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AFR Utilization in ACC - 2014

GO Green

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Karthikeyan Jagannathan
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132 views11 pages

AFR Utilization in ACC - 2014

GO Green

Uploaded by

Karthikeyan Jagannathan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Waste Co-processing in Cement Kilns

A demonstrated solution for managing wastes in an


Environmentally sound and Ecologically sustaining manner

Ulhas Parlikar
Director – Geocycle Business
© 2012 Holcim/Switzerland

Growth, Waste & Environment :

Population

Economy

© 2012 Holcim/Switzerland, July 12, 2012 2

1
How much waste is getting treated
• Hazardous Waste (Land fillable)
• Landfill capacity - 1.50 Million Tonnes /year
• Generation - 2.73 Million Tonnes/ year.

• Hazardous Waste (Incinerable)


• Landfill capacity - 327705 TPA
• Generation - 415794 TPA

• Industrial Waste (Non Hazardous)


• Generation - ??????? TPA
• Treatment capacity - ?????????

• Municipal Solid Waste


• Generation – >40 Million TPA

ALMOST EVERY THING THAT WE GENERATE!!!!!!!!!!!!!!!

3 © 2012 Holcim/Switzerland, July 12, 2012

What does it mean????????????

• We are not able to conserve about 8-10 Million TPA of Coal.


• We are not able to conserve about 8-10 million TPA of natural
resources such as lime, iron, silica, alumina etc.
• We are not able to provide an ecologically sustaining solution for
management of different kinds of wastes.
• We are resorting to disposal options that locks up precious land for
any further use, makes us spend large amount of expensive fuels
and whose cost of implementation keeps on increasing with time.
• Government, Waste generator and Solution provider carry large
amount of liability towards refurbishment of damage to the landfill.
• High level of carbon footprint on account of increase in the GHG
emissions.
• Ever increasing backyard volumes and associated environmental
hazards

4 © 2012 Holcim/Switzerland, July 12, 2012

2
Is there a workable alternative???

Avoid

Reduce, Recycle and Recover

Co-processing

Incineration
& Landfill

Dumping

5 © 2012 Holcim/Switzerland, July 12, 2012

Co-processing Addressing Sustainability Issues

 Decreases (largely) the costs of waste


management
 Regional job creation in waste collection and
pretreatment etc.
 Zero-emission technology
 Leads to fewer landfills and reduces pollution
caused by dumping
 Reduces greenhouse-gas emissions, thereby
fighting global warming
 Reduces the environmental impact of extraction
(mining/quarrying), transporting and processing
of raw material
 Conserves natural (non-renewable) energy and
material resources

© 2012 Holcim/Switzerland, July 12, 2012

3
Mechanism of Waste Management Through Co-
processing In Cement Kiln

The organic constituents are completely destroyed due to


 high temperatures,
 long residence time and
 oxidizing conditions in the cement kiln.
Acid gases such as HCL and SO2 are absorbed and
neutralized by the freshly formed lime and other alkaline
materials within the kiln.
The inorganic constituents react with the raw materials
while heavy metal becomes immobilized in clinker matrix

© 2012 Holcim/Switzerland, July 12, 2012

Geocycle: Exploring a greener waste management


pathway through cement kilns
• Geocycle is an environmental management initiative of Holcim
• It was recognized that the challenge of increasing waste volumes on
one hand and fast depletion of natural resources on the other hand can
be addressed through innovative green thinking of co processing
wastes as Alternative Fuels and Raw materials in the cement kilns
• ACC Limited and Ambuja Cement Ltd. are the two group companies
of Holcim. They have taken up this Geocycle initiative in the country for
providing waste management solutions for achieving green transition in
our economic development
• This initiative solves a growing problem of waste management by
encouraging the philosophy of industrial ecology.
• Wastes from industries or society which would otherwise have been
disposed through, dumping, land filling or incineration without any
resource/energy recovery are safely co-processed in our cement kilns.
WASTE RESOURCE

8 © 2012 Holcim/Switzerland, July 12, 2012

4
Geocycle India : Initiatives for Safe Waste Co-processing
Collection of
Establishment safety data and
of Laboratories preparation of
& facilities for relevant safety
assessing co documents for all
process ability wastes co-processed
and acceptability
of wastes

Waste Pre -
processing Processe
d Waste

Designing safety in
operations with required
precautions during waste
transportation, use of right
PPEs , relevant safety
trainings to personnel Implementation of Pre-processing platforms
handling waste

© 2012 Holcim/Switzerland, July 12, 2012

Emission concerns during Co processing

• Emission results of ten co processing trials are


evaluated.
• CPCB defined Trial protocol was used for emission
monitoring. (Pre processing – 1 day, Co processing – 3
days, Post co processing – 1 day).
• Emissions monitored – Particulate matter, SOx, NOx,
HCl, HF, TOC, Heavy Metals, Dioxin / Furans
• Emission monitoring from the cement kiln stack was
carried out by two CPCB approved agencies.
• Seven different types of waste streams were used
representing five industrial sectors – Engineering, Steel,
Chemicals, FMCG & Pharma
• Trials carried out in five different Cement plants.

10 © 2012 Holcim/Switzerland, July 12, 2012

5
Particulate Matter

11 © 2012 Holcim/Switzerland, July 12, 2012

SOX, Nox, HCL & HF

12 © 2012 Holcim/Switzerland, July 12, 2012

6
Heavy Metals and TOC

13 © 2012 Holcim/Switzerland, July 12, 2012

Dioxin/Furan

14 © 2012 Holcim/Switzerland, July 12, 2012

7
Illustrative Examples of wastes co processed

Sludges

Expired Acid tar deposit


FMCG products

Plastic waste
Organic residue

Recalled toys

© 2012 Holcim/Switzerland, July 12, 2012

Journey so far

5.0 • More than 5 Lakhs ton of


4.4
4.5 TSR AFR utilized
4.0 • More than 1400 industries
3.5 mapped
3.0
• More than 2000 waste
2.5 2.2 streams evaluated for co
2.0
1.6
processing acceptance.
1.5 • 125 long term agreements
1.0 signed
0.5
• 126 streams are introduced
0.0 for co-processing.
2011 2012 2013 YTD Oct

© 2012 Holcim/Switzerland, July 12, 2012

8
Communication
Stake Holder Engagement

• Total of eight stakeholder meets organized in association with CPCB and


respective SPCBs
• More than 150 awareness presentations made in different forums.

© 2012 Holcim/Switzerland, July 12, 2012

Volumes Co processed

18 © 2012 Holcim/Switzerland, July 12, 2012

9
Different Wastes Preprocessed to AFR

Saw Dust Municipal waste Paint Sludge

Plastics

Tyres
Final Product

© 2012 Holcim/Switzerland, July 12, 2012 19

Pre-processing Platforms under implementation

• ACC
• Wadi
• Kymore
• Madukkarai
• ACL
• Ambujanagar
• Rabriyawas
• Maratha
• Bhatapara

20 © 2012 Holcim/Switzerland, July 12, 2012

10
Co-processing of wastes shall surely go a long
way in turning cement from Grey to Green in
the Indian Cement industry.

21 © 2012 Holcim/Switzerland, July 12, 2012

11

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