1. Presentation to the Environmental Portfolio Committee 11 March 2008
Cement Kiln Co-processing An essential part of the waste management toolkit
Dumisani Tembe
Egmont Ottermann
Presentation to the Environmental Portfolio Committee
11 March 2008

2. Economic Growth Victims of our own economic success as a nation
Economic success has created sustainability challenges
Energy Efficiency Challenges
South Africa is growing faster than the current waste management options can handle. We are victims of our own success.
Future growth in the economy will lead to an increase in the generation of waste, especially hazardous industrial waste.
High Hazard (H:H) Landfill site options in South Africa are very limited and the permitting of any new H:H landfill space in South Africa will be very difficult.
The recent economic success of our country have lead to sustainability challenges, like the electricity crisis, that we as a nation must overcome. One of these is the sustainable and environmentally responsible management of waste.
Waste Management Challenges
Air Quality Challenges

3. Energy Challenge South Africa’s coal resources under pressure
Cement industry faces similar problems to Eskom (quantity and quality of coal)
The cement industry risks becoming non-competitive internationally due to excessive resource input cost locally
Solution: better utilisation of available energy resources
Our natural resources are increasingly coming under pressure. The surge in coal prices has lead to an increase in the export demand for South African coal, beyond expectations.
This has put pressure on the local users of coal to procure the right coal at the right price. The cement industry has not been spared from this and has had to content with significant price increases, with increased difficulty in obtaining the right quality of coal.
A solution to this problem is the improved utilisation of the available energy resources in the country with a renewed focus on the use of renewable energy sources, one of which is waste.

4. Waste Management Challenge
EU decision on Waste Hierarchy
13 February 2007
Prevent
Re-use
Recycle
Recovery
(Including Co-processing)
The above diagram clearly explains the position of cement kiln co-processing as a recovery activity in the waste management hierarchy. The diagram above was adopted for use in the EU on the 13th of February 2007.
The diagram clearly indicates the difference between cement kiln co-processing (recovery) and incineration (disposal). The co-processing of waste in cement kilns results in the recovery of the energy value in the waste (by substituting coal) and the mineral value of the waste (by substituting raw materials). Recovery is also complete with no solid or liquid waste generated in the process.
Modern waste management alternatives to landfill are very expensive and unlikely to offer a practical solution within the next decade. Thus we have a problem:
Land filling is not sustainable as the only hazardous waste management option available. By using only landfill we are effectively storing the waste, leaving it for our children to take care of in the future. We are bequeathing a dangerous legacy to our children.
Recycling and waste minimisation are great solutions but only go part of the way. They are not the complete solutions and other alternatives to the current primary technology i.e. landfill need to be developed.
Cement Kiln Co-Processing is a key element of the waste management hierarchy, not competing with any of the other technologies, but complementing them.
Dispose
(including incineration, landfill, chemical treatment )

5. Co-processing The South African Way:
We solve problems with existing resources!
We solve many problems with one solution!
Using Internationally accepted best practice.
Co-processing is normal practice in the cement industry world-wide
Co-processing benefits recognised by WWF
How is cement kiln co-processing an appropriate “South African” solution?
The ability to solve problems with existing resources
The ability to integrate the solution to multiple problems into one solution
Co-processing has been accepted as best practice for the management of waste by the EU, USA, Brazil, Mexico, Argentina, Vietnam, Japan, Switzerland, Norway, Sweden, Thailand and many other countries, as well as by international conventions such as the Stockholm Convention (Guidelines to Best Available Technology) and the Basel Convention.
The EU has accepted the co-processing of waste in cement kilns as best practice in a number of publications:
The Waste Incineration Directive 2000/76-EC
The IPPC Reference Document on the Best Available Techniques for the waste management Industry
The World Wildlife Fund (WWF) has recognised the environmental benefits of energy recovery from wastes in cement kilns when this is done safely.
More than 10 Million tons of waste are consumed annually through co-processing in cement kilns.

6. Co-processing in a cement kiln
Raw meal
CaO/CaCO3
SiO2
Fe203
Al2O3
Combustion gases: °C
Time > 4- 6 sec at >1450 °C
Clinker : 1450°C > 15 min.
Pre-calciner
Gases: ~1200 °C
Raw meal: ~900 °C
Gases self-cleaning (CaO)
No ash
All minerals in final product
The co-processing of waste in cement kilns is really quite straightforward. Instead of using fossil fuels and natural raw materials, selected waste materials are used in the process in a carefully controlled manner.
The high temperatures and long residence times in cement kilns ensure the complete combustion of all organic portions of the waste. This has been demonstrated in many trials around the world. This total combustion of the waste is ensured by maintaining an oxidising atmosphere in the kiln
Compared to incinerators, cement kilns have far superior capabilities, with longer residence times and higher temperatures.
The high thermal capacity of cement kilns also ensure the total combustion of any waste in the system during a power failure.
The self-cleaning nature of the cement kilns ensures an efficient emissions barrier for hazardous emissions, with 5 stages of inherent emissions control built into the cement process.
The best features of the co-processing of waste in cement kilns are that:
The emissions from the co-processing of waste are essentially the same as when using conventional fuels.
There is no ash from the co-processing of waste in cement kilns. All the ash from the waste materials is incorporated into the clinker.
The ACMP will be glad to, on request, host the committee at a cement operation in South Africa to explain the technical advantages of the cement process in more detail.

