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“Co-processing of Wastes in Cement Kilns”

Business opportunity

&

Sustainability act

CEMENTISCEMENTISCEMENTISCEMENTISConsultingConsultingConsultingConsulting




Jean-Pierre Degré

Cementis

October 2012

Sustainability act

A Vision ? Or Reality ? ….A Vision ? Or Reality ? ….

Jean-Pierre Degré ([email protected])

Chemist & Geologist Engineer, 41 years experience with Holcim.

� > September 2011: Partner Cementis…

� 1970-2011: Holcim Belgium

� 1997 – 2011 : Senior Vice-President – Head of the Alternatives Resources Division Holcim Group

Support

� In charge of the worldwide “Wastes to Resources” strategy

� 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

� Expert in the development of low/neutral CO2 cementitious binders production



� Expert in the development of low/neutral CO2 cementitious binders production

� 1991 - 1997: Development Manager Holcim France and BNL

� 1984 – 1991: BD Manager Holcim FrBNL and development of the “co-processing concept”

� 1974 - 1984: Expert in Clinker & Cement production processes, thermal efficiencies and

environmental strategies

� Some other assignments:

� Expert delegate to the UN/SBC

� Expert in waste management to the European Commission

� Consultant as world expert for energy efficiency in clinker process

Cementis is an international Swiss based consulting company specialized in the Cement (www.cementis.com)

Summary

1 The Cement Industry: a “Resource Intensive Industry”

2 Co-processing• Opportunity for Environment foot print reduction

• Definition & legal framework

• Preferred business model




• Sourcing and best practices

3 Co-processing: The complete AR chain

4 Vision for a cleaner future

The building activity chain is today a linear process that consumes

large volumes of resources and produces large waste and emissions

Natural Raw Materials

Fossil Fuels

ClinkerManufacturing

CementManufacturing

RMX concreteAsphaltOther building

Construction &building activity

Buildings &infrastructureuse

Demolition andrenewal

• In 2010 global cement production consumed> 4,000 mio ton raw materials> 250 mio tons of oil equivalent

Aggregatesproduction



Other buildingproducts

building activityuse

Waste & Emissions to

Disposal in land, air, water

renewal

Production and use processes

• CDW in Europe ~510 mio ton/a• 5% of man-made CO2 emissions globally from cement • Buildings are the source of 40% of the CO2

emissions of developed countries

production

Bitumen andother binders

Worldwide cement demand increases > 3% p.a. leading to

further increases in energy and raw material demands

50 mio toe

850 mio trm

220 mio toe

3500 mio trm

300 mio toe

5000 mio trm

19002000

2500

3000

3500

4000

China

China

Cement consumption

in million tons

3100’

4200’

**

2200

250 mio toe

4000 mio trm

> 350 mio toe

5000 mio trm



850 mio trm

toe = tons of oil equivalent (42 GJ) ; trm = tons of raw material ; CAGR = Compound annual growth rate

249400 500

301

900

1500

1900

26

0

500

1000

1500

2000

1970 2010 2020ECAGR*

Emerging

markets

Mature

markets

576

The Cement Industry has 3 main strategic levers to reduce

ecological footprint (CO2) and manage resources sustainably

Impact

Clinker

Substitution

Alternative

Binders

1995P Pozzolan Cement

S Slag Cement

F Fly Ash Cement

L Limestone Cement

M Multiple Blend Cement

2008 22%

11%

8%

23%

15%

17%

2%2%

M

L

FP

S

OPC

OPC56%

2%

8%

9%

4%

7%

11%2%<1% 1%

S

PF

LM

1. Product development: strong increase of composite cements and accompanying

decrease of clinker factor from to 71.5% in 2008.

