FICEM-APCAC 1ER FORO DE CO-PROCESAMIENTOficem.org/CIC-descargas/belgica/Co-processing-of...FACTS & FIGURES ON EU WASTE MGMT •Huge potential of reducing disposal and increasing the

1

CO-PROCESSING OF WASTE IN

CEMENT PLANTS

- THE EUROPEAN EXPERIENCE -

Vagner Maringolo - CEMBUREAU Issues Manager

FICEM-APCAC

1ER FORO DE CO-PROCESAMIENTO

21 July 2010 – Coral Gables

CEMBUREAU

2FICEM 1st Forum on Co-processing 21 Jul 10

FULL MEMBERS

AUSTRIA, BELGIUM, BULGAR

IA, CZECH

REPUBLIC, DENMARK, ESTO

NIA, FINLAND, FRANCE, GER

MANY, GREECE, HUNGARY, IR

ELAND, ITALY, LATVIA, LITHU

ANIA, LUXEMBOURG, NETHE

RLANDS, NORWAY, POLAND,

PORTUGAL, ROMANIA, SLOV

ENIA, SPAIN, SWEDEN, SWITZ

ERLAND, TURKEY, UNITED

KINGDOM

ASSOCIATE MEMBER

CROATIA

N

PL

CH

S

FIN

UK

IRL

EP I

F

BL

NLD

GR TR

A

CZ

ROH

EST

DK LV

SIHR

BG

LT


EMPLOYEES IN THE EU CEMENT INDUSTRY


Africa4,6%

China54,2%

Japan1,8%

India6,2%

Others Asia13,4%

Oceania0,4%

CEMBUREAU8,6%

Others Europe*0,4%

CIS2,5%

Other America5,5%

USA2,4%

3 billion tonnes

WORLD CEMENT PRODUCTION - 2009

* Including EU27 countries not members of CEMBUREAU5FICEM 1st Forum on Co-processing 21 Jul 10

262 Mt

600

530

403

534

390

189

252325 310

321

413

599

137

164

1005

321 332402

580

377

585625

208

601551

154

0

200

400

600

800

1000

1200

CONSUMPTION IN CEMBUREAU COUNTRIES

Note: Denmark and Greece n.a.

2009 (kg/per capita)


EU ENVIRONMENTAL REGULATIONS

(1990 – 2009)

1944

6492

125147

180

220

258

315

377

427

501534 547

562577 589

608624

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009


CO-PROCESSING OF WASTE IN

CEMENT PLANTS

- THE EUROPEAN EXPERIENCE -


CO-PROCESSING – THE EU EXPERIENCE

• Waste management in the European Union (EU)

• Co-processing regulation framework

• Thermal energy efficiency

• Use of alternative fuels and biomass

• Co-processing: lever to reduce CO2 emissions

• Barriers to co-processing

• Communicating on co-processing

• Final remarks

FICEM 1st Forum on Co-processing 21 Jul 10 9

WASTE MANAGEMENT IN THE EU



WASTE FRAMEWORK DIRECTIVE



THE WASTE HIERARCHY


FACTS & FIGURES ON EU WASTE MGMT

• Huge potential of reducing disposal and increasing the use of

waste as a resource

Total EU-27 waste generation: 3 billion tonnes/year 6

tonnes/person/year

More than 50% disposed

Less than 50% recovered (recycling + energy recovery)


CASE LAW: CO-PROCESSING AS RECOVERY

• Various aspects of co-processing fall within different legal definitions in Annex

II of the Framework Directive on Waste 75/442/EEC of 15 July 1975

One of the key criteria used in relation to fuel or other measures to

generate energy (R1) is the calorific value of waste

• A ruling delivered by the European Court of Justice on the law case C-228/00

(European Commission vs. Germany 13/2/03) holds that using waste as fuel

in cement kilns should be classified as recovery, while burning

municipal waste in dedicated incinerators, even with energy recovery,

should be classified as disposal

• “The calorific value of the waste is not a relevant criterion for the purpose of

establishing whether an operation involving the combustion of waste is a

recovery operation.”


