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STATUS OF CO-PROCESSING OF
WASTE IN CEMENT PLANTS AS PER
HAZARDOUS AND OTHER WASTES
MANAGEMENT RULES, 2016
Presented at 3rd International Conference on Alternate Fuels & Raw
Materials in Cement Industry – Towards Realising Swachh Bharat Dream
on 23rd & 24th March 2017 at New Delhi, India
Dr B Sengupta,Former Member Secretary,
Central Pollution Control [email protected]
“Co-processing” The use of suitable wastematerials in manufacturing processes for thepurpose of energy and/or resource recovery andresultant reduction in the use of conventionalfuels and/or raw materials through substitution.
CO-PROCESSING
» Environmental damage is getting out of control.
» Climate change is impacting us all.
» Communities are objecting to implementation oflandfills and incineration facilities for wastemanagement.
» Landfill is building liabilities for the business &society.
» Industries are shifting to Green procurementprocesses.
» Importing countries are demanding compliance tosustainable waste management practices.
» Promotes Circular Economy
» Reduces
˃ required number of landfills
˃ pollution caused by dumping
˃ greenhouse-gas emissions
˃ environmental impact of extraction through mining
˃ dependence on primary resource markets
˃ cost of production of Cement
» Mitigates Climate Change Impacts
» Conserves Energy and Material resources
» Involves highly organised industrial sector
CEMENT DEMAND IN 2024 AND
INPUTS REQUIREMENT
Particulars 2013-14 2023-24 (estimate)
Cement
production
360 MT/Annum 750 MT/Annum
Coal for kilns and
CPP
60 MT / Annum 156 MT/Annum
Limestone 380 MT/Annum 998 MT/Annum
Gypsum 12 MT/Annum 33 MT/Annum
Power 5100 MW 13300 MW
Source: CMA 2015
CO-PROCESSING OF WASTE IN CEMENT KILN
AGREEMENT IN INTERNATIONAL CONVENTION
Cement kiln co-processing technology is
accepted by Basel convention for disposal of
hazardous wastes
The cement kiln co-processing technology is
accepted by Montreal protocol for disposal of
POPs. Cement kiln co-processing of POPs,
hazardous and non hazardous wastes is
practiced widely and successfully in manycountries around the world
INITIATING POLICY REFORMS FOR
SUSTAINABLE WASTE MANAGEMENT
THROUGH CO-PROCESSING
Important Recommendations of Basel ConventionGuidelines :
1. The waste management hierarchy needs to be respected.
2. Additional emissions and negative impacts on human health
must be avoided
3. The quality of the cement must remain unchanged
4. Companies that co process must be qualified with appropriate
infrastructure.• Assure compliance with all laws and regulations
• Have good environmental and safety compliance records
• Have personnel, processes, and systems in place committed to
protecting the environment, health, and safety
• Safe and sound receiving, storage, processing and feeding of
hazardous wastes
• Systems for the provision and analysis of waste representativesamples should be in place Contd…
INITIATING POLICY REFORMS FOR
SUSTAINABLE WASTE MANAGEMENT
THROUGH CO-PROCESSING
Important Recommendations of Basel ConventionGuidelines :
5. For optimal performance , AFRs should be fed to the cement
kiln through appropriate feed points, in adequate proportions
and with proper waste quality and emission control systems.
6. Due to the heterogeneity of waste, pre-processing is required
to produce a relatively uniform waste stream for co-
processing in cement kilns. To be carried out in a purpose-
made facility, which may be located outside or inside the
cement plant
Alternative Fuels which can be used to increase
thermal substitution rate (TSR) in cement
industry
(use of CV of waste as fuel in cement kiln)
