co-processing in cement kiln concepts and in oil and gas sector | john jones, regional operations...

Technical Session # (Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector

Co-processing in cement kilnConcepts and in Oil and Gas Sector

John JonesRegional Operations DirectorGeocycle Asia


Overview

• Concepts and Benefits of Waste Co-processing

• Challenges During Waste Co-processing

• Initiatives on Co-processing: South East Asia Experience

• Case study of Oil & Gas sector from Indonesia

• Recognition of the initiatives of Geocycle


Waste Management Hierarchy

Main drive: LCA

3R+C

Co-processing

Recycling Technology

Society

Industry A

Industry B

* GIZ Guidelines on Co-processing of waste materials in Cement Production


What is Co-processing?

Co-Processing is……the disposal of waste materials in RII’s (Resources Intensives Industrial processes) such as cement, lime, steel, glasses, power generation etc.*

* GIZ Guidelines on Co-processing of waste materials in Cement Production


Advantages of Co-processing in Cement Kiln

High temperatures and long residence time

In all cases more than 3” > 1100 °C

Self cleaning process

Lime represent > 60% in mass

Double valorization: organic and minerals

Organic totally destroyed

Ash incorporated in the final product

Reduction of global emissions

No additional emission if A.F.R. used - Global CO2 is reduced

Existing, local industry


Reduction of GHGs

Co-processing and IncinerationReduction in GHG Emissions

Co-processing and LandfillPrevention of Methane* Emissions

* Methane has 21 times more global warming potential than CO2

Co-processing is THE alternative to save our environment and

improve industry ecological footprint


Co-processing: Moving to an UN Legal Frame

• Presentation of the co-processing concept at

the CoP Bali June 2008

• 2008-2011: SBC in charge to develop 4 new

technical guidelines for waste management

(used tires/e-wastes/ Hg/co-processing)

• Chile volunteered to draft a project, on the

web since Dec 2009

• Draft to be reviewed at the COPWG on May

10, 2010

• Final proposal presented and ratified at the

COP October 2011 Cartagena, Colombia


Co-processing Guidelines

Holcim and GTZ through a Strategic alliance Proposed international guidelines for the co-processing

of waste materials in the cement production Secured the public acceptance of these guidelines Finalized them in July 2006

Guidelines available in English, Spanish, Portugese, Chesk, Slovak, Hungary, French, Chinese and Russian

From those guidelines, specific legal frames on co-processing are under implementation in around 15 countries

More advanced: Mexico, Salvador, Colombia, Ecuador, Brazil, Chile, China, Phillipines, …

SA: new policy signed April 26 - 2009


Co-processing guidelines….

CPCB Guidelines on Co-Processing February 2010

Co-processing is recognized by

government authorities in other South Asia

Countries

• Indonesia

• Sri Lanka

• Thailand

• Vietnam


Waste & Sustainability: The Challenge


Waste Pre-processing Activities

SLUDGYWASTE

SAWDUST PREMIX

SOLIDWASTE

Pits Building

A.F.Storage Building

Oversize > 200 mm

Primary Shredder

Dual Stage Rotary Screen

DrumsTilter

Scraper

0-10 mm 10-200 mm

HydraulicCrane

Pit

Pit

Overband

Flow-Sheet example

Fine SolidA.F.

Coarse Solid A.F.Truck

Loading

SLUDGYWASTE

SAWDUST PREMIX

SOLIDWASTE

Pits Building

A.F.Storage Building

Oversize > 200 mm

Primary Shredder

Dual Stage Rotary Screen

DrumsTilter

Scraper

0-10 mm 10-200 mm

HydraulicCrane

Pit

Pit

Overband

Flow-Sheet example

Fine SolidA.F.

