For a zero-waste future

© 2015 Geocycle

Beneficial Recovery of Materials in

Cement Industry

Presentation title, Function, 2015-01-01 © 2015 Geocycle

© 2015 Geocycle

Geocycle – Facts and Figures

Subsidiary of LafargeHolcim since the 1970’s

2000 employees

50 countries on all continents

180 cement plants (co-processing) facilities

80 pre-treatment facilities

14M tonnes of waste treated by Geocycle every year leaving no

residues

North America – 3M tonnes

16M tonnes of C02 emissions prevented through recovery of energy

from processed waste

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© 2015 Geocycle

Exshaw Cement Kiln

© 2015 Geocycle

Lafarge Exshaw – Future of Co-Processing

• Lafarge Exshaw Cement Plant is actively working on securing a

permit to co-process the following materials:

Construction, Renovation and Demolition Waste (CRD)

Non-Recyclable Plastics

Wood based materials

Asphalt Shingles

Carpet and Textiles

Treated Wood (pressure treated, creosote)

Rubber

Nylon Fibre (derived from tires)

© 2015 Geocycle

Co-Processing and Beneficial Resource Recovery

“Sometimes the best thing to leave our children

is nothing”

© 2015 Geocycle

What is Co-Processing?

Simultaneous recovery and recycling process

Combustible Waste = Energy

Mineral Waste = Raw Material

Developed in the late 1970’s

Co-processing is NOT incineration (WTE)

Higher on waste management hierarchy than incineration and

recognized as such in various jurisdictions worldwide

Unique waste management solution

Main objective is substitution of primary fossil fuels and raw

materials in one single industrial process. The production of clinker

and cement.

No ash residues generated through co-processing as mineral

components are recovered in the cement product

Regulated process

Higher on waste management hierarchy than incineration (WTE)

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© 2015 Geocycle

Advantages of Co-Processing

LCA demonstrates co-processing offers superior environmental

performance to landfilling and incineration

Completely destroys waste material due to high temperature (1450C) and

long residence time

Avoids formation of dioxin and furan due to temperature profile

Leaves no ash that needs to be landfilled

Reduced GHG emissions as waste is used to replace fuel

Preserves non renewable materials (fossil fuels and minerals)

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© 2015 Geocycle

Co-Processing Reduced GHG Emissions

Presentation title, Function, Name, 2015-01-01 8

© 2015 Geocycle

Typical Alternative Fuels

• Wood materials • Non-Recyclable

Plastics • Paper • Coated paper • Biomass such as seeds

and shells • Treated Wood • Used oils • Oil sludge

• Municipal Solid Waste

• Roofing tear-off

• Tires – whole or shred

• Carpet

• Textiles

• Waste oils and solvent

• Coffee chaff

• Haz wastes

• And many more….

© 2015 Geocycle

Presentation title

Cement Manufacturing Process

Presentation title, Function, Name, 2015-01-01 10

“Understanding the cement manufacturing process is of

prime importance to understanding the business of waste

derived alternative fuels and working with cement plants.”

© 2015 Geocycle

Cement vs Concrete – There is a difference!

Cement Concrete

Water + Rocks +Sand

© 2015 Geocycle

Cement Manufacturing Process

Step 1. Create a raw mix

Step 2. Burn the raw mix in a kiln to produce

“clinker”

Step 3. Pulverize the clinker to make the powder

known as cement

Knowledge of the cement manufacturing process is crucial

to understanding the alternative fuel (AF) business

© 2015 Geocycle

Step 1. Creating a raw mix

• Raw materials are combined in exact proportions to create

a chemically correct raw mix Silica (sand, clay, shale)

Alumina (clay, shale, low grade bauxite)

Iron (mill scale, smelter slag)

Lime (limestone)

• Raw mix is pulverized in a mill

© 2015 Geocycle

Creating a Raw Mix

Cement

Alumina: Ash

Silica: Sand Limestone: Quarry

1450oC

Chemical

Transformation

Iron: Steel slag

Burning the raw mix

Pulverizing Clinker to

Cement w/Gypsum

© 2015 Geocycle

Step 2. Burning the raw mix in a kiln

• Raw mix is burned in a kiln

• Material temperatures >1450 0 C

• End product is cooled to form pellet size material “Clinker”

• Alternate fuels are introduced here

© 2015 Geocycle

Step 3. Pulverizing the Clinker

• Clinker is combined with a small percentage of

gypsum and ground in a mill to produce the powder

know as cement

© 2015 Geocycle

Cement Manufacturing Process

© 2015 Geocycle

Cement Kiln – Heating and Burning Zones

AF burned here

AF burned here

© 2015 Geocycle

Cement Kiln – Heating and Burning Zones

• Exshaw kiln is newest technology (short dry kiln with 5 stage cyclones

and PRE-CALCINER)

• Precalciner burning zone

• “Forgiving” for AF. Can accept larger particle size (2” minus), some

contamination (i.e. oversize, metal that gets through), and higher

moisture than feeding into the main burner zone

• 7 seconds retention time

• Main Burner Firing

• Requires the highest quality fuels

• Requires very good heat values (20 gj/t +) in order to maintain

constant flame shape and temperature – otherwise cement

production is compromised

• Particle size of 3/8” minus (very high grinding costs)

• Very low moisture required and NO contamination

• Currently no fuel is fired in the pre-calciner

• Burner nozzle subject to plugging

© 2015 Geocycle

Cement Kiln – Heating and Burning Zones (2/2)

• Preheater Tower Kilns (Delta, Lafarge Kamloops, Lafarge Bath)

• Primary difference is these kilns have no pre-calciner (firing point) in

the tower.