S. NO.
Fuel Calorific Value(kcal / kg)
1. RDF from Municipal Solid Waste 2800-3800
2. Used Tires 6700-7700
3. Hazardous Waste 4000-9500
4. Industrial Plastic Waste 4070-6620
5. Biomass 2500-3800
6. Slaughter House Waste 700-1400
7. Poultry Litter 2700-3800
8. Dried Sewage Sludge 1700-1900
Source : Holtech & CPCB
Alternative Raw Materials which can be
used as blending material
S.No. Alternative Raw Material Available Quantity in million tonnesper annum
1. Fly Ash (cement blending material) 200.0
2. Blast Furnace Slag from Steel Industry 10.0
3. Lime Sludge (Paper, Carbide, Sugar Industry Sludge)
4.5
4. Red Mud from Aluminum Industry 3.75
5. Foundry Sludge / Sand -
6. Chrome Sludge as mineraliser -
7. Lead Zinc Slag 0.5
8. Phosphate Chalk -
Source : Holtech
POTENTIAL AVAILABILITY OF WASTE FOR
CO-PROCESSING IN INDIA
A.Fuel
B. Alternate Raw Material
Hazardous Waste 0.65 MTA
Biomass 150 MTA
Used Tyre 0.83 MTA
Industrial Plastic Waste 0.20 MTA
RDF from MSW 6.88 MTA
Flyash 200 MTA
Blast Furnace Slag 10 MTA
Source : CPCB & Holtec
AVAILABILITY OF OTHER COMBUSTIBLE WASTE
Source: NCBM 2015
S.
No.
Name of fuel Availability Present disposal method
1. Paint sludge 48000 tonnes/ annum Incineration / secured landfill
2. ETP sludge 6.2 million tones / annum Dried ETP sludge are disposed
in landfill
3. Ink sludge 240 MT / annum Dried ETP sludge are disposed
in landfill
4. Refuse
Derived Fuel
---- ----
5. Groundnut
shell
---- Incineration / composting
6. Tire Derived
Fuel
90000 tonnes / annum Incineration
7. Pharmaceutic
al waste
0.33 MT / annum Co-processing
8. Spent wash
from distillery
---- ----
GENERAL PRINCIPLE FOR CO-PROCESSING
The important general principles in co-processing are :
1. Additional emissions and negative impacts on humanhealth must be avoided
2. The quality of the clinker/cement must remain unchanged.
3. Companies that co process must be qualified
• Assure compliance with all laws and regulations
• Have good environmental and safety compliancerecords
• Have personnel, processes, and systems in place
committed to protecting the environment, health, andsafety
• Be capable of controlling inputs to the productionprocess
Contd…
Requirements for undertaking co-processing are
1. Best available technology for air pollution prevention andcontrol with continuous emission monitoring
2. Exit gas conditioning/cooling and temperature less than200OC in control devices to prevent dioxin formation.
3. Adequate emergency and safety equipment andprocedures, and regular training
4. Safe and sound receiving, storage, processing andfeeding of hazardous wastes
5. The operator of the co-processing plant should develop a
waste evaluation procedure to assess health and safety of
workers and public, plant emissions, operations and
product quality, variables that should be considered when
selecting waste include:
(a) Kiln operation
(b) Emissions
(c) Clinker, cement and final product quality
AVAILABLE HAZARDOUS WASTE
WHICH CAN BE USED AS PARTIAL FUEL IN
CEMENT KILN
Organic residue from Pharmaceuticals and Pesticide industry
Spent solvent
Sludge from petrochemical / oil refinery
Slaughter House Waste
Waste Oil
Paint sludge
Effluent Treatment Plant Sludge
Spent Pot Lining from Aluminum Industry
Spent Carbon
1. Amendment of the Hazardous Waste Management Rules,1989, under the Environment Protection Act, 1986, toinclude co-processing in cement plants as a disposal option.
2. Preparation of technical guidelines for setting upenvironmentally sound pre-processing facilities to preparehomogenous waste mixes suitable for co-processing incement kilns.
3. Developing emission standards for co-processing alternatefuel and raw (AFR) material in cement kilns includinghazardous wastes.