Fuel & Raw

2. Optimization of fuel and raw material mix by co-processing of waste:

still further potential Coal



Fuel & Raw

Material

Substitution

still further potential Coal

Petcoke

Heavy fuel

Natural gas

Shale and lignite

Alternative fossil fuels

Alternative biomass fuels

56%

21%

1%

8%

2%10% 2%

TSR = 12%

Modern

Equipment

…

3. Clinker: Improvement of thermal energy efficiency reached a plateau:4'565

3'8613'699 3'7003'690

3'000

3'500

4'000

4'500

1990 … 2000 2006 2007 2008

MJ/

ton

clin

ker

Current wastes management practices leave a substantial

part of the resource potential of waste unused

paper & pulp 16%

steel industry 34%

chemical industry 25%

cement industry 6% none ferrous industry 5%

none met. industry 14%

Potential energy from waste excluding

458 Energy consumption power plants

243

Energy consumption EII (energy intensive industries)

528

302

300

400

500

600

Energ

y c

onsum

ption (

EU

25)

[Mto

e]

Energy from waste

Example: EU



Theoretical energy from waste including

waste that can be recycled

Potential energy from waste excluding

waste that can be recycled149

243

215 225 248

0

100

200

300

Energ

y c

onsum

ption (

EU

25)

[Mto

e]

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

Energy from waste

Summary











Co-Processing is…

…the use of waste materials in RII’s (Resources Intensives Industrial

processes) such as cement, lime, steel, glasses, power generation etc.

..instead of fossil fuels & natural resources

Applied locally Co-processing benefits to:

• Upgrades waste management within the waste hierarchy

Co-processing is a THE alternative to save our environment

and improve industry ecological footprint



• Upgrades waste management within the waste hierarchy• Reduces wastes health & environmental impacts• Maintains and improves the industrial sector's competitiveness• Decreases (largely) the costs of waste management• Improves all human and technical-economical factors

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

Co-processing

100 % material recoveryMain drivers:

- Life Cycle Assessment

- Decision tree process



Co-processing

Incineration / co-incineration with energy recovery

Landfilling

100 % Energy recoveryRecovery

Disposal

- Decision tree process

Co-processing … Now fully recognized !!!



Co-processing: UN/SBC International recognition



Waste volumes Co-processed last 5 years…

Wastes as AFR co-processed 2010 last 5 years….

>> 30 000 000 tons>> 30 000 000 tons



Co-processing: The Main Business philosophies

SERVICE Business:

� revenue

PROCUREMENT Activity:

� volume

VOLUMEVALUE

HYBRID:

� managed business

SUSTAINABILITY

Maximizing



� revenue

� (new) dedicated

resources

� service mindset

(revenue driven)

� direct to market

� flexibility

� volume

� existing resources

� purchasing mindset

(lowest cost)

� brokers/3rd parties

� market volatility

� managed business

� mainly pre-

processing by 3rd

party

� reduced liability

� cement plant only

co-processes

From Wastes to AR: Preferred Business model

� Ideally, each operational Cement group (Corporate, regional and

country level) should manage

� its specific AR business unit,

� services oriented

� eventually with a specific brand

Direct access to clients & Pre-processing facilities



� eventually with a specific brand

� Objectives:

� interface between the wastes markets and the cement factory

� for wastes sourcing, identification, logistic, pre-processing, control,

conditioning, etc0

� and AR delivery to the cement operation facility

Co-processing / AR organization - Specificities

AR Core • Mother company to become the leader in Co-processing

• To increase the profitability of the company maximizing the use

of Alternatives Resources

• To contribute to environmental and social development

Key objectives • Strategically position the Group as a leader in the waste value

chain with no compromise on OH&S, environment, quality and



chain with no compromise on OH&S, environment, quality and

process

• Develop a greater degree of internal and external recognition

of value creation

• AR to be recognized as the leader in solutions of co-processing

in all regions where the Group is present

Collectors

Waste generators

The AFR Value Chain and the competition

Integrated

Service

Provider



Recycling AnywhereIncinerators

Physical

chemical

treatment

Landfill

Pre-processing facility

Co-processing

(kiln)

Co-processing saving’s - Achievable target…..

• Y1 starting when a clear and coherent AR

organization is implemented at group level

• Estimation when specific legal frame

implemented and controlled



Hazardous Wastes are limited in volumes but delivering the

highest added-value



Generic Structure for AR Co-processing activities development.

