1. Environmentally Sound Management of Plastics Wastes through Cement Kiln Co-processing
Ulhas Parlikar
Dy Head, Geocycle India
ACC Limited

2. About Geocycle For a zero-waste future
Geocycle is the global waste management brand of LafargeHolcim. LafargeHolcim is the promoter of both ACC Limited (ACC) & Ambuja Cements Ltd. (ACL) ACC & ACL extend cement kiln co-processing solution for environmentally sound management of wastes under this brand. Wastes from Industrial, Municipal & Agricultural sources are managed through co-processing

3. Cement Industry & Circular Economy
CaCO3 Slurry
Marble Slurry
1950
2010
Ammonium Sulphate
Fertilizer Plant
Marble Processing Plant
GBF Slag
Fly Ash
1960
1990
CEMENT
Thermal Power Plant
Steel Plant

4. What is Co-processing? Co-processing is…
…based on the principles of industrial ecology and stands for the usage/disposal of waste material (as raw materials, as a source of energy or both) in resource intensive industries to replace natural mineral resources (material recycling) and fossil fuels such as coal, petroleum and gas (energy recovery) by wastes….
Benefit of co-processing are………
Provides a permanent solution to waste
Reduces emissions and greenhouse gases
Lessens reliance on fossil fuels
Preserves natural resources
Provides opportunity to achieve Zero Waste Future
Reference Documents: AFR Classification HARP 13 4

5. Co-processing completely utilises the resource value present in wastes
Acidic Emissions X
Raw
Materials
(Ca, Fe, Al, Si)
Coal
Wastes
as AFRs
(IMAP)
Clinker
Cement
Gypsum
Fly Ash
Phospho-Gypsum
Slag
Heavy Metals X
Dioxin / Furans X
Leachability X
Ash treatment X

6. Co-processing Promotes Circular Economy & Sustainability
Incineration
Coprocessing
100% Material Recovery
100% Energy Recovery
Prevention / Reduction
Reuse
Recycling
Waste to Energy
Land filling
Beneficial use of Material and Energy
Waste Disposal

7. 9/20/2018
Wastes need to be Pre-processed to produce uniform quality AFRs required in Cement manufacture
Waste
Pre -Processing
Processed Waste
Reference Documents: AFR Turntable 2013 AFR Pre-Processing
Waste Co-Processing-Concepts and Benefits 7 7

8. Well laid out approach for gainfully utilising wastes1
Waste assessment
We can provide a complete survey of your waste and a full assessment of its suitability for co-processing. 2
Waste analysis
We offer dedicated laboratory testing to analyze your waste to ensure it is suitable. We at Geocycle are able to manage waste such as solids, sludge and liquids 3
Waste transportation
We provide a seamless service – ensuring the waste is transported in appropriate packaging with required labelling and documentation. The waste is carried by operators with required skills, qualifications and permits. 4
Pre-processing
Further analysis of waste is conducted in our laboratories if required. We have extensive facilities to blend liquids, shred solid materials and homogenise waste prior to its usage in kilns. 5
Co-processing
Waste is then safely co-processed in cement kilns. Our cement kilns operate at temperatures of up to 2000°C – which leaves no residue or waste after co-processing is complete.

9. Is co-processing a proven technology in India?
There have been >90 co-processing trials in India in different cement plants across the country.
Materials included:
Simple Plastics to complex ODS
>40 different Haz waste categories
Waste mix of different kinds
Large variation in physico-chemical characteristics
All these trials confirmed that wastes do not impact the cement kiln emissions

10. How much waste can be co-processed in the cement kilns?

11. Cement Kiln Co-processing of Plastic Wastes
ICPE + ACC together conducted the co-processing trial for use of plastics as AFR in cement kiln in March 2008
Objective was to demonstrate suitability of cement kiln for environmentally sound and ecologically sustaining management of plastic wastes in cement kilns
Trial was conducted with the approval of CPCB and MPPCB
Dr. B. Sengupta – Ex Member Secretary, CPCB and Prof. S. P Gautam, Chairman, MPPCB provided the guidance and support.
Plastic waste consisted of a mix of PE, PBT, PET, PP & PS
Emission monitoring and product evaluations were carried out by SGS Ltd.
Dioxin / Furan evaluation was carried out in the Belgium facility of SGS
CPCB approved protocol was utilised in the co-processing trial

12. Co-processing trial results and its impact
CPCB evaluated the results of the emission monitoring and also the product quality.
These results were confirmed that plastic co-processing did not influence the emissions or the product quality.
CPCB advised State Pollution Control Boards to encourage management of plastics in the cement plants.
With the collaborative efforts of the various State Pollution Control Boards, several cement plants initiated co-processing of segregated plastic wastes from the Municipal sources in their cement kilns.
Co-processing of plastic wastes was initiated on larger scales in Gujarat State where it gets generated on very large scales from the paper recycling industry

13. Segregation of Plastics from MSW and its management
Geocycle collaborated with several ULBs to manage the segregated plastic waste generated at their end.
Shimla
Baddi
Jabalpur
Katni
Madukkarai
Panjim & other parts of Goa
Bangalore etc.
Geocycle manages large quantum plastic wastes from paper recycling industries in Gujarat and other states.
Circuit Bench at Shimla of National Green Tribunal approved the co-processing option for management of plastic waste in and advised its implementation in HP.

14. Co-processing of plastic wastes and other non-recyclable Combustible Fractions (SCF) from MSW
Segregated Combustible Fraction (SCF)
Composting/RDF/Biomethantion
Kitchen waste/organics
Glass
Metals
MSW
Construction and Demolition waste
Recycling
RDF / Co-processing / WTE
Inert Material
Land fill
Recyclable Plastics
Multi layered packaging, Rexene, leather, rubber, tyre pieces, contaminated plastics, contaminated paper, contaminated cloth, Thermocol, wood pieces, etc. 14

15. Zero waste through co-processing1.
Madukkarai Model
Swatch Bharat Team has already made video films on these models and uploaded on You Tube
..\MK G&C\Clean & Green Madukkarai 3min.mp4 2.
Goa Model
Segregation, efficiency and specifications are key. 3.
Vengurla Model

16. Management of Plastic waste with other non-recyclable combustible wastes from MSW is more appropriate solution
Madukkarai town
Few Wards of Coimbatore
Several Municipalities in Himachal Pradesh
Panjim & other locations from Goa
Hyderabad Municipal Corporation
Chennai Municipal Corporation,
Jaipur Municipal Corporation
Katni Municipal Corporation,
Jabalpur Municipal Corporation
Bangalore Municipal Corporation
Varanasi Municipal Corporation
Raipur Municipal Corporation
Reclamation of land by remediating existing MSW dump yards and management of excavated SCF through co-processing is becoming a workable option

17. We are very grateful to you!!!
Thanks