4. Increasing the use of fly ash generated by coal based powerplants and refuse-derived fuels (RDF) in cement plants.
5. Developing guidelines for the transport and storage ofhazardous waste
List of White-papers prepared by Regulatory Forum
consisting of Member Secretaries of 5 SPCBs under
the Chairmanship of MS, GSPCB
HAZARDOUS AND OTHER WASTES
(MANAGEMENT AND
TRANSBOUNDARY MOVEMENT)
RULES, 2016
» For the management of hazardous and other waste,and occupier shall follow the following steps, namely:-
a) Prevention;
b) Minimization;
c) Reuse;
d) Recycling;
e) Recovery, utilisation including co-processing;
f) Safe disposal.
» Title of the Rules has been amended as Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016
» Major Amendments made in following areas
˃ Authorization / Renewal of authorization (introduced new forms, compliance verification report , Emergency Response Plans and undertaking for submitting bank guarantee)
˃ New Schedule-II for identification of HW
˃ Utilization of Hazardous waste includes Schedule IV wastes also.
˃ SoPs for recycling/utilization introduced
˃ Pass books applicable for all actual users
˃ Removal of Registration scheme
˃ Responsibilities of State Government
˃ Revised Import-Export provisions (Banned items 49 from 30; more clarity)
˃ Filing of Annual Reports by SPCBs & CPCB
» New Definitions added:
- Captive Treatment, storage and disposal facility
- Common Treatment, storage and disposal facility
- Co-processing
- Critical care medical equipment
- Pre-processing
- Utilisation
- Waste & byproduct
- Other waste
- More clarity in earlier definitions
» Waste management hierarchy has been introduced as follows:
- Prevention
- Minimization
- Reuse
- Recycling
- Recovery, utilisation including co-processing
- Safe disposal
» Department of Industry in the State or any other governmentagency - to earmark or allocate industrial space or shed forrecycling, pre-processing and other utilisation of hazardous orother waste in the existing and upcoming industrial park, estateand industrial clusters.
» Submit annual report to the Ministry of Environment, Forest andClimate Change on integrated plan for ensuring environmentallySound Management of Hazardous and other wastes.
» Department of Labour in the State or any other government agency shall ensure the following in respect of workers involved in recycling, pre-processing and other utilisation of HW ;
a) Recognition and Registration of workers
b) Imparting industrial skill development activities
c) Monitoring safety and health of workers.
» Occupier shall obtain an authorization / renewal of authorisation from the
State Pollution Control Board in Modified Form 1. Applicant shall enclose
copies of CTE, valid CTO. A Self certified compliance report shall be
enclosed in case of renewal application.
» State Pollution Control Board shall grant authorisation in Modified Form 2
after ensuring technical capabilities and equipment complying with the
Standard Operating Procedures or other guidelines specified by CPCB
through site inspection.
» The authorisation granted shall be accompanied with copy of field
inspection report signed by that Board.
» Handing over of the hazardous and other wastes to the authorised actual
user shall be only after making the entry into the passbook of the actual
user
» Includes Authorization for recycling of Other wastes listed in Schedule - III
Rule-9 : provisions of Recycling and Utilization of HW
(1) SPCBs/PCCS may grant authorisation to actual users for utilization or
recycling of Hazardous Wastes for which Standard Operating
Procedures (SoPs) or guidelines have been provided by CPCB
(2) Where SoPs or guidelines are not available, the applicants shall
approach CPCB for grant of approval, which may be given by CPCB on
the basis of trial runs.
Upon completion of successful trial run, CPCB shall prepare SoPs for
such Utilization and circulate the same to all SPCBs.
(3) No trial runs are required for co-processing once the co-processing
standards are notified.
However, till the time the standards are notified, the procedure as
specified at (2) above shall be followed.
» The sender of the waste shall obtain ‘No Objection Certificate’from the SPCB of both the States for transportation of waste incase of final disposal to a facility existing in a State other than theState where the hazardous waste is generated.
