Toward a WasteToward a Waste--toto--Resources CommunityResources Communityyy-- Experiences and Solutions Experiences and Solutions --

M k tM k t K t i iK t i iMakoto Makoto KatagiriKatagiri

February 21, 2012February 21, 2012Taiheiyo Cement CorporationTaiheiyo Cement Corporation

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Taiheiyo Cement Corporation Taiheiyo Cement Corporation

TCC’sTCC’s activities span the worldactivities span the world

Dalian（China）

Qinhuandao（China）USA

Soul（Korea）

Qinhuandao（China）

Nanjing（China）

VietnamVietnamPhilippines

Papua New Guineap

Oversea Cement Sales :22,649kt (2009)U.S.A. 2,035Kｔ （9.0％）

China 4,766Kｔ （21.0％）

Korea 12,815Kｔ （56.6％）

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Others 3,033Kt （13.4％）

Domestic Sales 14,829kｔ + Export 5,009kｔ

Basic cement manufacturing processBasic cement manufacturing process

Limestone

Kiln with SPSilica sandGypsum

Sintered at1450 ℃

Cement Mill

Clay

Iron source

Raw MillClinker

Ca, Si, Al, Fe id itRaw Mill oxide composite

Cement

Raw material Sintering Finishing

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Annual use of waste and byproductsAnnual use of waste and byproducts

Type Used for FY2000 FY2005 FY2009(kt/y)Statistical data in Japan by JCA

Blast Furnace Slag Raw , Additive １２，１６２ ９，２１４ ７．６４７

Coal Ash Raw, Additive ５，１４５ ７，１８５ ６，７８９

Sewage Sludge Raw (Additive) １，９０６ ２，５２６ ２，６２１

Soil from Construction Raw Material － ２ ０９７ ２ １９４Soil from Construction Raw Material ２，０９７ ２，１９４

By –product gypsum Raw Material ２，６４３ ２，７０７ ２，０９０

Ash Raw, Fuel ７３４ １，１８９ １，１２４

Nonferrous Slug Raw Material １，５００ １，３１８ ８１７

Foundry Sand Raw Material ４７７ ６０１ ５０５

Steel Slug Raw Material ７９５ ４６７ ３４８

Waste Plastic Fuel １０２ ３０２ ４４０

Wood Chips Raw Fuel ２ ３４０ ５０５Wood Chips Raw, Fuel ２ ３４０ ５０５

Reclaimed Oil Raw, Fuel ２３９ ２２８ ２０４

Waste Oil Fuel １２０ ２１９ １９２

Waste White Clay Fuel １０６ １７３ ２０４

Coal Mining Waste Raw, Fuel ６７５ ２８０ ０

Waste Tire Raw, Fuel ３２３ １９４ １０３

Meat and Bone Meal Raw, Fuel ０ ８５ ６５

Others － ４３１ ４６８ ５１８

4Consumption (kg/ton-cement)： ３３２ ４００ ４５１

Others ４３１ ４６８ ５１８

Total ２７，３５９ ２９，５９３ ２６，２９１

Conventional recycling cement plantConventional recycling cement plantTypical recycling loops

Power Plant

C t Pl tLimestone Coal ash

Cement Plant

Gypsum

３Steel PlantBlast-

furnace slug

5Limestone

Trend of waste recycling in cement productionTrend of waste recycling in cement production7,647

6,7897 000

8,000

Recycling area expands

5 000

6,000

7,000 Recycling area expands to Urban waste

2,621

2 1943 000

4,000

5,000

（K

ｔ/y）

2,194 2,090

1,124817

429 348 440505

204 192 204 103 65518

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2,000

3,000

348 440 204 192 103

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In Japan FY2009(JCA)

Advantages of urban waste recyclingAdvantages of urban waste recycling

To elongate the life of land-fill sitegAfter starting the recycling in cement production, the concern for the life of land-fill sites will be relieved.

To decompose dioxinEven if a small amount of dioxin is contained in the wastes, dioxin will be decomposed safely in cement kilns.

To stabilize heavy metalsUrban wastes practically contains some heavy metals, however, p y y , ,hardened cement and concrete will prevent those heavy metalsfrom leaching out for long term.

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Flow of sewage treatmentFlow of sewage treatmentSewage

Sedimentation Aerobe/ Aeration Clean water

Sludge14Billion㎥/y

Condensation Digestion Dewater Incineration ash 220kt/y8Mt/y

In Japan FY2009(JCA)

Agriculture Fields 36%Cement plants 32%

8Landfills 20%Building Material 10%

Flow of Flow of MSWMSW treatmenttreatment

Land fill 80％39Mt 5Mt

Incineration (81%)

MSW 48Mt/year Land fill 80％

4Mt

Recycling (19%) Cement Plant ~6%~300kt( )

- Recycled after separation- RDF (Refuse Derived Fuel)- Fertilizer/ meal for livestockFertilizer/ meal for livestock

15kt

9In Japan FY2009(JCA)

WasteWaste--toto--resources on resources on MSWMSW managementmanagement

Development of Community

AK (Applied Kiln)

MSW

AK (Applied Kiln)

IncineratorsAsh processing

Incinerators

Incinerated ashExisting Cement Plants

Eco cement

Incinerated ash

Cement & ConcreteEco-cement

10Eco-cement PlantsLandfill sites (extension of life)

AKAK（（Applied KilnApplied Kiln）） SystemSystem

Hidaka City: Population 50,000Hidaka City: Population 50,000

Saitama Plant, TCC

Population 50,000MSW 15,000 ton/yPopulation 50,000MSW 15,000 ton/y

Crushing, Sieving & Separation

Crushing, Sieving & Separationpp

Aerobic BioAerobic BioAerobic Bio-digester

Aerobic Bio-digester

Cement production line making use of

digested MSW

Cement production line making use of

digested MSW

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Ash processing systemsAsh processing systemsFly Ash Washing System

(15,000 tons/y)Bottom Ash ProcessingSystem (50,000 tons/y)

12Kumagaya Plant, TCC

Chloride bypass systemChloride bypass systemEnable stable operation with no clogging

Calciner

Exhaust to kiln fl lflue-gas line

Bottom cyclone

Chloride bypass system

Chloride solid to finish grinding Probe

Chloride gasChloride liquid

g g Probe

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C o de qu dChloride solid

Rotary kiln

EcoEco--cement plantcement plant

Futatsuduka Landfill, Tokyo

One third of MSW in Tokyo has been recycled as Eco-cement since 2006.Tokyo Metropolitan Government has constructed the plant in their landfill site and operation has been commissioned to Taiheiyo’s subsidiary.

14- Input MSW (as incinerated ash) 300t/d- Output Eco-cement 430t/d

Process flow of EcoProcess flow of Eco--cementcement

15Research and development of the Eco-cement process technology were supported by NEDO

Comparison of EcoComparison of Eco--cement and cement and OPCOPC

Raw materials of Eco-cement and OPC

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WasteWaste--toto--resource communityresource community

Development ofcommunities

MSWMSW

communities

Industrial waste

Industrial waste

Independent

IncineratorsCement & Concrete

Cement & Eco-cement plants

17Landfill sites

TCC can introduce such technologies and experiences on waste management

TCC can introduce such technologies and experiences on waste management

Thank you for your attentionThank you for your attention

Makoto Katagiri, Ph. D.Deputy General ManagerGreen-Innovation Business Promotion DepartmentGreen Innovation Business Promotion DepartmentTAIHEIYO CENMENT CORPORATIONmakoto_katagiri@taiheiyo-cement.co.jphttp://www.taiheiyo-cement.co.jp/http://www.taiheiyo cement.co.jp/

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