Wastes co-processing in Holcim

Transcription

1 Wastes co-processing in Holcim Erika Guerra May 13, 2009

2 Agenda Holcim and Sustainable Development Co-processing of wastes in cement kilns Co-processing Guiding principles Case Studies Conclusions 2

3 Holcim is a leading global supplier of cement & aggregates and other building materials, present in over 70 countries. Mature markets Emerging markets Selected Key Figures of the Holcim Group Sales of cement million t Sales of aggregates million t Net sales 23,969 million CHF Personnel 88,783 people Thermal Energy Needs million toe Raw Materials Consumed 1) 190 million t 1) For cement production only, excl. alternatives 3

4 Sustainable Development (SD) is an element of our vision and mission and is well embedded in our strategy Vision Our vision is to provide foundations for society's future. Mission Our mission is to be the world's most respected and attractive company in our industry creating value for all our stakeholders. Goal Strategy Mindsets Base Holcim Strategy House Product Focus Sustainable Environmental Performance Environmental performance Better Cost Management Economic growth Creation of Value Geographic Diversification Triple bottom line Permanent Marketing Innovation People Human Resources Excellence Local Management Global Standards Corporate Social Responsibility Social progress SD performance is widely recognized Holcim is the leader of the industry in the DJSI for the third year running 4

5 Agenda Holcim and Sustainable Development Co-processing of wastes in cement kilns Co-processing Guiding principles Case Studies Conclusions 5

6 The cement manufacturing process is both energy and materials intensive. Raw materials quarry Raw meal preparation Clinker burning Cement grinding and dispatch Raw mat. (examples) Ca: limestone Si: sand Fe: hematite Al: clay Clinker Calcination & burning at 1,450 C Formation of clinker minerals C2S, C3S, C3A, C4AF Cement Grinding with gypsum (OPC) Blended cement with slag, fly ash filler tons Raw Materials kg coal kwh/t power = 1 ton OPC 6

7 Cement manufacturing also contributes to our (increasing) ecological footprint. October 6 marked the day when the world had already spend the yearly available natural resources in 2007 At this time, only using natural resources, we would need 3 planets to recover Example: cement industry s share of global CO 2 emissions Natural 88% Total Manmade 12% Energy 5% Transport 24% Power & Heat 35% Manmade Residential Heating 14% Cement 5% 7

8 Cement or Concrete? Cement is the fine, gray powder that, when mixed with water, sand, and gravel or crushed stone (fine and coarse aggregate), forms the rock-like mass known as concrete. When concrete is mixed in the right proportions, water triggers a chemical reaction in cement called hydration, which causes the cement to harden and bind the aggregate into a solid mass. The process of hydration is the key to concrete's strength and versatility. Cement while energy intensive to produce, is a small proportion of concrete, which is one of the world s most CO2-efficient building materials 8

9 The cement kiln offers technical characteristics that help to explore materials substitution. Mineral wastes: CaO, SiO 2, Al 2 O 3, Fe 2 O 3 Preheater cyclones Act like a dry scrubber for acid gases and metals Precalciner Gases: > 900 C Retention time > 3 s Raw meal: 700 C (Non)-hazardous AFR: liquid, solid, coarse particles, Kiln Inlet (Non)-hazardous AFR: lump fuel Clinker: Thermal, macromolecular immobilization of metals Kiln main burner Flame: C Combustion gases: >1100 C Retention time > 10 s Material : 1450 C > 15 min. (Non)-hazardous AFR: liquid, fine solid particles, readily combustible Mineral by - products 9

10 Co-processing is a sound alternative to improve the cement industry s ecological footprint Co-processing is the use of waste materials in EIIs* such as cement, lime, steel, glasses, power generation etc. instead of fossil fuels & natural resources Co-processing benefits Upgrades waste management within the waste hierarchy Reduces global environmental impacts Maintains and improves the industrial sector's competitiveness Decreases (largely) the costs of waste management Improves all technicaleconomical factors *Energy Intensive Industrial processes 10

11 Agenda Holcim and Sustainable Development Co-processing of wastes in cement kilns Co-processing guiding principles Case Studies Conclusions 11

12 Internally, Holcim has defined a policy to govern the Group companies behavior and operations when using AFR The 9 principles of Holcim s AFR policy Elements of sustainability I. Act as a partner to society by offering waste management solutions II. Keep our environment safe III. Add value to our core business What we will do IV. Ensure occupational health & safety V. Refuse the listed banned wastes VI. Guarantee the quality of our products How we will do it VII. Comply with the relevant regulations and promote best practices VIII.Monitor and control the inputs, process, products and emissions IX. Communicate transparently Acceptance criteria Emissions Product Quality 12

13 Externally, Holcim supports various initiatives for implementing co-processing legal frameworks Holcim-GTZ Strategic alliance Published international guidelines for co-processing of waste materials in the cement production* Fosters recognition of those guidelines by authorities, NGOs, international bodies etc. Implementation in local legal frames UNEP / Basel Convention Goal: to solve the problem of hazardous waste management in large urban areas in the developing world, and disseminate these best practices in other similar urban areas. *available at 13

14 Holcim has a dedicated organization to support its AFR strategy and master the waste to AFR challenge At corporate level an organization CIE AFR-BD an AFR policy working on international legal frames for co-processing recognition At Group Company level Co-processing activities in progress in 38 countries More than 2000 direct jobs on waste management 22 pre-processing facilities - 3 under construction in to 100 mio. U$ investment per year > 6 mio t AFR co-processed in mainly hazardous around 4 mio tons of fossil fuels preserved per year 14