» In case of transit of waste for recycling, recovery, reuse orutilisation through a State other than the State of origin ordestination, the occupier shall intimate the concerned SPCBbefore he hands over the hazardous wastes to the transporter.
» The authorisation for transportation shall either be obtain by thesender or the receiver on whose behalf the transport is beingarranged.
» Gray color Manifest – shall only be sent to the SPCB of the senderin case sender is in another State
S. No. Type of Waste generated Quantity of Waste
generation
Area of utilization
/ recycling / reuse
1. Fly ash from thermal power
plant
200 Million Tonnes
Per Year (600 MTA
by 2030)
Fly ash pozzolona
cement, increase of
ash dyke height,
road construction,
brick manufacturing
2. Blast furnace slag from iron
and steel plant
10 MTA Slag cement
3. Steel melting shop slag (SMS)
from steel plant
- Slag cement after
removal of iron
4. Phospho gypsum 8 MTA Cement making
5. Distillery spent wash About 100 distillery
in operation
(capacity 60-600
KLPD)
Concentrated spent
wash for power
generation
Contd…
S. No. Type of Waste generated Quantity of
Waste
generation
Area of utilization /
recycling / reuse
6. Spent pot lining (aluminium
industry waste)
- Carbon portion of SPL can
be used as fuel in cement
kiln
7. Pharmaceutical / pesticide
industry (distillation
residue, process residue,
mixed waste solvent, high
COD waste)
200,000 TPA Can be used as partial fuel
in cement kiln
8. Municipal solid waste 1,30,000
Tonnes /day
RDF from MSW can be
used as fuel in cement kiln
/ boiler
9. Plastic waste 15,500 Tonnes
/day
Can be recycled / used as
a fuel in cement kiln
10. Municipal waste water 35,000 Million
litres /day
Treated water can be used
in industrial process /
irrigation etc.
11. Used tyres 83,000 TPA Shredded tyres can be
used as fuel in cement kiln
Most Promising Alternate Fuels
RDF from municipal solid waste [ MSW ]
Used tyres
Hazardous waste
Industrial plastic waste
Hazardous Waste
Barriers
Technical Barriers
Non uniform quality due to varying sources
Presence of high moisture and Chlorine
Lack of pre-processing facilities
Limited technical knowledge and skilled manpower
Financial Barriers
Time consuming and expensive trial runs needed for each
new stream
High capital cost for setting pre-processing platforms
Huge competition for HW, impacting gate fee
Contd…
PARAMETER MIN MAX
Moisture (%) 0.60 67.4
Ash (%) 0.96 98.70
VM (%) 0.3 94.9
FC (%) 0.1 45.7
Carbon 0.4 75.6
Hydrogen 0.2 9.1
Nitrogen 0 15.5
Sulphur 0.1 22
Oxygen 0 76.3
GCV (Kcal/Kg) 80 7960
NCV (Kcal/Kg) 114.8 6042
Mineral matter 3.5 34.5
Chloride as Cl (mg/kg) 0 14200
Fluoride as F (mg/kg) 0 20.1
PARAMETER MIN MAX
Cadmium (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 MAX
VOC (mg/kg) 4.20 207.0
SVOC (mg/kg) BDL 0.2
PCB (mg/kg) 0.00 0.5
PARAMETER MIN MAX
PCP (mg/Kg) BDL 1.4
TOC (%) 0.00 66.0
Source: Dr. Parlikar, Geocycle India
» There is large variation in the characteristics of wastes on dayto day and batch by batch basis.
» Waste streams are required to be mixed in differentproportions to prepare uniform AFRs. Hence, individualcharacteristics of the wastes bear no relevance to that of thewaste mix.
» It took 10 years for Indian cement industry to conduct trials ofabout 100 waste streams. There are thousands of wastestreams to deal with.
