Workshop on CoProcessing of

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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

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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.

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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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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)

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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
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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.

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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

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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.

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The target groups

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

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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

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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.

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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
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Co-processing is part of an integrated waste
management concept
Cleaner Production
Incineration
Sanitary Landfilling
Integrated Waste Management
Co-Processing
Re-use of material
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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.

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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.

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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.

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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

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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

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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 .

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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

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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.

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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?

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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?

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