Title: Workshop on CoProcessing of
1The 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
2Background - 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.
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5Background - 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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7Who 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)
8Public-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
9Joining 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.
10Objective 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
11Who 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.
12The target groups
- government organizations and public institutions
- local communities
- non-governmental organizations
- the cement industry and their associations and
federations - waste generators
13Structure 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
14Level 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.
15The 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
16Co-processing is part of an integrated waste
management concept
Cleaner Production
Incineration
Sanitary Landfilling
Integrated Waste Management
Co-Processing
Re-use of material
17Level 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.
18Level 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.
19Level 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.
20Level 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
-
21Level 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 -
22Level 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 .
23Level 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 -
24Level 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.
25Aspects 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?
26Aspects 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?
27The GTZHolcim Public Private Partnership
Thank you!
Contact under dietmar_at_eecz.org