7. Air Quality Challenges
Potentially a non-issue because emissions are controllable
The emissions from the co-processing of waste are essentially the same as when using conventional fuels.
EPA - FR40 CFR Part 60
European Union
Stockholm Convention
Co-processing should take place in a regulated environment.
If done responsibly – Emissions from cement kilns that co-process waste are not significantly different than emissions from kilns that do not co-process waste.
The Stockholm Convention (Guidelines to Best Available Technology) indicates that:
“If certain provisions for waste quality and waste feeding are met the co-processing of waste will not change the emissions from a cement kiln stack significantly.”
The USA EPA, in the Federal Regulation 40 CFR Part 60, state the co-processing of waste does not impact on the emissions of dioxins and furans from a cement kiln.

8. Co-processing and Climate Change
Climate Change Impact of Co-processing
As the diagram indicates, the climate change impact of the cement industry is impacted significantly by the co-processing of waste in cement kilns. The waste materials used in cement kilns replace fossil fuels, and thus reduce the impact on climate change of the emission of these fossil fuels.
Organic waste materials that would have been land filled, generating methane emissions, would now replace fossil fuels, saving greenhouse gas emissions both from the reduction in landfill emissions and the reduction of emissions from the combustion of fossil fuels.
By enabling co-processing in South Africa, through regulation, significant Clean Development Mechanism opportunities are created. This will create a positive inflow of foreign currency into the country through the purchase of carbon credits from CDM projects, developed in South Africa.

9. Sustainable Co-processing
Energy Efficiency
Effective Waste Management
Unchanged Emission Standards

10. Perceptions and Trust Acknowledge concerns of stakeholders
Communities
NGOs
Public representatives
Cement kiln co-processing is controversial, but accepted internationally as best practice.
We will implement international best practice, to generate confidence and build trust.
The ACMP acknowledges that there have been concerns of stakeholders and that these have not always been addressed.
Communities have a poor perception of the cement industry; possibly due to a lack of information and communication gaps.
The co-processing of waste in cement kilns is a controversial activity and is subject to much opposition from international and local environmental NGO’s, but is accepted as international best practice by many governments in the developed and developing world.
Communication to public representatives about the opportunities and potential benefits of cement kiln co-processing and about the cement industry has perhaps been lacking.
The cement industry has the technical know how and will apply international best practise to the co-processing of waste in South Africa, but must build trust with all stakeholders including the three spheres of government, local communities and environmental organisations.
Communication is essential. We thereby commit to frequent communication with stakeholder groups
Onora O’ Neill;
Trust is a voluntary action, while suspicion is natural
To build trust we must therefore remove suspicion
To remove suspicion we must respect people’s rights!

11. Co-benefits With co-processing: Waste is diverted from landfills
Natural resource usage is reduced
Climate change impact is reduced
Jobs are created and empowerment is enhanced
National solution (kilns in all provinces except Free State)
A public license to operate is essential for the success of co-processing. If we fail to do so the very existence of our industry is at risk. On the other hand, if we can start to co-process waste, perhaps on a modest basis to start with, we can deliver various benefits that can be shared with our stakeholders.
Cement kiln co-processing, although an accepted international practice, is a typical South Africa response in that it provides a cost effective solution to a national challenge, using existing resources, while at the same time reducing the environmental impact of the cement industry.
Capacity to divert large amounts of waste from landfill, thereby extending the capacity of current landfills and preventing the need to build more.
Reduces resource intensity of cement production through the reduction of the use of natural fuels and raw materials
Reduction in the climate change impact of the cement industry.
Creation of jobs, small impact, through the pre-processing of waste
Cement Kilns are located around the country, in all provinces except the Free State – and the cement industry is crucial to our continued growth, not to mention delivering a successful 2010 FIFA World Cup!
The technology is proven. Cement Kilns are used in the developed and developing world as a waste management option, sometimes mandated by the government to co-process waste. Examples are:
Erica disaster in France
Mad Cow residues in Europe
Pesticide disposal in Vietnam and also China
Many trials have proven total destruction of organic portion of the waste and the integration of the ashes into the clinker product.

12. ACMP Undertakings on Co-Processing
We will ensure occupational health and safety
We will keep our environment safe
We will not accept listed banned wastes
We will guarantee the quality of our products
We will offer waste management solutions to our partners
We will comply with relevant legislation and promote best practices.
We will communicate transparently

13. Co-processing = Co-Benefits!
Prevent
Re-use
Recycle
Recover
Dispose
Co-processing = Co-Benefits!
Meeting Energy Challenges
Meeting Environmental Challenges
Meeting Waste Management Challenges
Indeed, co-processing is a sustainable solution that is an important part of the waste management toolkit in South Africa.
We would be glad to take you questions and listen to your comments.

14. Conclusion
Indeed, co-processing is a sustainable solution that is an important part of the waste management toolkit in South Africa.
The ACMP would be honoured to host the committee at a cement operation, as requested in the previous meetings.

15. We would be glad to take you questions and listen to your comments.
Thank You
Dumisani Tembe
Egmont Ottermann