© 2015 Geocycle

For a zero-waste future

Ulhas ParlikarDy Head – Geocycle India

Cement Kiln Co-processingfor

Sustainable Management of Hazardous and Other Wastes

2015-11-03

© 2015 Geocycle

Incineration

Coprocessing100% Material Recovery 100% Energy

Recovery

Prevention / Reduction

Reuse

Recycling

Waste to Energy

Land filling

Beneficial use of

Material and Energy

Waste Disposal

Cement kiln co-processing is an ecologically sustaining solution for management of wastes

1. Higher in Waste Management Hierarchy over landfill and incineration options2. Recovery option having better environmental performance 3. Practiced widely on large scales globally and encourages circular economy.4. Conserves natural resources, reduces GHG emissions.5. Approved by Basel Convention for disposing Hazardous & other Wastes 6. Recommended by stockholm convention for disposing Persistent Organic Pollutants.

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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’

• Benefit of co-processing to the industry & community are………

Provides a permanent solution to waste management problems

Reduces emissions and greenhouse gases

Lessens reliance on fossil fuels

Preserves natural resources

• Benefit of co-processing to the cement industry are……

Service charges towards co-processing/tipping fees

Reduces cost of Fuel and Raw material

In short, co-processing is the environmentally-friendly

alternative business model for responsible industries

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Technical Characteristics of Cement Kiln

PreheatercyclonesAct like a dry scrubber for acid gases and metals

Clinker: Thermal, macro-molecular immobilization of metals

Mineral wastes:CaO, SiO2, Al2O3, Fe2O3

Kiln main burnerFlame: 1800 - 2000 °C Combustion gases: >1100 °C Retention time > 10 sMaterial : 1450°C > 15 min.(Non)-hazardous waste: liquid, fine solid particles, readily combustible

(Non)-hazardous waste: lump fuel

Mineral by -products

PrecalcinerGases: > 900 °C Retention time > 3 sRaw meal: 700 °C(Non)-hazardous waste: liquid, solid, coarse particles

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What happens to the waste in the Cement Kiln ?

• Organic constituents are completely destroyed due to the high

temperatures, long residence time and oxidizing conditions in

the kiln. Combustion of an organic compound composed only

of carbon and hydrogen produces CO2 and water.

• If the organic compound (coal or waste materials), contains

chlorine or sulphur, then acid gases such as HCL and SO2 are

produced. These gases are absorbed and neutralized by the

freshly formed lime and other alkaline materials within the kiln.

• The inorganic constituents including heavy metals reacts with

the raw materials in the kiln and are included in the clinker

matrix leaving the process as part of the cement.

© 2015 Geocycle

100

150

200

250

300

Thou

sand

s

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999(es t )

T/y

haz.

A.F

.R.

T/y

haz.

A.F

.R.

0 , 0001

0 ,001

0 ,01

0 , 1

1

mgr

/Nm

3 - d

ry -

11 %

O2

199 0 19 91 199 2 1 993 1 994 19 95 199 6 1 997 19 98 199 9 (es t )

Sb+Cr+Cu+Pb+VSb+Cr+Cu+Pb+V

As+Co+Ni+Se+TeAs+Co+Ni+Se+Te

Cd+Hg+TlCd+Hg+Tl

Zero Impact of Co-processing On Emissions

0,1

1

10

100

1000

ppm

1990 1991 1992 1993 1994 1995 1996 1997 1998 es t 1999

Sb+Cr+Cu+Pb+VSb+Cr+Cu+Pb+V

As+Co+Ni+Se+TeAs+Co+Ni+Se+Te

Cd+Hg+TlCd+Hg+Tl

ppm

ppm

On final products

On emissions

Output products

Cement Quality

© 2015 Geocycle

Zero 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

issi

ons

in n

g I-T

EQ

/m3

regular fuel with secondary fuel

with secon-dary raw material

Source VDZ

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No 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

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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.

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Waste & Sustainability: The Challenge

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Waste Pre -Processing Processed Waste

Large scale coprocessing - Pre-Processing Activities

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Co-processing Deliverables• Zero waste residue

• Zero Liability once the waste is accepted at Geocycle

• Safe, secure and environmentally sound way of waste

disposal

• 100% compliance with local environmental regulations

and the setting of best practices

• Continuous Emissions Monitoring

• Optimized asset utilization, eliminating unnecessary

onsite waste storage

• Complete documentation of waste disposal activities

• Locally available solutionCo-processing is, therefore, a local & desired route to manage wastes

with zero liability, environmental impact addressing all concerns of

sustainable development.

