Co-processing in Cement kilns
The way to treat wastes
Jean-Pierre Degré
Cementis
May 2013
CEMENTIS
Consulting
Jean-Pierre Degré ([email protected])
Chemist & Geologist Engineer, 41 years experience with Holcim.
> September 2011: Partner Cementis… (www.cementis.com)
1997 – 2011 : Senior Vice-President – Head of the Alternatives Resources Division
Holcim Group Support
In charge of the worldwide “Wastes to Resources” strategy
For Holcim, Co-processing business Implementation in more than 40 countries
At the base of the worldwide development and recognition of the co-processing
concept: using wastes as Alternatives Resources in Resource’s Intensives
Industries
Board Chairman for the GIZ-Holcim strategic alliance (2003-2009)
Introduction of the “Co-processing” concept at the COP 9 Bali – June 2008 which
was driving to the UN/SBC Co-processing guidelines.
Expert in the development of low/neutral CO2 cementitious binders production
CEMENTIS
Consulting
Current wastes management practices leave a substantial
part of the resource potential of waste unused
none ferrous industry 5% cement industry 6%
none met. industry 14%
chemical industry 25%
Example: EU
paper & pulp 16%
Energy consumption (EU25)
steel industry 34%
600
500
Energy consumption EII (energy intensive industries)
[Mtoe]
400 302
Energy from waste
300 Potential energy from waste excluding
200 waste that can be recycled
100 215
149 225 248 Theoretical energy from waste including
0 waste that can be recycled
AY2010 E2010 E2030 E2030
Estimates indicate that world-wide >> 10 billion tons of waste are discarded
each year. Despite all the efforts to minimize waste, more than 80% is
currently landfilled, dumped or burned illegally…
More clear overview needed for Latam countries
CEMENTIS
Consulting
Co-processing to be positioned in the Waste Management Hierarchy as a
combined option to recover mineral and organic parts of the wastes
Avoidance & Reduction
Reuse
Recovery
Main drivers: 100 % material recovery
- Life Cycle Assessment
- Decision tree process Co-processing
100 % Energy recovery
Recovery
Disposal Incineration / co-incineration with energy recovery
Landfilling
CEMENTIS
Consulting
Examples of AFRs and hazardous wastes co-processed ….
In 2010: more than 20 mio tons in the Cement Industry
Austria Czech Republic
Canada
Slovakia
Haz liqs, solids, tyres, sewage sludge, animal meal and
Tires, haz liq fuels, solids and Russia
Germany alternative raw materials
alternative raw material Switzerland
Estonia
Netherlands Croatia
Hungary Pesticides
Belgium Rumania
Bulgaria Azerbaijan
USA Tires,France
liquids and Macedonia
Italy Uzbekistan
Haz Liquids and oils
solids
Spain China
Tires and haz liquids Dominican Republic Vietnam
Morocco
Thailand
Mexico Caribbean
Guatemala Haiti Cambodia
Venezuela
Lebanon India Philippines
Honduras Guinea
Pesticide contaminated Cyprus Malaysia
El Salvador Greece
soil
Nicaragua Ivory Coast Sri Lanka Singapore
Nigeria
Egypt Haz liquids including
Costa Rica New Caledonia
Colombia Burkina Faso pesticides
Fiji
Ecuador Peru Guayana
La Reunion
Liquids haz waste Madagascar
Brazil South Africa New Zealand
Tanzania
Chile Australia
Genetically modified agri
Argentina
products Oil, liqs
CEMENTIS
Consulting
Examples of Waste used for Co-processing in Cement kilns
(pop’s related wastes in red )
As Alternatives Fuels Non-exhaustive lists
Diaper trimmings Paint wastes
Expired & contaminated seeds Used oil & grease
Damaged beans Scrap tyres
Plastics Wood chips
Expired products Solvents
Expired food/ health products Carbon fines
Packaging materials Oil filter fluffs
Rubber wastes Coking wastes
Textile waste Shipping wastes
Refinery wastes RDF fluff & pellets
Bleaching earth Surfactants
Herbicides Pharmaceuticals
Insecticides Sorted municipal solid waste
Pesticides Contaminated solids, liquids & sludge's
PCB’s
As Alternatives Raw materials
Lime sludge from water treatment Filter cake
Fly ash & bottom ash from power plants Synthetic gypsum from sulfur scrubbers
Mill scale Refinery catalyst
Blasting grit Calcium fluoride from circuit boards
Diatomaceous earth Foundry sand
Aluminum production waste Contaminated soils (with pop’s or other
organic’s)
CEMENTIS
Consulting
POP’s…..What‘s the issue?
Googling „obsolete pesticides“ gives the answer
>500‘000 tons of Obsolete Pesticides (OPs) are
stockpiled throughout many third world countries.
In 2001, the pop’s Stockholm convention was
considering Cement kiln as a potential source for D/F
emissions if using hazardous wastes as fuels….
Between 2003 until now, a set of official trial burns has
been done and published to prove the full efficiency
of the Cement process to treat POP’s …
So: Cement kilns are now fully recognized by
international institutions (Basel Convention, UNEP,
UNIDO) as a suitable option for POPs treatment
Sri-Lanka…. pure pyralene oil with 56-62% of PCBs Treatment of pesticides in Australia …
10,000 liters of mixture co-processed at 2 feed rates
under well controlled process conditions
Accredited 3rd party monitors
emissions and samples all materials
Results
DRE > 99.9999%
Emissions unaffected
by PCB
CEMENTIS
External report available
38 34
Holcim Group Support Holcim co-processing experience 17.10.2012/LDS Holcim Group Support Holcim co-processing experience 26.05.2009/LDS
Consulting
Wastes Co-processing: LCA and External Audits
NO COMPROMISE Hazardous and Non-hazardous
On Health and Safety For pop’s: DRE & Certification
Employee Chemical Health and Occupational Safety model to be developed
External auditing systems requested
On Environment
EMR: Emission monitoring, compliance and reporting systems
ERT: Emission reduction target
On product quality
End-products criteria’s (mortar & concrete) fixed to be used in any case for
drinking water applications
End-of life products recyclability
On production process control and efficiency
Total QC systems on place – wastes-to-AFR & co-processing total traceability
Pre-processing activities
Cement production processes improved to handle LGR
CEMENTIS
Consulting
Generic Structure of a Co-processing development.
Company / plant level
Projects
Vision
Process factors Wastes markets Legal frame
Foundations
CEMENTIS
Consulting
Co-Processing: a WIN – WIN – WIN solution….
For Resources preservation and Environment protection
Part of the local / National wastes management strategies
Global reduction of CO2 and other pollutants
Optimizing the resources management preserving fossils fuels and natural resources
For the RII’s and more particularly: the Cement sector
Keeping and improving competitivity
Improving independence, right to operate and business sustainability
Enlarging the end-product portfolio with the production of Cementitious at low or 0
environment footprint impact
For the local Authorities and Collectivities
Developing local competences and local solutions including for highly hazardous wastes
Improve Environment capacity building and understanding
THANK YOU
CEMENTIS
Consulting