• Thus AF’s are primarly fed through the main burner and possibly the

kiln inlet (back end)

• Requires 3/8” minus sizing (expensive to grind)

• Recommend this particle size is screened (always better to screen

than grind) out for customers requiring this particle size, when

making fuel for Lafarge specs

© 2015 Geocycle

Presentation title

Co-Processing and Beneficial

Resource Recovery

Presentation title, Function, Name, 2015-01-01 21

© 2015 Geocycle

Alternative Fuel Opportunities: C&D

• Construction and

demolition debris,

industrial solid waste,

and other waste are

ground for use as an

alternative fuel/ coal

replacement.

• Richmond, BC Plant

© 2015 Geocycle

Alternative Fuel Opportunities: Wood residues

• Cedar shavings

• Mill planings

• Mill wastes

• Secondary

manufacturing Wood working

(cabinetry etc)

• Green wood (hog)

typically not suitable

due to high moisture

© 2015 Geocycle

Alternative Fuel Criteria - Expected Exshaw Specs

Description Minimal Nominal Maximum

Moisture As low as possible 15% 20-30% (TBD)

Particle Size (2D) 90% passing at 3.0” Max 4” any dimension

Particle Size (3D) 90% passing at 2.0” Max 3” any dimension

Thickness < 10mm

Chlorine (Cl) As low as possible 0.3% TBD

Ash < 20% TBD

Low Heat Value 12 Gj/tonne 16 Gj/tonne

Sulfur 1.0%

Lab Analysis Required to Qualify ASF:

• Proximate Analysis and Ultimate Analysis

• Net Calorific Values

• Moisture %

• Chlorine %

• Total Metals – SALM (EPA 6020A)

• Mercury total by CVAA (BCMOE/EPA)

Contamination:

When sourcing materials for the

production of ASF, the material

should be as free of contamination

as possible (i.e. rocks, dirt, metals,

other non-combustible materials)..

© 2015 Geocycle

Lafarge Exshaw – Future of Co-Processing

• New kiln commissioned June 2016 – 2M tonne total plant

capacity (two kiln lines)

• Estimated co-processing capacity at 150,000-180,000

tonnes of waste byproducts annually based on 50%

thermal substitution rate by alternative fuels

• Permit process underway Partner with Pembina Institute, University of Calgary

Project Advisory Council set up with stakeholders (local

gov’t, community members, NGO’s, plant staff)

• If permit approved next stage is construction of a

storage, handling and feeding system ($30M+) Capital approval process

© 2015 Geocycle

Low Carbon Fuel System

Richmond

Pneumatic

Transport &

injection

Kiln Building

Reception

& Storage

Hall

Screening Blending

Main burner

Reception

© 2015 Geocycle

Risk Management

Risks professionally managed

© 2015 Geocycle

The H&S “rules”

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H&S policy H&S rules

H&S management system

AFR policy

Commercial directive

Design & engineering

directive Operations directive

ACert

© 2015 Geocycle 29

What is ACert*?

Overview of the ACert Risk Management System

ACert Program is a comprehensive assurance

methodology for LafargeHolcim Group Companies

involved in the waste management for co-processing

value chain to gauge compliance in order to evaluate,

understand and control their H&S, environmental and

specific business risk exposure.

© 2015 Geocycle 30

The AFR policy defines the principles which are mandatory to be followed including H&S

This policy should be implemented in all pre-processing and co-processing facilities

The AFR directives defines the requirements which are mandatory to comply with, in order to fulfill

the AFR Policy principles

They cover dedicated points to waste management business and complete LH «rules »

AFR Policy and Directives

Commercial Design and

engineering

Operations

• Qualification of the waste

• Risk assessments for all new AFR

• Logistics and transport

• General Health and Safety Aspects

(human contact, ventilation,

escape routes, alarms, AFR lab,

etc)

• Explosion risks

• Fire risks

• Industrial hygiene and medical

monitoring

• Risk assessments for all new AFR

or ways to process AFR

• Emergency plan

• Qualification of the waste

• Acceptance, quality and H&S

control

• Acceptance, emergency equipment

• Acceptance, unloading

• Non compliance management

• Logistics and transport

© 2015 Geocycle

Cement Kiln Use Summary

© 2015 Geocycle

Cement Kiln Beneficial Recovery

• Cement kilns can provide complete and safe

destruction for a variety of byproducts while

recovering their inherent value.

• Beneficial recovery is aligned with the concept of

sustainable development through the replacement of

fossil fuels and conventional materials with

byproducts.

• Proven safe use of byproducts at many cement

plants worldwide.