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Thermal Substitution Rates in cement kilns with wastes

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72

64

60 60

49 48 47

3230 29

2725

22

1816

14 13 1210

7

1

TSR (%) achieved in cement kilns by countries

© 2015 Geocycle2015-11-03

Mining urban areas to ‘green’ the nations backyard

HW - >7 Mio TPA

MSW - >60 Mio TPA

NHW - ???? Mio T

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Potential for reduction in GHG and conservation of coal*

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Parameter UnitBase case Low demand High Demand

2010 2020 2030 2050 2020 2030 2050

Cement Production  Mio TPA 217 416 598 780 492 848 1361

Clinker to Cement Ratio 0.74 0.7 0.64 0.58 0.7 0.64 0.58Thermal Intensity of clinker production

Kcal / Kg Clinker 725 709 694 680 703 690 678

Alternative Fuel share in total energy used % 0.6 5 19 25 5 19 25Coal Conserved having CV of 4500 Kcal / Kg Mio TPA 0.16 2.3 11.2 17.1 2.7 15.8 29.7

CO2 emission reduced Mio TPA 0.19 2.8 13.8 21.0 3.3 19.4 36.5

* Based on figures projected in “Low Carbon technology road map for Indian Cement Industry” IEA & WBCSD

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What is required to be done?

Recognition for co-processing• Recognition of co- processing as a preferred technology for

waste management

Modifications in the Regulatory framework• Hassle free Interstate movement of wastes and clear

guidelines to avoid any disputes• Mandate in MSW Rules for producing RDF suitable for

cement plant co-processing

Generic permissions for pre & co-processing facilities• Generic Permit for Co-processing to cement plants adhering to

Pre-qualification criteria• Uniform permitting procedure for Hazardous and non-

hazardous wastes at all SPCBs

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• Principle of “disposal” as against desired principle of “sustainability”.

• Mandatorily diverts wastes to landfill or incineration facilities. Drains available resource value present in the wastes. Increases waste foot print in the environment.

• Instantaneous permit for landfill or incineration and more than one year for co-processing.

• Generic permit for landfill and incineration facilities and waste by waste permit for co-processing option.

• No demonstration trial for landfill or incineration but an elaborate demonstration trial for co-processing.

Existing regulatory framework

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Perceptions and facts related to co-processing

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Perception Fact ReasonCharacteristics of a category of waste varies within a band width of maximum 10%.

False. The characteristics of wastes change from time to time and batch to batch. The variation range is observed to a level of more than 1000 times as well. 

Waste is a produce from the process of rejection and its quality is never monitored at the generation level. 

Chemical characteristics of the waste ‘may’ influence cement kiln emissions and emit large quantum of toxic gases. 

False. No negative influence has been observed on any of the emission parameters while co‐processing wastes in the cement kiln. 

When inputs & process are properly monitored, the organics and in‐organics present in natural materials or waste material get treated exactly same manner.

Cement product quality ‘may’ get impacted by varying characteristics in the waste.

False. No negative influence has been observed on the product quality while co‐processing wastes in the cement kiln.

© 2015 Geocycle

Perceptions and facts related to co-processing

2015-11-03

Perception Fact ReasonCement industry ‘may not’ have capability to safely store, handle and manage different kinds of Hazardous & other wastes generated by the industry.  

False. No negative influence hasbeen observed on theenvironment while undertakingthe co‐processing trials and alsowhile undertaking regular co‐processing of the hazardouswastes.

Cement industry is already investingin safe storage and handling systemsand building necessary skills tomanage Hazardous wastes.

A trial of every waste stream is necessary for demonstrating its suitability for co‐processing but the same is not requiredfor land fill and incineration options.

False. Co‐processing is a recoveryprocess, has proven betterenvironmental performance thanincineration or landfill options andis higher in the waste managementhierarchy than landfill andincineration operations

The temperature, residence timeand turbulence in the kiln during co‐processing operation aresubstantially stringent and favorablefor achieving better Destruction andRemoval Efficiency (DRE) thanIncineratiors.

© 2015 Geocycle

Perceptions and Facts on co-processing

2015-11-03

Perception Fact ReasonAbout 100 to 150 co‐processing trials of the waste materials will provide opportunity to demonstrate  safe co‐processing of  almost all types of hazardous & other wastes. 

False. There are >20,000 wastestreams that are successfully co‐processed in cement kilns globally.This will require as many trialswhich is unwieldy.

In the past 10 years, in India wehave been able to conduct trial ofonly 100 waste streams.

By granting co‐processing permission based on the demonstration trial of a waste stream, the environmentally sound disposal of that waste stream is always ensured.

False. The chemical composition ofthe mix material in the kiln alsodepends upon other inputmaterials entering the kiln alongwith the waste.

The resultant chemical compositionof the input material entering thekiln varies depending upon thecomposition of other input materialsfed along with the waste.

Mixture of two or more approved wastes can be considered as approved waste

False. The composition of thewaste mix of two or moreapproved waste materials will bedependent upon their proportionof mix.

The characteristics of the waste mixof two or more waste streams willbe completely different from oneanother depending upon theproportion of their mix.