THE WASTE HIERARCHY


END-OF-WASTE

• The Waste Framework Directive opens the door to the lifting of

the waste status of some waste streams, e.g. used tyres, prior

to the completion of the recovery operation

• CEMBUREAU actions

Build own cement industry’s proposal on the end-of-waste criteria

for used tyres

Aim at limiting as much as possible the declassification of used

tyres


LANDFILL DIRECTIVE



THE LANDFILL DIRECTIVE

• Aims at preventing or reducing...

Negative effects on the environment and global environment

– Surface water, groundwater; soil and air, greenhouse effect

Risks to human health

... from the landfilling of waste, during the whole life-cycle of the

landfill

• Sets up provisions covering location of landfills and technical

and engineering requirements

Water control and leachate management, protection of soil and

water, and methane emissions control


TARGETS IN EU WASTE

LEGISLATION



TARGETS IN EU WASTE LEGISLATION


EU CO-PROCESSING

REGULATION FRAMEWORK



PRINCIPLE

CO-PROCESSING REGULATION FRAMEWORK


BAT


BREF

• The Best Available Technique Reference

document (BREF) is the outcome of a

process of information exchange between

the main stakeholders for each major

industrial sector

• The BREFs are intended to give guidance to

regulators on each sector and its emissions,

what can be considered as BAT for the

sector, the levels of pollution abatement

achievable, the cross-media implications,

energy use, costs, etc.

• 2nd Cement, Lime and MgO BREF

published on 25 June 2010 in the Official

Journal of the European Union

• Co-processing of waste in the cement

industry is covered by the Cement BREF


OVERVIEW



OVERVIEW

• Recast: Integrated Pollution Prevention and Control (IPPC)

Directive 2008/1/EC + Waste Incineration Directive (WID)

2000/76/EC + 5 other directives

• Industrial Emissions Directive (IED) (entry into force 2012)

– Integrated approach

– Strengthen application of BAT/BREF

– Better implementation (inspections, permit review)

– Stricter emission limit values (ELVs) and monitoring (“minimum

requirements”)


INDUSTRIAL EMISSIONS

DIRECTIVE – IED



INDUSTRIAL EMISSIONS DIRECTIVE

• Annex I: Categories of activities

3.1. (a) Production of cement clinker in rotary kilns with a

production capacity exceeding 500 tonnes per day...

5.2. Disposal or recovery of waste in waste incineration plants or in

waste co-incineration plants:

– (a) for non-hazardous waste with a capacity exceeding 3 tonnes/hour

– (b) for hazardous waste with a capacity exceeding 10 tonnes/day


INDUSTRIAL EMISSIONS DIRECTIVE

• Chapter IV - Special provisions for waste incineration and co-

incineration plants

• Annex VI - Technical provisions relating to waste incineration

and co-incineration plants

Part 4 Determination of air emission limit values for the co-

incineration of waste

2. Special provisions for cement kilns co-incinerating waste

– “Minimum” ELVs remain the same as under the Waste Incineration

Directive, except Lepol kilns and long rotary kilns co-incinerating waste:

NOx not more than 800mg/Nm³ until 2016

• If more than 40% of the heat release comes from hazardous

waste, or the plant co-incinerates untreated mixed municipal

waste, the ELVs for dedicated incinerators apply


THERMAL ENERGY EFFICIENCY

IN THE EU CEMENT INDUSTRY



EU CLINKER PRODUCTION BY TECHNOLOGY


REDUCTION OF SPECIFIC ENERGY

32

3 500

4 000

4 500

5 000

5 500

6 000

1960 1965 1970 1975 1980 1985 1990 1995 2000 2005

Fu

el E

nerg

y i

n k

J/k

g c

lin

kerDevelopment of the

specific fuel energy

consumption in

CEMBUREAU countries

since 1960

So

urc

e:

CE

MB

UR

EA

U E

L D

ec

em

be

r 0

7

FICEM 1st Forum on Co-processing 21 Jul 10

EU 27 THERMAL ENERGY/TONNE CLINKER


POTENTIAL FOR ENERGY CONSUMPTION REDUCTION

Remaining potential for specific energy consumption

reduction through technological innovation and

process improvement

LESS THAN 2%!


