waste co-processing in the scheme of industrial...
TRANSCRIPT
Waste Co-processing in the Scheme of Industrial Ecology
Pavel Cech, October 2013, Kuala Lumpur
Presentation Flow
Brief introduction of Lafarge
• Group
• Malaysia
Industrial Ecology Concept
Co-processing Fundamentals
Lafarge IE Activities in Malaysia
Possible Opportunities
Closing Remark
Brief Introduction of Lafarge
Profile 2012
World leader in building materials
Major player in the cement, aggregates and concrete industries
We contribute to the construction of cities throughout the world
with innovative solutions, providing cities with more housing, and
make them more compact, more durable, more beautiful and
better connected
Operating in 64 countries
65,000 employees
€15.8 billion of annual sales
1,570 production sites
Listed on the Paris Stock Exchange
4
Sustainable development is rooted in Lafarge’s history and values
More than 170 years of history and experience to build on
Principles of Action since 1977, updated in 2003
Participation in the Rio Earth Summits in 1992 and 2012
Founding member of the World Business Council for
Sustainable Development (WBCSD) in 1992
First industrial partner of WWF in 2000
CO2 emissions reduction commitments since 2001
Business Code of Conduct since 2004
We have been a pioneer and intend to remain so
Lafarge Malaysia
Cement
• 1,120 employees
• 3 integrated cement plants
• 1 clinker grinding plant
• >12.0 million tonnes p.a.
Malaysia is one of Lafarge’s key markets in South-East Asia. It became a part of Lafarge in 2001
through the acquisition of Blue Circle.
Industrial and sales activities in Cement, Aggregates & Concrete.
Lafarge Malaysia Berhad is the largest cement manufacturer in Malaysia serving local and export
market
Lafarge Malaysia Berhad is listed on Bursa Malaysia and as at1 March 2013, it was ranked 35th
by market capitalization worth RM8.3 billion with 2012 revenue at RM2.74 billion.
Aggregates
• 97 employees
• 5 quarries
• > 2.0 million tonnes p.a.
Concrete
• 375 employees
• 29 ready-mix plants
• 2.0 million m3 p.a.
Singapore Operations held via Alliance Concrete Singapore
• 11 ready-mix plants
• >1.5 million m3 concrete p.a.
• 1 cement terminal
Lafarge industrial network in Malaysia
Integrated Cement Plants
Grinding Station
Ready-Mix Plants
Aggregates Quarries
Industrial Ecology Concept
Lower
consumption
of natural
resources
Minimum
of rejects
Someone’s waste becomes resources for others
Energetic Surplus = Energy sources
Logistic improvement (supply + collection)…
Minimization of waste disposal capacities
Industrial Ecology is scientific approach which consists of mimicking the low consumption
equilibrium of ecosystems
Inspired by the efficiency of natural ecosystems
9
Bending the line…
In the traditional manufacturing concept the life of material is a
line which by applying Industrial Ecology we can turn into a cycle.
Material Extraction Logistics Manufacturing Distribution Usage Disposal x
Lo
gis
tics
Usa
ge
Innovative
Know-How
Process & Technology
Industrial Ecology
Co-processing Fundamentals
What is Co-processing?
Thermal or material recovery (or
combination of both) in a cement
manufacturing process generating
no residual waste.
Why do we co-process Waste?
Cost reduction
Reduction of emissions
Environmental protection (sound and safe
disposal solutions for industries and
communities)
Conservation of non-renewable resources
Co-processing in the waste management hierarchy
Co-processing prerequisites
Cement manufacturing process
Raw mix preparation
Burning
Cement grinding
Alternative Raw Materials
Chemical Flexibility of the raw mix
Alternative Fuels
Very High temperature
Long residence time
Gas cleaning inherent to
the process
Additive to
Cement
Fly Ashes
Blast Furnace
Slag
Silica Fumes
A closed cycle process without residual or waste/byproduct.
Co-processing of waste reduces pollution!
Emission reduction
Hazardous
Waste
Hydro-
carbons
Municipal
Solid Waste
Biomass
Industrial
and
Commercial
Waste
Co-processing
solutions
Rubber
Waste
What can be co-processed?
Lafarge IE Activities in Malaysia
Industrial Ecology in Malaysia
Lafarge Industrial Ecology is locally present COPROCEM
Malaysia which organizes waste management services to the
customers (waste generators) for waste co-processing in cement
kilns of Lafarge Malaysia.
Lean, versatile and agile team from diverse backgrounds
With about 400 kt/y of co-processed waste a leading player in
AFR
Catering to a wide range of customers from sectors such as:
heavy industry (metallurgy, mining, chemical…), light industrial
manufacturing (FMCG, electronics, food…), agriculture or even
government
No customer is a small customer but a responsibility (moral and
financial) for waste generation strictly lies with the waste
generator.
Co-processed waste streams in Malaysia
Agricultural biomass
Industrial biomass
Processed C&D waste
Tires and tire residues
RDF
Bleaching media
Solid non-combustible SW
Semisolid non-combustible SW
Combustible industrial solid waste
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Waste Code Examples
SW104 Spent blasting media, dross, PFA
SW204 Metal hydroxide sludge containing heavy metals
SW205 Waste containing calcium sulfate from power plant
or chemical industry
SW207 Sludge containing fluoride
SW313 Spent filter earth
SW320 Phenolic resin waste
DOE approved hazardous waste streams
SW207
SW104
SW204
SW205
Orbis pictus…
Information
• Customer’s manufacturing process inquiry
• Waste description (physical, qualitative and quantitative)
• Sampling of waste
Assessment
• Review of chemical analysis and it’s comparison with internal WAC
• Process impact computation
• Technical evaluation with the cement plant
Commercials
• Commercial proposal to the waste generator
• Waste disposal agreement
Permitting
• Approval application at DOE
• Transporter registation
Operation
• Disposal logistics, disposal and billing
• Regulatory compliance (emission monitoring, manifests…)
Standard process for Customer On-boarding
Closing Remark
Cement industry provides an existing
infrastructure for safe, sound and cost
effective disposal of many waste streams.
How can we place this proposition into the
broader framework?
Thank YOU!