© 2015 Geocycle2015-11-03

Assessment of approved co-processing trials conducted by ACC and ACL

• Waste Feed rates:

• Min – 1 TPD• Max – 72 TPD

Clinker Production:Min – 1200 TPDMax – 6940 TPD

Single waste trials – 20 Mixed waste trials - 12

Trials conducted

32

Waste streams

4411 No.

Different Kilns

No. of HW Categories

20

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Range of variation in the characteristics of the approved wastes(AS RECEIVED BASIS)

PARAMETER  MIN MAXMoisture (%) 0.60 67.4 Ash (%)  0.96 98.70VM (%) 0.3 94.9FC (%) 0.1 45.7Carbon 0.4 75.6Hydrogen 0.2 9.1Nitrogen 0 15.5Sulphur 0.1 22Oxygen 0 76.3GCV (Kcal/Kg) 80 7960NCV (Kcal/Kg) 114.8 6042Mineral matter 3.5 34.5Chloride as Cl (mg/kg) 0 14200Fluoride as F (mg/kg) 0 20.1

PARAMETER  MIN MAXCadmium (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 MAXVOC (mg/kg) 4.20 207.0 SVOC (mg/kg) BDL 0.2 PCB (mg/kg)  0.00 0.5 PCP (mg/Kg)  BDL 1.4 TOC (%) 0.00 66.0 

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Range of variation in the characteristics of the approved wastes(ON CLINKER BASIS)

Parameter Min MaxAsh (gm/T) 1.4 4,738 Fixed Carbon (gm/T) 0.2 6,093 Chloride as Cl (mg/T) 0.2 85,491 Fluoride as F (mg/T) 0.0 264 Cadmium (mg/T) 0.0 10 Chromium (mg/T) 0.1 78,256 Copper (mg/T) 0.0 28,885 Cobalt (mg/T)  0.0 2,353 Manganese (mg/T) 0.2 23,500 Nickel (mg/T) 0.1 21,500 Lead (mg/T) 0.0 2,128 

Parameter Min MaxZinc (mg/T) 0.0 47,500 Arsenic (mg/T) 0.0 56 Mercury (mg/T) 0.0 17 Selenium (mg/T) 0.0 28 Antimony (mg/T) 0.0 36 Vanadium (mg/T) 0.1 284,280 Thallium (mg/T) 0.0 6 Tin (mg/T) 0.0 416 PCB (mg/T) 0.0 2 PCP (mg/T) 0.0 4 TOC (mg/T) 0.0 3,027,200 

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• The approved wastes had large variations in their characteristics

• It is not necessary for wastes to have similar characteristics for environmentally sound co-processing

• Mixing of two or more waste streams is requirement for making a uniform quality material for utilisation of wastes as AFRs.

• A mix of two or more approved waste streams does not produce a waste having approved waste characteristics.

• Cement kilns have large capacity to deal with the variations in the characteristics of the wastes.

Conclusions!!

Hence, ‘similarity’ mandated in the waste characteristics and permitting based on demonstration trial is not a

relevant process at all.

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The desired Permitting Process

Waste stream based

Permitting Change to

Compliance based

Permitting

This will be a globally aligned Permitting process.

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• Compliance to the prescribed emission standards so that the environmental impact is monitored and controlled.

• Compliance to specified infrastructural requirements so that safe and environmentally sound management of wastes is ensured in the cement plants.

What kind of compliance?

This process is practical and substantially easy to monitor

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• Chapter I- Definition of Co-processing and Pre-processing

• Chapter II- Rule 10 : Utilization of hazardous and other wastes.-

The utilization of hazardous and other wastes as asupplementary resource or for energy recovery, or afterprocessing shall be carried out by the units only afterobtaining authorization in Form 1 from the State PollutionControl Board.

Desired changes in New Draft HWM Rules 2015

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(A) The hazardous and other wastes shall be utilized for pre-processing and/or co-processing and / or for resource recovery in authorized cement plants or units that fulfill the prequalification criteria prescribed in the guidelines issued by the Central Pollution Control Board from time to time.

(B) The hazardous and other waste qualified for use as a resource of energy or material as per the guidelines issued by CPCB from time to time, shall not be disposed of by incineration or land filling.

• Modifications of Form 1, Form 2 and Form 3 to include pre-processing, co-processing and resource recovery facilities

Desired changes in Rule 10 of HWM Rules 2015 (Contd.)

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Compliant Infra-

structure

Characterization

Transportation

Storage

Handling

Pre-processing

Emission monitoring

To ensure

Environmentallysafe management

ofwastes

Compliant Infrastructure

Infrastructure in cement plants / pre-processing plants needs to be compliant to New HWM Rules 2015 / Revised co-processing guidelines

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Compliant Emissions

Raw Mix

Fuel

Waste / AFR

HCl, HF, TOC, HM, D/F (Off-line)

(Once a year)

Cement kiln emissions need to be within prescribed limits notified by MoEFCC from time to time

SPM, NOx, SOx, (On-line)

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• To include co-processing as a preferred option for management of Hazardous and other wastes in Hazardous & Other Waste (Management and Transboundary Movement) Rules 2015.

• To notify prescribed emission standards for co-processing kilns with monitoring protocol.

• To revise guidelines on co-processing in Cement /Power / Steel Industries published by CPCB in Feb 2010 to include compliant infrastructure and emission standards based permitting system.

• To address the permitting system for undertaking pre-processingof wastes by cement plants or the waste management companies in the revised guidelines on co-processing.

• To address co-processing of wastes in other Resource Intensive Industries (RII) in the revised guidelines on co-processing.

Recommendations

2015-11-03

….Strive for a ZERO Waste Future