and all necessary national/locallicenses.

Compliance with all relevant national and localregulations.

Compliance with the Basel and the StockholmConvention.

An approved location, technical infrastructure and

processing equipment.

Reliable and adequate power and water supply.

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Adequate air pollution control devices andcontinuous emission monitoring ensuring compliance

with regulation and permits - needs to be verifiedthrough regular baseline monitoring and reporting.

Rapid exit gas conditioning/cooling and low

temperatures (


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An error reporting system for employees.

Qualified and skilled employees to manage wastesand health, safety and environmental issues.

Adequate emergency and safety equipment and

procedures, and regular training.

Authorized and licensed collection, transport andhandling of wastes.

Safe and sound receiving, storage, preparation andfeeding of wastes.


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Adequate laboratory facilities and equipment forwaste acceptance and feeding control.

Demonstration of wastes destruction performancethrough test burns.

Adequate record keeping of wastes and emissions.

Adequate product quality control routines.


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An environmental management and continuousimprovement system certified according to ISO14001, EMAS or similar.

Regular independent audits on all aspects of co-processing and independent emission monitoring andreporting.

Regular stakeholder dialogues with local communityand authorities, and for responding to comments and

complaints. Open disclosure of performance reports on a regular

basis.

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Dr Karstensen - Final Basel & Stockholm 21 June 13

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