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Title: Workshop on CoProcessing of


1
The GTZHolcim Public Private Partnership
Presentation of the Guidelines developed within
this Strategic Alliance by Rolf Dietmar, GTZ
China Based on a presentation produced by
Professor Dieter Mutz
  • Workshop on Co-Processing of
  • Hazardous Wastes and Alternative Fuels Raw
    Materials in Cement Kilns
  • Thursday, 12 May 2005
  • Beijing

2
Background - Present Situation of WM
  • General agreement exists for an urgent need to
    improve waste management in developing countries
    and countries in transition.
  • Despite innovative solutions there is still a
    lack of technical infrastructure for
    environmentally sound and financially feasible
    recycling, recovery and final disposal of waste.
  • Every day there is a significant increase of
    irreversible contamination of natural resources
    (water, soil, air) by uncontrolled dumping of
    waste.

3
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5
Background - Present situation of the cement
industry
  • The cement industry is consuming a significant
    amount of natural resources and fossil energy.
  • Worldwide cement consumption is increasing and
    there is a common understanding for a need to
    optimize the use of raw material and energy.
  • In many industrialized countries the substitution
    of fossil fuel and virgin raw material by waste
    (Alternative Fuels and Raw material AFR) has
    been recognized as an environmentally sound
    recovery and disposal method of waste

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7
Who are GTZ and Holcim?
  • GTZ www.gtz.de
  • ? Government-owned, non-profit company for
    international cooperation for sustainable
    development
  • ? Present in 130 countries
  • ? Turnover approx 900 million Euro
  • Holcim www.holcim.com
  • ? One of the worlds major cement
    manufacturers
  • ? Turnover 13 billion CHF (2004)

8
Public-Private-Partnership What does it mean?
development-policy PPP
private industrys goals
goals greater
development-policy impact through
cooperation between development organisations
and private-sector businesses
9
Joining forces for solving problems
  • The cement industry offers an infrastructure for
    reducing waste problems in any country.
  • Co-processing of waste in cement kilns means
    substituting scarce primary energy and virgin raw
    materials with waste.
  • However, some basic rules and principles have to
    be considered while applying co-processing in
    order to avoid negative environmental impacts.

10
Objective of the Holcim-GTZ PPP
  • Drafting of internationally recognized guidelines
    on Co-Processing of Waste Materials in Cement
    Production,
  • and model application in selected countries
  • 2003 -2006

11
Who prepared the Guidelines?
  • The Guidelines were prepared by experts from
    Holcim and GTZ.
  • Support and advice was given by external experts
    from the cement industry and from organizations
    working in the field of international development
    cooperation.
  • The elaboration of the document was coordinated
    by the Institute of Environmental Engineering
    from the University of Applied Sciences in Basel,
    Switzerland.

12
The target groups
  • government organizations and public institutions
  • local communities
  • non-governmental organizations
  • the cement industry and their associations and
    federations
  • waste generators

13
Structure of the Guidelines
Beside basic information about waste management,
cement production and co-processing the
Guidelines are structured on a three level
hierarchy
  • Level 1 General principles to be respected
    when applying pre- and co-processing
  • Level 2 Specific principles combined with
    practical information to be considered with
    regards to legal, environmental, operational, HS
    and communication issues
  • Level 3 Sector overview, examples, further
    information, links to literature and institutions
    etc, given as annex to the Guidelines and
    compiled on a CD

14
Level 1 General principles - Principle I
  • Co-processing respects the waste hierarchy
  • Co-processing does not hamper waste reduction
    efforts, and waste shall not be used in cement
    kilns if ecologically and economically better
    ways of recovery are available.
  • Co-processing shall be regarded as an integrated
    part of modern waste management, as it provides
    an environmentally sound resource recovery option
    for the management of wastes.
  • Co-processing is in line with relevant
    international environmental agreements, namely
    the Basel and Stockholm Conventions.

15
The waste hierarchy
Waste Volume
Avoid
Energetical and material use of waste
Minimise
Recover Materials (Recycle Reuse)
Desirability
Co-Processing
Incineration
Physical chemical Treatment
Elimination of waste
Landfil-ling
16
Co-processing is part of an integrated waste
management concept
Cleaner Production
Incineration
Sanitary Landfilling
Integrated Waste Management
Co-Processing
Re-use of material
17
Level 1 General principles - Principle II
  • Additional emissions and negative impacts on
    human health must be avoided
  • to prevent or keep to an absolute minimum the
    negative effects of pollution on the environment
    as well as risks to human health.
  • On a statistical basis, emissions into the air
    shall not be higher than those from cement
    production with traditional fuel.

18
Level 1 General principles - Principle III
The quality of the cement product remains
unchanged
  • The product (clinker, cement, concrete) shall not
    be abused as a sink for heavy metals.
  • The concentration of trace elements in the final
    cement product shall statistically not be higher
    than that of cement produced with primary energy
    and virgin raw materials.

19
Level 1 General principles - Principle IV
Companies engaged in co-processing must be
qualified and trustworthy
  • To have good environmental and safety compliance
    track records and to provide relevant information
    to the public and the appropriate authorities
  • To have in place personnel, processes, and
    systems demonstrating commitment to the
    protection of the environment, health, and
    safety
  • To assure that all requirements comply with the
    existing national laws, rules, and regulations
  • To be capable of controlling inputs process
    parameters required for the effective
    co-processing of waste materials
  • To ensure good relations with the public and
    other actors in local, national, and
    international waste management schemes.