USE OF ALTERNATIVE FUELS

AND BIOMASS IN THE EU CEMENT

INDUSTRY



EU FUEL MIX


Energy Consumption - 2006 -(Average CEMBUREAU countries Members of EU)

Coal & Petcoke

15.9%

Fuel Oil

2.0%

Alternative Fuels*

17.8%

Coal

19.0%

Petcoke

38.4%

Lignite/Shale/Schiste

4.8%

HVFO

1.1%

Gas

1.0%

© CEMBUREAU EL 5 March 2008

* Eight countries consumed betw een 25% & 90% of alternative fuels

CEMBUREAU database

ALTERNATIVE FOSSIL / BIOMASS FUELS


Alternative fuels used in cement kilns - 2006(Average CEMBUREAU countries EU Member)

1.8%

0.6%

8.1%

18.5%

12.4%

1.5%7.6%1.7%

15.1%

1.5%2.4%

13.3%

4.4%

11.1%

Wood, paper, cardboard

Textiles

Plastics

RDF

Rubber/Tyres

Industrial sludges

Municipal Sewage sludges

Animal meal, fats

Coal/Carbon Waste

Agricultural waste

Solid alternative fuels (impregnated

saw dust)

Solvents and related waste

Oil and oily waste

Others

© CEMBUREAU EL 5 March 2008

38

THE EUROPEAN CEMENT INDUSTRY RECOVERS THE

LARGEST VOLUMES OF WASTE

Absolute volumes of alternative fossil fuels

1'121

3'746

4'369

0

1000

2000

3000

4000

5000

6000

7000

8000

1990 2000 2005

Th

ou

san

d t

on

s o

f a

lte

rna

tiv

e f

os

sil

fu

els

Da

ta f

rom

th

e C

SI “G

ett

ing

th

e N

um

bers

Rig

ht”

sys

tem


Absolute volumes of biomass

66

535

2'121

0

500

1000

1500

2000

2500

3000

3500

4000

4500

1990 2000 2005

Th

ou

san

d t

on

s o

f b

iom

ass

North America

Latin America

Japan Aus NZ

Europe

CIS

Asia

Africa + ME

39

THE EUROPEAN CEMENT INDUSTRY RECOVERS THE

LARGEST VOLUMES OF BIOMASS

Absolute volumes of biomass

66

535

2'121

0

500

1000

1500

2000

2500

3000

3500

4000

4500

1990 2000 2005

Th

ou

san

d t

on

s o

f b

iom

ass

North America

Latin America

Japan Aus NZ

Europe

CIS

Asia

Africa + ME

Da

ta f

rom

th

e C

SI “G

ett

ing

th

e N

um

bers

Rig

ht”

sys

tem


CO-PROCESSING: LEVER TO

REDUCE CO2 EMISSIONS



41

WASTE & BIOMASS IN CEMENT PROCESS REDUCE ABSOLUTE EMISSIONS

CO2 CO2

CO2Emissions

Waste

IncineratorCement plant+ Cement plant

Waste incineration &

cement manufacturing

Waste used as alternative fuel

in cement manufacturing

Waste Fossil Fuels Waste Fossil

FuelsResources

Cement CementProducts


42

SOLID WASTE IN CEMENT PROCESS (B) PREVENTS METHANE

EMISSIONS FROM LANDFILL (A)

Landfill without flare + Cement plant Cement plant

Fossil fuel Fossil fuelWaste

CO2

MethaneGWP 21 CO2eq

Waste

CO2

B)

CO2CO2

Resourcescarbon content

Cement CementProductsLandfill &

Leachate

Emissions

Waste landfilling &

cement manufacturingWaste used as alternative fuel

in cement manufacturingA)