» Although incineration or landfill options are lower in wastemanagement hierarchy, no trial is required for any waste??.
» Technically, there has to be a mechanism to ascertain safety inhandling & storage of wastes and compliance to co-processing emission standards.
Source: Dr. Parlikar, Geocycle India
35
Appropriate Laboratory for waste qualification
Adequate waste storage facility with proper facilities to controlfires and spillages.
Environmentally sound facilities for waste Handling, pre-processing and feeding into kilns.
Skilled and trained manpower for waste management
Adequate systems for EHS and Medical Surveillance
Emergency Response Plan.
Online emission monitoring to ascertain environmentalcompliance to prescribed emission standards.
Avoiding waste feed when kiln is in light up, shutdown or upsetmode.
Kiln specific trials for materials attracting Stockholm convention.
36
All wastes, other than the banned ones, can be pre & co-processed depending upon the availability of the suitableinfrastructure to handle & manage them.“Banned wastes" not to be pre-processed or co-processed
• Radioactive waste
• Asbestos-containing waste
• Explosives and ammunition / weapons
• Anatomical medical waste
“Banned wastes“ not to be co-processed
• Electronic fraction of electrical and electronic waste (e-waste)
• Whole batteries as a targeted material stream
• Waste of unknown or unpredictable composition, including unsorted municipalwaste
˃ These wastes however can be co-processed after pre-processing to remove thebanned portion of the waste
» Waste generator is required to manage his waste respecting theWaste Management Hierarchy and SPCBs are required to authorizethe same. (Rule 4)
» A facility is required to obtain authorization from SPCB for receiving,storing and pre-processing of wastes based on the availability ofcompliant infrastructure to handle them safely. (Rule 6)
» Co-processing in cement plant is to be implemented based on thecompliance to prescribed emission standards. (Rule 9)
» Interstate movement of wastes for recycling or co-processing to beimplemented by intimation to the respective SPCBs. (Rule 18)
» Pre-processing centers to be developed rather than landfill sitesand convert SCF to RDF and wastes to AFRs.
» Guidelines on penalties for damaging environment while handlinghazardous wastes need to be adhered to.
S.No. Industry Name Hazardous
waste
Raw
material
Non-
hazardous
waste
Dolachar /
carbon
black
BBD
1. Anjani Cements 23122 2153
(iron
sludge)
-- -- 657
2. My Home industries 13253 -- -- --
3. Kesoram Cements 3528 -- -- --
4. Zuari Cements 11447 -- 12148 (RDF-
848 T+
Biomass -
11300)
2020
5. Keerthi industries 2533 -- -- --
6. Sagar Cements -- -- -- --
7. India Cements,
Nalgonda District
1273.19 -- -- --
8. India cements, Tandur -- -- -- --
9. Orient Cement,
Mancharial.
15,555 25
Total 55156.19 2153 27703 2045 657Source: Telangana SPCB
Sl.No
.
Industry Name Hazardous
waste
Raw
material
Non-
hazardous
waste
Dolachar
1. Ultratech Cements, Tadipatri, AP. 4530.16 -- -- --
2. Zuari Cements, Erraguntla, AP. 8000 -- -- --
3. Bharathi Cements, Erraguntla, AP. 4674 -- -- --
4. Dalmia Cements, Erraguntla, AP. 2500 -- -- --
5. M/s Chettinadu Cements, Kalburgi,
Karnataka
271 -- -- --
6. M/s Rajashree Cements,
Gulbarga, Karnataka.
457 -- -- --
7. M/s Sree Jayajothi Cements Pvt.
Ltd., AP.