20
Level 2 Specific legal principles
  • An appropriate legislative and regulatory
    framework must be set up.
  • - Co-processing must be integrated into overall
    legislation
  • - Legally binding regulations and standards are
    necessary
  • Baselines for traditional fuels and raw materials
    must be defined.
  • - Monitoring and control of inputs, outputs and
    emissions while operating with
  • virgin fuel and primary raw materials
  • - Evaluation of situation prior to co-processing
  • - Use baseline data to define potential impact
    of AFR (EIA)
  • All relevant authorities should be involved in
    the permitting process.
  • - Build open, consistent and continuous
    communications
  • - Apply Best Available Techniques (BAT)
  • - Cement plant operator shall provide
    necessary information
  • - Install community advisory panels

21
Level 2 Specific principles related to the
environment
  • Rules must be observed to ensure the use of
    alternative fuels / materials does not
    significantly change emissions.
  • Emission monitoring is obligatory to demonstrate
    compliance with national regulations and
    corporate rules and reliability of initial
    quality control of the process input materials.
  • Pre-processing is required for certain waste
    streams optimum operation requires uniform
    quality and quantity of raw material and fuel
    flows.
  • EIAs confirm compliance with environmental
    standards.
  • - Risk assessments identify weaknesses in the
    system
  • - Material flux and energy flow analyses
    optimize the use of resources

22
Level 2 Specific principles for operational
issues
  • Waste and AFR sourcing is essential.
  • - Only accept waste from trustworthy sources
    refuse waste unsuitable for co-processing
  • - All candidate wastes shall undergo a detailed
    source identification test procedure before
    acceptance
  • - Pre- or co-processing facility shall ensure
    traceability of wastes
  • Materials transport, handling and storage must be
    monitored.
  • - General Guidelines for waste and AFR
    transportation must comply with regulations
    provide and maintain instructions and equipment
    for transport, handling and storage
  • - Design conveying, dosing and feeding systems
    to minimize fugitive dust emissions, prevent
    spills and avoid toxic vapors
  • Operational aspects must be considered.
  • - Feed AFR into the kiln only at appropriate
    introduction points, determined by the AFRs
    characteristics
  • - Control and monitor technical conditions that
    influence emissions, product quality and capacity
  • - Document and make accessible strategies for
    managing AFR feed during start-up, shut-down or
    upset conditions
  • Quality control system is a must develop and
    implement documented control plans for wastes and
    AFR provide procedures, adequate equipment and
    trained personnel and implement and communicate
    appropriate protocols in cases of non-compliance.
  • Monitoring and auditing allow transparent
    tracing develop and implement waste and AFR
    management monitoring and auditing protocols
    provide instructions and training in performing
    internal audits .

23
Level 2 Specific principles of occupational
health safety
  • Site suitability avoids risks proper location,
    good infrastructure.
  • Documentation and information is a must as the
    basis for openness and transparency, information
    must be made available before starting any
    co-processing activity
  • Training should be provided at all levels.
  • - Train management personnel at other, existing
    facilities
  • - Training of authorities builds credibility
  • - Complete hazardous operations training for new
    workers and sub-contractors before starting
    co-processing carry out periodic certification
    for workers and sub-contractors
  • -Understanding risks and how to mitigate them is
    key to training
  • Emergency and spill response plans are
    obligatory good, regular emergency and spill
    response planning and simulations, including
    neighbouring industries and authorities

24
Level 2 Specific principles for communication
issues and social responsibility
  • The following principles have to be considered
  • Openness and transparency provide all necessary
    information to stakeholders admitting mistakes
    is part of transparency, leading to corrective
    actions.
  • Credibility and consistency build credibility by
    being open, honest and consistent match rhetoric
    with demonstrated facts and good performance.
  • Cultivate a spirit of open dialogue, based mutual
    respect and trust communication also means
    seeking feedback, dialogue with stakeholders and
    integrating external views.
  • Cultural sensitivity take into account different
    cultural environments.
  • Continuity start early, and once you start,
    never stop.

25
Aspects to be considered before applying
Co-Processing (1)
  • Does a legislative and regulatory framework
    exist?
  • Do the authorities have sufficient regulatory
    capacities?
  • Does an integrated waste management plan exist?
  • Do the industry and authorities apply the concept
    of waste hierarchy?
  • Are the authorities qualified to authorize,
    control and monitor the co-processing?
  • Is a quality control system for waste source
    qualification guaranteed?
  • Is the cement plant able to comply with the needs
    for monitoring?

26
Aspects to be considered before applying
Co-Processing (2)
  • Are independent testing laboratories available
    and experienced for controlling AFR and
    emissions?
  • Does the cement plant fulfill national
    environmental standards?
  • Is an adequate transport, storage and handling of
    the waste material ensured?
  • Do adequate emergency response plans exist?
  • Are occupational health safety standards
    ensured?
  • Are management and staff in cement industry and
    haulage companies trained sufficiently in
    handling hazardous materials?

27
The GTZHolcim Public Private Partnership
Thank you!
Contact under dietmar_at_eecz.org
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