through Cement Kiln Coprocessing 20160414 Ulhas Parlikar Dy Head Geocycle India ACC Limited About Geocycle Geocycle is the global waste management brand of LafargeHolcim ID: 1044937
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1. Environmentally Sound Management of Plastics Wastes through Cement Kiln Co-processing 2016-04-14Ulhas ParlikarDy Head, Geocycle IndiaACC Limited
2. About GeocycleGeocycle is the global waste management brand of LafargeHolcim. LafargeHolcim is the promoter of both ACC Limited (ACC) & Ambuja Cements Ltd. (ACL)ACC & ACL extend cement kiln co-processing solution for environmentally sound management of wastes under this brand.Wastes from Industrial, Municipal & Agricultural sources are managed through co-processing For a zero-waste future
3. Cement Industry & Circular EconomyAmmonium Sulphate Fertilizer PlantSteel PlantThermal Power PlantMarble Processing PlantCaCO3 SlurryGBF SlagMarble SlurryFly AshCEMENT1950196020101990
4. 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 resource intensive industries to replace natural mineral resources (material recycling) and fossil fuels such as coal, petroleum and gas (energy recovery) by wastes….Benefit of co-processing are………Provides a permanent solution to waste Reduces emissions and greenhouse gasesLessens reliance on fossil fuels Preserves natural resourcesProvides opportunity to achieve Zero Waste Future
5. Co-processing completely utilises the resource value present in wastes 2016-04-145Raw Materials(Ca, Fe, Al, Si)CoalWastesas AFRs(IMAP)Wastesas AFRs(IMAP)Wastesas AFRs(IMAP)CoalClinkerCementGypsumFly AshPhospho-GypsumSlagAcidic EmissionsXXXXHeavy MetalsDioxin / FuransLeachability XAsh treatment
6. Co-processing Promotes Circular Economy & Sustainability IncinerationCoprocessing100% Material Recovery100% Energy RecoveryPrevention / ReductionReuseRecyclingWaste to EnergyLand fillingBeneficial use of Material and EnergyWaste Disposal
7. Waste Pre -Processing Processed WasteWastes need to be Pre-processed to produce uniform quality AFRs required in Cement manufacture
8. Well laid out approach for gainfully utilising wastes1Waste assessmentWe can provide a complete survey of your waste and a full assessment of its suitability for co-processing.2Waste analysisWe offer dedicated laboratory testing to analyze your waste to ensure it is suitable. We at Geocycle are able to manage waste such as solids, sludge and liquids3Waste transportationWe provide a seamless service – ensuring the waste is transported in appropriate packaging with required labelling and documentation. The waste is carried by operators with required skills, qualifications and permits.4Pre-processingFurther analysis of waste is conducted in our laboratories if required. We have extensive facilities to blend liquids, shred solid materials and homogenise waste prior to its usage in kilns. 5Co-processingWaste is then safely co-processed in cement kilns. Our cement kilns operate at temperatures of up to 2000°C – which leaves no residue or waste after co-processing is complete.
9. Is co-processing a proven technology in India?There have been >90 co-processing trials in India in different cement plants across the country. Materials included:Simple Plastics to complex ODS>40 different Haz waste categoriesWaste mix of different kindsLarge variation in physico-chemical characteristics All these trials confirmed that wastes do not impact the cement kiln emissions
10. How much waste can be co-processed in the cement kilns?
11. ICPE + ACC together conducted the co-processing trial for use of plastics as AFR in cement kiln in March 2008 Objective was to demonstrate suitability of cement kiln for environmentally sound and ecologically sustaining management of plastic wastes in cement kilnsTrial was conducted with the approval of CPCB and MPPCBDr. B. Sengupta – Ex Member Secretary, CPCB and Prof. S. P Gautam, Chairman, MPPCB provided the guidance and support.Plastic waste consisted of a mix of PE, PBT, PET, PP & PSEmission monitoring and product evaluations were carried out by SGS Ltd.Dioxin / Furan evaluation was carried out in the Belgium facility of SGS CPCB approved protocol was utilised in the co-processing trialCement Kiln Co-processing of Plastic Wastes 2016-04-1411
12. CPCB evaluated the results of the emission monitoring and also the product quality.These results were confirmed that plastic co-processing did not influence the emissions or the product quality.CPCB advised State Pollution Control Boards to encourage management of plastics in the cement plants.With the collaborative efforts of the various State Pollution Control Boards, several cement plants initiated co-processing of segregated plastic wastes from the Municipal sources in their cement kilns.Co-processing of plastic wastes was initiated on larger scales in Gujarat State where it gets generated on very large scales from the paper recycling industry Co-processing trial results and its impact2016-04-1412
13. Geocycle collaborated with several ULBs to manage the segregated plastic waste generated at their end. ShimlaBaddiJabalpurKatniMadukkaraiPanjim & other parts of GoaBangalore etc.Geocycle manages large quantum plastic wastes from paper recycling industries in Gujarat and other states. Circuit Bench at Shimla of National Green Tribunal approved the co-processing option for management of plastic waste in 2014 and advised its implementation in HP.Segregation of Plastics from MSW and its management2016-04-1413
14. Co-processing of plastic wastes and other non-recyclable Combustible Fractions (SCF) from MSW2016-04-141414Recyclable PlasticsSegregated Combustible Fraction (SCF)Composting/RDF/BiomethantionKitchen waste/organicsGlassMetalsMSWConstruction and Demolition wasteRecyclingRDF / Co-processing / WTEInert Material Land fillMulti layered packaging, Rexene, leather, rubber, tyre pieces, contaminated plastics, contaminated paper, contaminated cloth, Thermocol, wood pieces, etc.
15. Zero waste through co-processing15..\MK G&C\Clean & Green Madukkarai 3min.mp4 Madukkarai Model 1.Goa Model 2.Vengurla Model3.Swatch Bharat Team has already made video films on these models and uploaded on You TubeSegregation, efficiency and specifications are key.
16. 16Madukkarai townFew Wards of CoimbatoreSeveral Municipalities in Himachal PradeshPanjim & other locations from Goa Hyderabad Municipal CorporationChennai Municipal Corporation, Jaipur Municipal CorporationKatni Municipal Corporation, Jabalpur Municipal CorporationBangalore Municipal CorporationVaranasi Municipal CorporationRaipur Municipal CorporationManagement of Plastic waste with other non-recyclable combustible wastes from MSW is more appropriate solutionReclamation of land by remediating existing MSW dump yards and management of excavated SCF through co-processing is becoming a workable option
17. ThanksWe are very grateful to you!!!