30.01
8. JSW Cement, Kurnool, AP 108.02
Total 20570.19 -- -- --
Source: Telangana SPCB
Source: Gujarat SPCB
Sr.No Industry Name Hazardous
waste(MT)
Raw material
(MT)
Non-
Hazardous
waste(MT)
Dolachar/carb
on black(MT)
BBD
1 M/s. Ambuja Cement Ltd
Gir Somnath299574 1255619 1308307 885
_
2 M/s. Ultratech Cement Ltd
– Kovaya Works163726 65472.2 767921 0
_
3 M/s. Ultratech Cement Ltd
– Jafrabad Works0 5673.5 129806 0
_
4 M/s. Ultratech Cement
Ltd–Sewagram Works-
Kutch
2745 329249 347784 0
_
5 M/s. Gujarat Sidhee
Cement Ltd – Junagadh12323 116451 153963 0
_
6 M/s. Sanghi Industries Ltd
– Kutch121533 334283 228755 0
_
7 M/s. Shree Digvijay
Cement Co. Ltd –
Jamnagar
4152.15 101770.2 137024 0
_
8 M/s. Recycling Solution
Pvt. Ltd – Panoli18442 0 1949.3 0
_
9 M/s. Saurashtra Cement
Ltd – Porbandar19337 210805 255970
_
TOTAL 641832.15 2419323 3331479.3 885
Source: Gujarat SPCB
Sr.No Industry Name Hazardous
waste(MT)
Raw
material
(MT)
Non-
Hazardous
waste(MT)
Dolachar/ca
rbon black
1 GNFC Dahej Unit 1134 _ _ _
2 GNFC Unit : 2 Bharuch 1180 _ _ _
3 Alembic Pharmaceuticals
Limited, Panelav
342 _ _ _
4 Novel Spent Acid
Management, Vatva,
Ahmedabad
_ 69650 _ _
5 Gujarat Paper Mills
Association, Vapi
_ 4531 _ _
TOTAL 2907 74181
1. For hazardous waste management following
hierarchy should be followed:-
a) Prevention – Waste generation can be prevented
using clean technology
b) Minimization – waste generation can be Minimized
by using good practices
c) Reuse;
d) Recycling;
e) Recovery, utilisation including co-processing;
f) Safe disposal.Contd…
2. For chemical industry (pharma, pesticides, dye
and dye intermediates etc.) the waste
minimization scheme as prescribed by CPCB
should be followed.
3. After following waste minimization scheme the
high COD waste to be segregated and high CV
waste should be co-processed in cement kiln.
4. The spent solvent / mix solvent generated by
chemical industry should be co-processed in
cement kiln.
5. Setting of pre-processing plant to be
encouraged either at cement plant site or at
TSDF site.
Contd…
6. Co-processing emission standards to befollowed by Cement plant who are engaged inco-processing of waste as fuel in cement kiln.
7. Rule 9 of hazardous waste management rulesincluding SOP given by CPCB to be followed.
8. Fly ash / bottom ash, RDF, Phospho-gymsum,lime sludge and other industrial waste shouldbe co-processed in cement plant for itseffective utilization.
9. SPCB / PCC should play a catalytic role topromote co-processing in their respectivestate.
10. Data on inventory of waste both hazardous andnon-hazardous should be made available bySPCB / PCC in their website.
Contd…
11. For setting of co-processing plant, SPCB / CPCB/ MoEF should play important role by providingnecessary technical and financial assistance (asgiven for CETP and TSDF).
12. SPCB / PCC to build-up capacity for monitoringemission of toxic pollutants including dioxine /furan in cement kiln emission.
13. Risk assessment for storing of hazardous wastein co-processing plant to be done and allprecautions to be followed as recommended byCPCB in its guidelines on storing of hazardouswaste.
14. RDF from MSW to be used as partial fuel incement kiln. This may be included as a part ofCSR programme to manage the MSW disposalproblem. Contd…
15. Coke oven sludge / distillation residue / mixedwaste solvent, spent carbon etc. should beused as partial fuel in cement kiln
16. Oily sludge from oil refinery / petrochemicalindustry should be used for co-processing incement plant
17. Spent pot lining (carbon portion) fromaluminum industry should be used as partialfuel in cement kiln.