Wastes co-processing in Holcim

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Wastes co-processing in Holcim

Erika Guerra

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2 Holcim co-processing experience

Agenda



Holcim and Sustainable Development



Co-processing of wastes in cement kilns



Co-processing

Guiding principles



Case Studies

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Emerging markets

Mature markets

Holcim is a leading global supplier of cement & aggregates

and other building materials, present in over 70 countries.

Selected Key Figures of the Holcim Group

Sales of cement 140.7 million t

Sales of aggregates 187.6 million t

Net sales 23,969 million CHF

Personnel 88,783 people

Thermal Energy Needs 11.05 million toe

Raw Materials Consumed1) _{190 million t} 1) For cement production only, excl. alternatives

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Sustainable Development (SD) is an element of our vision

and mission and is well embedded in our strategy

Vision

Our vision is to provide

foundations for society's

future.

Mission

Our mission is to be the

world's most respected and

attractive company in our

industry – creating value for

all our stakeholders.

Creation of Value

Mindsets Strategy Goal

Base

Product Focus Geographic Diversification Local Management Global Standards People Better Cost Management Permanent Marketing Innovation Human Resources Excellence Corporate Social Responsibility Sustainable Environmental Performance Creation of Value Mindsets Strategy Goal Base

Product Focus Geographic Diversification Local Management Global Standards People Better Cost Management Permanent Marketing Innovation Human Resources Excellence Corporate Social Responsibility Sustainable Environmental Performance



SD performance is widely recognized – Holcim is the leader

of the industry in the DJSI for the third year running

Holcim Strategy House

Triple bottom line Social progress Economic growth Environmental performance

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Agenda



Co-processing Guiding principles



Case Studies

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The cement manufacturing process is both energy and

materials intensive.

Raw materials quarry Raw meal preparation Clinker burning Cement grinding and dispatch

Raw mat. (examples)  Ca: limestone

 Si: sand

 Fe: hematite

 Al: clay

Clinker

 Calcination & burning at 1,450 °C

 Formation of clinker minerals C2S, C3S,

C3A, C4AF

Cement

 Grinding with gypsum (OPC)

 Blended cement with slag, fly ash filler... 1.7 tons Raw Materials + 120 kg coal + 100 kWh/t power = 1 ton OPC

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October 6 marked the day when the world had already spend the

yearly available natural resources in 2007

At this time, only using natural resources,

we would need

3 planets

to recover…

Cement manufacturing also contributes to our (increasing)

ecological footprint.

Energy 5% Total Natural 88% Manmade 12% Cement 5% Power & Heat 35% Transport 24% Residential Heating 14% Manmade Example: cement industry’s share of global CO₂ emissions

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Cement or Concrete?

 Cement is the fine, gray powder that, when mixed with water,

sand, and gravel or crushed stone (fine and coarse aggregate),

forms the rock-like mass known as concrete.

 When concrete is mixed in the right proportions, water triggers a chemical reaction in cement called hydration, which causes the

cement to harden and bind the aggregate into a solid mass.  The process of hydration is the

key to concrete's strength and versatility.

Cement while energy intensive to produce, is a small proportion

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The cement kiln offers technical characteristics that help to explore materials substitution.

Preheater cyclones

Act like a dry scrubber for acid gases

and metals Clinker: Thermal,

macro-molecular immobilization of metals Mineral wastes: CaO, SiO₂, Al₂O₃, Fe₂O₃

Kiln main burner

Flame: 1800 - 2000 °C

Combustion gases: >1100 °C Retention time > 10 s

Material : 1450°C > 15 min. (Non)-hazardous AFR: liquid, fine solid particles, readily combustible Kiln Inlet (Non)-hazardous AFR: lump fuel Mineral by -products Precalciner Gases: > 900 °C Retention time > 3 s Raw meal: 700 °C

(Non)-hazardous AFR: liquid, solid, coarse particles,

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Co-processing

is the use of waste materials in EIIs* such

as

cement

, lime, steel, glasses, power generation etc.

instead of fossil fuels & natural resources

Co-processing is a sound alternative to improve the

cement industry’s ecological footprint

*Energy Intensive Industrial processes

Co-processing

benefits

 Upgrades waste

management within the waste hierarchy

 Reduces global

environmental impacts

 Maintains and improves the industrial sector's competitiveness

 Decreases (largely) the costs of waste management

 Improves all technical-economical factors

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Agenda



Co-processing of wastes in cement kilns



Co-processing guiding principles



Case Studies

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Internally, Holcim has defined a policy to govern the Group

companies’ behavior and operations when using AFR

Elements of sustainability

I. Act as a partner to society by offering waste management solutions

II. Keep our environment safe

III. Add value to our core business

What we will do

IV. Ensure occupational health & safety

V. Refuse the listed “banned wastes” VI. Guarantee the quality of our products

How we will do it

VII. Comply with the relevant regulations and promote best practices

VIII.Monitor and control the inputs, process, products and emissions

IX. Communicate transparently

The 9 principles of Holcim’s AFR policy

Emissions

Acceptance criteria

Product Quality

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Externally, Holcim supports various initiatives for

implementing co-processing legal frameworks



Holcim-GTZ Strategic alliance

 Published international guidelines for

co-processing of waste materials in the cement production*

 Fosters recognition of those guidelines by

authorities, NGOs, international bodies etc.

 Implementation in local legal frames



UNEP / Basel Convention

 Goal: to solve the problem of hazardous

waste management in large urban areas in the developing world, and disseminate these best practices in other similar urban areas.