Coarse Solid A.F.Truck

Loading


Holcim’s Global Waste Co-processing Network

• Co-processing activities in 39 countries with over 4500 customers

• 28 pre-processing facilities

• More than 7 mil. tons of AFR co-processed in 2009

• Treated about 20,000 waste streams


The Geocycle Asia approach


Waste handled


Case study: Geocycle Indonesia

Total Services Solution Projects –Oil and Gas Sector -

• Chevron Pasific Indonesia Riau – Cement Drilling Cutting and General Waste Handling

• Chevron Geothermal, Gunung Salak – General waste Handling• Medco JOB Tomori, Sulawesi – Drilling Cutting Handling• Medco E&P Indonesia, Palembang – Contaminated Soil Handling• Arun NGL, Aceh – Sulfinol Handling• Star Energy Geothermal Wayang Windu - Drilling cutting Handling• MontD’Or Oil Tungkal Jambi - General Waste Handling and Pit Cleaning • Badak NGL Kalimantan - General Waste Handling• Pertamina Plaju, Palembang – Contaminated Soil Handling• Pertamina ONWJ, Marunda – Liquid and General Waste Handling• Pertamina Geothermal Energy - Drilling Cutting Handling


Chevron Pacific Indonesia

• Geocycle is awarded 2 years contract to handle Hazardous Waste Disposal at Chevron Pacific Riau (06 Feb 2012 – 06 Feb 2014)

• This is the third contract between Geocycle and Chevron since 2010

• Waste materials include : Cement drill cutting, chemical waste, oily rags, ash incinerator, used oil, etc.

• Total volume on contract is 3410 MT • Scope of work :

Handling and repacking Weighing Loading to shipping container Transporting (land and sea) - Interisland Co-processing in Cement Kiln


Star Energy Geothermal

• Geocycle is awarded one year contract to handle Drilling Cutting from Star Energy Geothermal

• Total volume on contract is 4550 M3 –Scope of work :

Supervision Loading to Dump Truck Transporting Co-processing in Cement Kiln


Clean Up Project – Montd’or Oil Tungkal Ltd Jambi

• Geocycle is awarded for 1 year contract to do site clean up for MontD’Or Oil Tungkal, Ltd

• Waste materials include : oil sludge, contaminated soil and some general waste


Pertamina Geothermal Energy

• Drilling Cutting Handling for Pertamina Geothermal Energy• 700 M3 of material from Pertamina Geothermal Energy was

transported to HIL• Scope of work :

Supervision Loading to Dump Truck Transporting Co-processing in Cement Kiln


Pertamina–Medco E&P Tomori

• Geocycle is just recently awarded 2 years contract (execution starts on September 2013) to handle Waste Management Disposal for Pertamina-Medco E&P Tomori

• Waste materials include : Drilling Cutting, Waste Oil and Chemicals• Total volume on contract is 9000 MT • Total Revenues of this contract is 4 Mio USD • Scope of work :

Handling and repacking Waste Water Treatment on Site Weighing Loading to shipping container Transporting (land and sea) - Interisland Co-processing in Cement Kiln


Updates of India so far….

Geocycle has been co-processing RFCCU spent catalysts from Barauni and Panipat Refineries at

its cement kilns at Chaibasa and Gagal respectively

• Geocycle has the necessary approval from CPCB for co-processing of hazardous RFCCU spent

catalyst (category 4.1, schedule 1)

• Recently participated in the tender for disposal of Oily sludge from Haldia refinery at its cement kiln at

Chaibasa (under TC evaluation by IOCL)

• Have assessed the feasibility of the following waste streams:

• Oily sludge from Barauni Refinery for disposal at Chaibasa Cement Works, Jharkhand

• ETP Sludge, Chemical Sludge & TB Sludge from Panipat Refinery for disposal at Cement

Works, located in Rajasthan

• Activated Carbon from Mathura Refinery for disposal at for disposal at Cement Works, located in

Rajasthan

• Undertaken a successful trial run of Drill Cutting waste from Cairns India and Lakheri Cement

Works


Thank you - Dhanyawad

Shukriya Terima Kasih

Bohoma istuti Khorb Kun Krup

Cám ón SalamatXie Xie

Contact for further queries

John JonesRegional Operations director Geocycle [email protected]

co-processing in cement kiln concepts and in oil and gas sector | john jones, regional operations...

Business

dump truck

shipping container

cement kiln

cement works

gas sector

supervision

oily sludge

waste materials