Operation monitoring Wastes market sourcing Legal framework

Co-processing projects

Vision & Business planning



Foundation

Operation monitoring Wastes market sourcing Legal framework

Current List of Banned Wastes

� Anatomical hospital waste

� Asbestos containing waste

� Bio-hazardous waste

� Electronic scrap

� Entire batteries



� Entire batteries

� Explosives

� High concentration cyanide waste

� Mineral acids

� Radioactive waste

� Unsorted municipal solid waste

Wastes Marketing strategy Volatile waste markets require flexibility and diversified product mix

Tyres

0.0

1.0

2.0

3.0

4.0

5.0

2000 2002 2004 2006 2008 2010 2012

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

2000 2002 2004 2006 2008 2010 2012

Strong competition

& less volumes

EBS crisis/

Disposal of all AM

compulsory

Very quick reaction

of cement industry

Tyres not

interesting for

cement ind (low

prices/difficult to

burn)

Enforcement of

EU directive

New treatment ways, incl.

Pyrolysis, co-processing in

other industries

Animal meal

Development of selected volume co-processing in cement kilns ( EU 27 - Mio. t)

NON-

HAZAR-DOUS



0.0

0.5

1.0

1.5

2.0

2.5

3.0

2000 2002 2004 2006 2008 2010 1012

0.0

0.1

0.2

0.3

0.4

0.5

0.6

2000 2002 2004 2006 2008 2010 2012

In recession periods,

streams are decreasing

because of non-

production

Enforcement of EU directive in some countries

(France e.g.) where landfilling is now forbidden

for organics

2000 2002 2004 2006 2008 2010 2012 2000 2002 2004 2006 2008 2010 2012

Sludge's (Water treatment and/or IndustrialSolvents

HAZAR-

DOUS

Sorted MSW: a potential for large AR volumes…

For all Wastes – to – energy needs….



Treatment of pesticides in Australia @

Cement clinker process:

NOW one of the best recognized tool for Pop’s treatment



China

Colombia

Australia

Sri Lanka

El Salvador

Venezuela

Vietnam

Philippine's

34

Holcim co-processing experience 26.05.2009/LDSHolcim Group Support

38

Holcim co-processing experience 26.05.2009/LDSHolcim Group Support

Sri-Lanka@. � pure pyralene oil with 56-62% of PCBs

� Accredited 3rd party monitors emissions and samples all materials

Results

� DRE > 99.9999%

� Emissions unaffectedby PCB

� External report available

� 10,000 liters of mixture co-processed at 2 feed rates under well controlled process conditions

USA

Canada

Vietnam

Germany

Switzerland

Belgium

France

Spain

Morocco

Russia

Czech Republic

HungaryCroatia

Italy

Slovakia

RomaniaBulgaria

Thailand

Guatemala

Azerbaijan

China

Cement clinker process:

NOW one of the best recognized tool for Pop’s treatment



Ecuador

Chile Brazil

Venezuela

Colombia

South Africa Australia

New Zealand

PhilippinesLebanon

Morocco

Argentina

Sri LankaEgypt

ThailandMexico

El Salvador

Costa Rica

Nicaragua

Indonesia

India

Business as usual On progress (trial burns) Under discussion

One of the key challenges is to transform inhomogeneous waste into

homogenous AFR for co-processing…



Waste

AFR

SLUDGY

WASTE

SAWDUST PREMIX

Primary Shredder

Hydraulic

Crane

PitSLUDGY

WASTE

SAWDUST PREMIX

Primary Shredder

Hydraulic

Crane

Pit

From Waste to AFR: The Pre-processing operations



WASTE

SOLID

WASTE

Pits Building

A.F.Storage Building

Oversize

> 200 mm

Dual Stage

Rotary Screen

Drums

Tilter

Scraper

0-10 mm 10-200 mm

Crane

Pit

Overband

Flow-Sheet example

Fine Solid

A.F.

Coarse Solid

A.F.Truck

Loading

WASTE

SOLID

WASTE

Pits Building

A.F.Storage Building

Oversize

> 200 mm

Dual Stage

Rotary Screen

Drums

Tilter

Scraper

0-10 mm 10-200 mm

Crane

Pit

Overband

Flow-Sheet example

Fine Solid

A.F.