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Holcim has a dedicated organization to support its AFR

strategy and master the waste to AFR challenge

 At corporate level

 an organization – CIE AFR-BD  an AFR policy

 working on international legal frames for co-processing

recognition

 At Group Company level

 Co-processing activities in progress in 38 countries  More than 2000 direct jobs on waste management  22 pre-processing facilities - 3 under construction in

2007

 80 to 100 mio. U$ investment per year

 > 6 mio t AFR co-processed in 2006 - mainly hazardous

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Holcim engages in all the technical steps of waste

co-processing…

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Holcim differentiates itself on the waste market by offering

its clients direct access to pre- and co-processing services

 Each local Holcim company has a specific AFR business unit, services oriented with an own brand

 Objectives

Interface between the wastes markets and the cement factory

For wastes pre-processing: marketing, identification, control, conditioning

And AFR delivery to the cement facility

 New global brand being introduced to strengthen market presence

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Holcim (US) Locations

 Holcim (US) Inc. is a leading manufacturer and suppliers of cement and mineral components in the United States with 16 plants and 70+ distribution terminals  More than 15 million metric tons of cement and related materials each year is distributed by Holcim.

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Introduction to Geocycle US

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Agenda

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Case Studies

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USA Canada Ecuador Chile _Brazil Venezuela Colombia

South Africa Australia

New Zealand Philippines Vietnam Lebanon Germany Switzerland Belgium France Spain Morocco Russia Czech Republic Hungary Croatia Italy Argentina Slovakia Sri Lanka Egypt Romania Bulgaria Thailand Mexico El Salvador Costa Rica Nicaragua Guatemala Azerbaijan Indonesia

Examples of AFRs and hazardous wastes co-processed or

treated by Holcim.

Oil, liqs Haz liquids including

pesticides Liquids haz waste

Tires, liquids and solids Tires and haz liquids

Tires, haz liq fuels, solids and alternative raw

material

Haz liqs, solids, tyres, sewage sludge, animal meal and alternative raw materials

Haz Liquids and oils

Pesticide contaminated soil Genetically modified agri products Pesticides Biomass

Common Brand

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Biomass waste is an important resource in south-east Asia

 Indonesia: rice husks and

palm kernel shells in Cilacap,

 Fed to clalciner

 ~80,000 t biomass in 2007  ~20% substitution achieved

 Rice husks in Vietnam

 Complex logistics

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Distribution Refineries

Exploration & Production

Co-processing of wastes of the oil industry in Mexico

 Ecoltec1) _{participates in all segments of the Oil}

industry as a waste management solution

 Co-processing is the preferred solution of Pemex and Semarnat2)

 National coverage

 Zero liability after the waste is co-processed

 Mexican cement kilns gained expertise in

managing the range of wastes generated in the oil sector

 Ecoltec invested more than $30MM in the last years to cater to this need

1) AFR Business unit of Holcim Apasco

2) Secretaría de Medio Ambiente y Recursos Naturales Platform Collection Center

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Garadagh cement plant close to Baku

 Ca.100,000 toe/y, currently uses Siberian natural gas  Several million tons of hydrocarbon sludge available

 AFR organization since September 2001, trial operations with

acid tar in September 2002

 Lobbying on-going to enforce stronger environmental legislation

In Azerbaijan and Egypt also large quantities of wastes from the hydrocarbon industries exist and are being co-processed.

El-Soukhna plant of, Egyptian Cement Company, close to Cairo  Ca. 7.5 mio t/a clinker, currently uses local natural gas

 Currently doubling co-processing capacity

 Only plant permitted for co-processing in Egypt  Complete service from collection to co-processing

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F₃C N Cl Cl N CN S O CF₃ NH₂

Pesticides treated in the Hon Chong plant, Kien Giang

Province, South Vietnam, October 2003.

 40 tons of pesticides

 Two different insecticide compounds  Fenobucarb 18.8%  Fipronil 2.4%  dissolved in 10,7% Cyclohexanone and 61% of aromatic solvents O CHCH₂CH₃ CH₃ O C CH₃NH  DRE > 99,9999%  External report

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Case Study

Collection & Transportation of Tires in the State of Oklahoma  The State of Oklahoma generates:

 ~ 3.5 million (32,000 tonnes) tires per year

 There are more than 662,000 tires (6,000 tonnes) in stock piles*

 Since 2006 Geocycle has:

 Opened a tire yard in Tulsa, Oklahoma that services 29

counties in the State of Oklahoma

 Invested in a Tire Pre-processing facility

 Purchased a fleet of trailers to support the service orientation of

the Ada Team

 Coprocessed 25,000 tons of tires annually ~ 2 million tires

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Case Study

Investments in Co-processing in Devil Slide, Utah

 3 Fuel Feedpoints; Main Burner, Preheater Riser, Tertiary Air Duct

 Alternative Fuel historically added to Riser

 New Project adds delivery system to Tertiary Air Duct

 The TAD provides increased AF flexibility with respect to material size, density, and energy value. Oxygen levels in the TAD are also ideal for the combustion of these alternative solid fuels

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Case Study

Investments in Preprocessing in Theodore, Alabama

 Capacity:

 Initially 20,000 tonnes/year  75% to be shredded

 Pre-Processing Capacity 0f 10 tph

 Engineered Fuel Specification:

 Non-hazardous solids and sludges  > 5,000 BTU per lb - 12 GJ/t

 < 2" sizing & full destruction of

waste stream

 Ten days of on site storage: 750

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Agenda

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Case Studies

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Concluding messages on co-processing

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Holcim has

Global presence, ensuring cement kilns are available

Strong SD commitment, ensuring strict standards apply



Cement kilns are unique tools for environmentally and

economically sound

Saving of resources through wastes co-processing

Safe hazardous wastes disposal

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Holcim already plays an important role, solving many

waste issues, including hazardous wastes

Experience in co-processing many wastes, also hazardous

The organization to ensure it is done safely

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