FICEM 1st Forum on Co-processing 21 Jul 10GWP = Global Warming Potential

CO2 FROM ALTERNATIVE FUELS & BIOMASS

• Alternative fuels include fossil-fuel based fractions, such as

waste tyres, waste oil and plastics, and biomass fractions, such

as waste wood, sewage sludge and animal meal

• CO2 from biomass fuels is considered climate-neutral, because

emissions can be compensated by regrowth of biomass in the

short term

• CO2 from fossil fuel-derived waste, in contrast, is not a priori

climate-neutral

For tyres, the share of biomass accepted at EU level is 27% (higher

factors accepted in some European countries, like Spain, 31%)

For Refuse-Derived Fuel the average biomass content is accepted

as 37,3%


CO-PROCESSING: CO2 AVOIDED

Year Substitution rate CO2 emissions avoided by

fossil fuels

1990 3% 1.6 Mt

2000 About 10.5% 5.5 Mt

2008 22% 12 Mt


LEVER: CARBON CAPTURE AND STORAGE

• A lot has been expected from this new technology in the EU

• Today, all capture technologies are far away from being

applicable to the clinker burning process

• However some capture technologies seem to be more

appropriate for the potential application at cement kilns than

others

• ecra - the European Cement Research Academy project is in

phase 3 out of 5, but still many questions need to be solved

Technical report on phases 1 and 2 available at http://www.ecra-

online.org/ecra/

• IEA Technology Roadmap on Carbon capture and storage, 2009


http://www.ecra-online.org/ecra/



LEVER: CLINKER SUBSTITUTION


Europe

substitutes

more than

25% of

clinker in

cement

production (WBCSD/CSI,

July 2010)

BARRIERS TO CO-PROCESSING

IN THE EU



REMAINING BARRIERS

• Member States, with a few exceptions, have shown a reluctance

to consider waste management as a high priority and have failed

to establish the proper policies

• At EU national level

No incentive schemes have been set up to develop waste collection

and sorting systems

No pressure is exercised to implement national waste management

plans where they exist

– e.g. Italy, Bulgaria, Romania, Greece are countries with poorly

developed national waste supply chain (same holds true for biomass)

In spite of the Landfill Directive, no appropriate measures are put in

place to prevent illegal landfilling and to reduce landfilling itself

Bioenergy Workshop – 12 -3-2009 48

NEW BARRIERS

• Various uncertainties surround access to biomass in the EU

EU policies

– Biomass Action Plan of the European Commission (Dec 2006)

• Biomass biomass for heating, electricity, biofuels for transport

– Renewables target (Mar 2007)

• EU target 20% of total energy consumption by renewables by 2020 use

of biomass fundamentally redirected

Increasing biomass price due to limited availability

If all the sectors, e.g. power, lime, cement, steel, ceramics, were to

consume the maximum biomass, there would not be enough

biomass to cover demand from all sectors, as resources are limited


COMMUNICATING ON

CO-PROCESSING



COMMUNICATION ACTIVITIES

• Sustainable Energy Campaign, 2009-11

A EU campaign to raise awareness and

change the landscape of energy

Use of waste as an alternative fuel as

one of the themes

CEMBUREAU a campaign associate

• Sustainable Energy Week, Feb 2009

Launch of new alternative fuels brochure

• European Energy Forum, Oct 2009

Diner debate at the European

Parliament

• Toolbox – Q&A

Overview of stakeholder questions and

harmonised answers

Fact sheets to help allay fears at local

level


FINAL REMARKS



KEY MEASURES FOR GROWTH

• CEMBUREAU has been strongly advocating EU institutions to

Take waste management seriously by improving collection and

sorting methods at the national level

End trade distortion created by EU policies in benefit of biofuels

industry and electric power

Put in place a well-functioning waste and biomass market to assure

a reliable, sustainable and sufficient supply


A WIN/WIN/WIN SITUATION


Ecology:

Environmentally sustainable

waste management and important saving

of natural resources

Society:

A long-term and sound solution

for the treatment of different types

of waste produced by

society

Industry:

A cost-effective substitution of

natural resources thereby improving competitiveness

Documents

FICEM-APCAC 1ER FORO DE CO-PROCESAMIENTOficem.org/CIC-descargas/belgica/Co-processing-of...FACTS & FIGURES ON EU WASTE MGMT •Huge potential of reducing disposal and increasing the