Coarse Solid

A.F.Truck

Loading

Wastes Co-processing: No Compromise

On Health and Safety

� Specific OH&S directive

� Employee Chemical Health and Occupational Safety model to be developed

� External auditing systems requested

On Environment

� EMR: Emission monitoring and reporting systems on place

� ERT: Emission reduction target

On product quality



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 total traceability

� Pre-processing activities

� Cement production processes improved to handle LGR

Impact of A.F.R. on emissions: Dust - NOX - SO2

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

2 2 0

2 4 0

Tho

usa

nd

s

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7

1 0 0 0

mg

r/N

m3

- d

ry -

11

% O

2

�� ExEx.:.: HolcimHolcim // BelgiumBelgium

NOxNOx

T/y haz. A.F.R.T/y haz. A.F.R.



1

1 0

1 0 0

mg

r/N

m3

- d

ry -

11

% O

2

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7

DustDust

SO2SO2

Impact of A.F.R. on emissions TOC - HCl - HF

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

2 2 0

2 4 0

Tho

usa

nd

s

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7



1 0 0 0

mg

r/N

m3

- d

ry -

11

% O

2 TOCTOC



0 , 0 1

0 , 1

1

1 0

1 0 0

mg

r/N

m3

- d

ry -

11

% O

2

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6

HFHF

HClHCl

TOCTOC

Sb+Cr+Cu+Pb+VSb+Cr+Cu+Pb+V

Impact of A.F.R. on the heavy metals emissions

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

2 2 0

2 4 0

Th

ou

sa

nd

s

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7



1

mg

r/N

m3

- d

ry -

11

% O

2




As+Co+Ni+Se+TeAs+Co+Ni+Se+Te

Cd+Tl+HgCd+Tl+Hg

0 , 0 0 0 1

0 , 0 0 1

0 , 0 1

0 , 1

mg

r/N

m3

- d

ry -

11

% O

2

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6

Cd+Hg+TlCd+Hg+Tl


Class 3

Impact of A.F.R. on H.M. concentration in cement.

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

2 2 0

2 4 0

Th

ou

sa

nd

s

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7



1 0 0 0




Class 2

Class 1

0 , 1

1

1 0

1 0 0

pp

m

1 9 9 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7


Cd+Hg+TlCd+Hg+Tl

The Three Gorges Dam corporation and Huaxin finalized a long-term commitment for

cleaning the Yanktze River

Example - Huaxin China

Three Gorge Dam Floating Material



� Thousands of tons of FM are collected annually to avoid the risk

of blockages/damages at the Three Gorges …

� Huaxin just starts co-processing in July 2010

� Estimated volumes are > 30000 t/y of floating materials

Summary











CO2 regulations have a particularly high impact on the cement

industry, due to its very high financial exposure

ton

CO

2e

/to

n p

rod

uct

kg

CO

2e

/US

$ R

ev

en

ue

CO2e and Financial Intensity of Individual Products

� Concrete and cement have relatively low

embedded CO2 intensity, compared to

other commodities such as steel, copper

and aluminum.

� However, despite the low CO2 intensity of

the product, the cement industry has a

very high financial exposure, with a high

CO2 emission per financial added value, a

result of the low cost of the products.



� So the only way to guaranty the long term sustainability of the business is to:

1. Diversify the end-product portfolio towards “binders” or “cementitious” with low or 0

environmental impacts

2. Maximize the use of low grade resources and wastes

3. Integration core business with other RII’s as for example steel and aluminum producers

4. Self production of activated mineral compounds replacing clinker

5. Adjust the end-product to the market real needs

6. Etc…. More ideas welcome …

AFRWaste-based Alternative Fuels and

Raw Materials

The Cement Industry must reduce its environmental footprint

AAgg.(CDW for CP)

Established

Conventional

Synthetic MIC from

LGR & waste

Advanced waste

processing

Alternative aggregates

- Urban quarrying

AMICOBFS, fly ash, nat. Pozzolana,

limestone

Target:

To integrate LGR and wastes in our end-products portfolio….

For lowering (Getting 0 ???) environmental foot frint….