15 Holcim engages in all the technical steps of waste coprocessing 15

16 Holcim differentiates itself on the waste market by offering its clients direct access to pre- and co-processing services Each local Holcim company has a specific AFR business unit, services oriented with an own brand Objectives Interface between the wastes markets and the cement factory For wastes pre-processing: marketing, identification, control, conditioning And AFR delivery to the cement facility New global brand being introduced to strengthen market presence 16

17 Holcim (US) Locations Holcim (US) Inc. is a leading manufacturer and suppliers of cement and mineral components in the United States with 16 plants and 70+ distribution terminals More than 15 million metric tons of cement and related materials each year is distributed by Holcim. The company employs more than 2,500 people, and generated over $1.5 billion in revenues in

18 Introduction to Geocycle US Part of a Global Network 18

19 Agenda Holcim and Sustainable Development Co-processing of wastes in cement kilns Co-processing guiding principles Case Studies Conclusions 19

20 Examples of AFRs and hazardous wastes co-processed or treated by Holcim. Canada Tires USA and haz liquids Mexico Guatemala Pesticide El Salvador contaminated Nicaragua soil Costa Rica Colombia Ecuador Liquids haz waste Tires, haz liq fuels, solids and alternative raw material Chile Venezuela France Brazil Belgium Spain Morocco Argentina Switzerland Tires, liquids Italy and solids Czech Republic Croatia Hungary Romania Bulgaria Egypt Lebanon Genetically South Africa modified Slovakia Haz liqs, solids, tyres, sewage sludge, animal Germanymeal and alternative raw materials agri products Common Brand Sri Lanka Pesticides Indonesia Haz liquids including pesticides Australia Vietnam Thailand Biomass Philippines New Zealand Russia Azerbaijan Haz Liquids and oils Oil, liqs 20

21 Biomass waste is an important resource in south-east Asia Indonesia: rice husks and palm kernel shells in Cilacap, Fed to clalciner ~80,000 t biomass in 2007 ~20% substitution achieved Rice husks in Vietnam Complex logistics 13,500 t biomass in

22 Co-processing of wastes of the oil industry in Mexico Exploration & Production Refineries Ecoltec 1) participates in all segments of the Oil industry as a waste management solution Co-processing is the preferred solution of Pemex and Semarnat 2) National coverage Zero liability after the waste is co-processed Mexican cement kilns gained expertise in managing the range of wastes generated in the oil sector Ecoltec invested more than $30MM in the last years to cater to this need Distribution 1) AFR Business unit of Holcim Apasco Collection Center 2) Secretaría de Medio Ambiente y Recursos Naturales Platform 22

23 In Azerbaijan and Egypt also large quantities of wastes from the hydrocarbon industries exist and are being co-processed. Garadagh cement plant close to Baku Ca.100,000 toe/y, currently uses Siberian natural gas Several million tons of hydrocarbon sludge available AFR organization since September 2001, trial operations with acid tar in September 2002 Lobbying on-going to enforce stronger environmental legislation El-Soukhna plant of, Egyptian Cement Company, close to Cairo Ca. 7.5 mio t/a clinker, currently uses local natural gas Currently doubling co-processing capacity Only plant permitted for co-processing in Egypt Complete service from collection to co-processing 23

24 Pesticides treated in the Hon Chong plant, Kien Giang Province, South Vietnam, October tons of pesticides Two different insecticide compounds Fenobucarb 18.8% Fipronil 2.4% dissolved in 10,7% Cyclohexanone and 61% of aromatic solvents DRE > 99,9999% CH 3 NH O C O CH 3 CHCH 2 CH 3 F 3 C Cl Cl N N NH 2 CN S O CF 3 External report 24

25 Case Study Collection & Transportation of Tires in the State of Oklahoma The State of Oklahoma generates: ~ 3.5 million (32,000 tonnes) tires per year There are more than 662,000 tires (6,000 tonnes) in stock piles* Since 2006 Geocycle has: Opened a tire yard in Tulsa, Oklahoma that services 29 counties in the State of Oklahoma Invested in a Tire Pre-processing facility Purchased a fleet of trailers to support the service orientation of the Ada Team Coprocessed 25,000 tons of tires annually ~ 2 million tires *2003 US Scrap Tire Market, Rubber Manufacturers Association 25

26 Case Study Investments in Co-processing in Devil Slide, Utah 3 Fuel Feedpoints; Main Burner, Preheater Riser, Tertiary Air Duct Alternative Fuel historically added to Riser New Project adds delivery system to Tertiary Air Duct The TAD provides increased AF flexibility with respect to material size, density, and energy value. Oxygen levels in the TAD are also ideal for the combustion of these alternative solid fuels 26

27 Case Study Investments in Preprocessing in Theodore, Alabama Capacity: Initially 20,000 tonnes/year 75% to be shredded Pre-Processing Capacity 0f 10 tph Engineered Fuel Specification: Non-hazardous solids and sludges > 5,000 BTU per lb - 12 GJ/t < 2" sizing & full destruction of waste stream Ten days of on site storage: 750 tonnes 27

28 Agenda Holcim and Sustainable Development Co-processing of wastes in cement kilns Co-processing guiding principles Case Studies Conclusions 28

29 Concluding messages on co-processing Holcim has Global presence, ensuring cement kilns are available Strong SD commitment, ensuring strict standards apply Cement kilns are unique tools for environmentally and economically sound Saving of resources through wastes co-processing Safe hazardous wastes disposal Holcim already plays an important role, solving many waste issues, including hazardous wastes Experience in co-processing many wastes, also hazardous The organization to ensure it is done safely 29

30 Strength. Performance. Passion.