Clinker

Manufacturing

Cement

Manufacturing

Concrete and

Building Products

Production

New

LGR & waste

New binders

AR & waste-based with

low CO2

processing

- BAT

- thermal (gas/py)

- Upgraded pre-proc.

…..

- Urban quarrying

- CDW

- IBA

......

AR

Binder

More Ways for Cement production development

Waste Co-processing to produce Alternatives Binders…. Around the CSA diagram

Blast-Furnace SlagFly-ashes from TPP

Synlag from steel/IBA/CKD ….

3

4



OPC-Clinker 1

2

4

1 – sewage sludge’s

2 – paper sludge’s

3 – drilling cuts

4 – red mud (Al. Ind.)

0-16 mm0-2 mm fraction

Raw IBA

Heros plant

EU – Example 1

From IBA (MSW), production of AA and/or AMICO

IBA processing at Heros (NL): a synergistic AR case



0-16 mm

IBA

0-2 mm fraction

(mostly mineral)

‘Cold Cement’2-16 mm

(mostly metals back to Heros)

Heros plant

0-40 mm minerals

(Alterative Aggregate)NE-metals

($)Fe-metals

(to Cu-separation)

Application risks under

evaluation (IBAgg)

� Treatment on 2.1 mio t/y wastes asphalt

� Gate fees: 30 €/t

� Existing specific Capex: 45 mio €� Calciner

� Product self burning + support natural gas

� Calcination : 810 to 850 °C

Van Bentum - Rotterdam

EU – Example 2

From Wastes Asphalt plant to produce AMICO



� Calcination : 810 to 850 °C

� Residence time: 45 minutes

� Production per line: up to 40 t/h

� Cooler

� From 850 to < 100 °C

� Residence time: 45 minutes

� Calciner materials re-processed in 3 different grain sizes

� 2-8 mm

� 8-30 mm

� Plant perfectly designed for alternative binders production

AMORAS is an acronym that stands for ‘Antwerpse

Mechanische Ontwatering, Recyclage en Applicatie van

Slib’ (Antwerp Mechanical Dewatering, Recycling and

Application of Sludge).

Flemish authorities and the Antwerp Port Authority are

investing in a sustainable solution for the storage,

processing and valorization of the dredging material

EU – Example 3



processing and valorization of the dredging material

from the Port of Antwerp.

• 3 000 0000 M3 per year to be dredged

• 130 000 0000 € Capex for dredging sludge’s

filtration

• R/D for filter cakes valorization with the

potential to generate around 500 000 t/y of

pozzolanic binder

• Pre results really promising, showing that,

after calcination at 600 °C, the materials is

much more active than fly ash from thermal

power plant

Summary











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 (Resources Intensives Industries) as the Cement production

� Keeping and improving competitivity





� Keeping and improving competitivity

� Improving independence, right to operate and business sustainability

� Improving process knowledge by the use of LGR

� For the local Authorities and Collectivities

� Developing local competences and local solutions including for highly

hazardous wastes

� Improve Environment capacity building and understanding

Reducing the clinker factor and waste co-processing are

major strategic levers to lower the ecological footprint of

cement production

Research is needed to further push clinker substitution and

maximize waste utilization along the whole construction

Conclusions



maximize waste utilization along the whole construction

material value chain

Resources management needs legal frameworks which foster

sustainable behavior and make waste streams available as

resources

Interested to diversify your resources portfolio ?

Interested to reduce your Environment foot print ?

Interested to increase your competitivity ?

What can we Offer ?

• Cementis and partners have more than 25 years of experiences in Industrial Ecology, wastes and low grade resources management, preparation and use of wastes as Alternatives Fuels, Alternatives Raw materials and Alternatives binders for Resources Intensives industries



Intensives industries

• For Cement operator, we can propose, develop and support their strategy and business development on AR

• For countries, regions or collectivities levels, we are able to offer a safe, secure and environmentally sound way of solving wastes concerns, from MSW to particularly sensitive and highly hazardous wastes

• To propose, promote and implement specific legal frame, lobbying and communication

a vision ? or reality - ficem vision ? or reality ? ... now one of the best recognized tool for...

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