The third International Industrial Rocks &
Construction Material Forum ,
31rd March – 1st April 2015.
Open new horizons for the recycling the
wastes of IR & Construction Material
Dr. Bassem Nassouhy
QHSE & BD Manager
We are 7 Billions inhabitants today. We will be 9 billions in 2050 :
Traditional human behaviour is not affordable anymore
The “Take-Make-Reject” historical way of life:

jeopardizes non renewable resources

assaults our environment
Make
Take
Reject
Environment
Historical oily ponds and contaminated
soil
The consequences, as
an example
Natural ecosystems : a
sustainable model
Minimum consumption of resources (material, water
and energy), based on optimum recovery of rejects
Industrial Ecology : Inspired by the
efficiency of natural ecosystems
A scientific approach which consists of mimicking
the low consumption equilibrium of ecosystems
Lower
consumption of
natural resources
Minimum of
rejects
 Someone’s waste becomes resources for others
 Energetic Surplus = Energy sources
 Logistic improvement (supply + collection)…
Waste Equivalent Energy
•
1 kg waste
10 MJ
•
1 kg fuel
42 MJ
•
1 kg carbon
30 MJ
•
1 kg dry wood
15 MJ
•
1 kg dry peat
12 MJ
10 MJ of energy can heat 80 litters of
water by 30°C = 1 hot shower !
10 MJ can light a bulb for 9 hours
Challenges Facing Us Everyday
Why the Industrial
Ecology Again ?
CLIMATE
CHANGE
LIMITED GLOBAL
RESOURCES
DOING MORE
WITH LESS
REGIONALLY
UNBALANCED
GROWTH IN
CONSUMPTION
AND RE-USE
EXISTING
Cement plants are at the heart of
many Industrial Ecology synergies
Municipal
wastes
Communities
non
recyclable
The Cement Process
Sewage
plants
Waste water
Pretreatment
Sewage
sludge
Alternative fuels
Landfill and
quarries
Power
Drying – Electricity
production
Waste
heat
Biogas
Landfill mining
Aggregates
Prétraitement
Power
plants
Fly ashes
Pretreatment
Cement plant
Slags
Power
ARM
Additives
Gypsum
Construction
Demolition
Blast
furnaces
Prétraitement
Alternative fuels
Industrial and
commercial
wastes
A perfect tool for recycling energy and matter
Industry
Pretreatment
Wood
plastics
Alternative Fuels
Alternative Raw Materials

Chemical Flexibility of the
raw mix
Up to 70 waste streams
and 350 Kg/ton of clinker
2.000 °C
Additive to
Cement

Very High temperatures

Long residence time

Gas cleaning inherent to
the process
Up to 12 waste streams and 85% rate
of substitution

Fly Ashes

Blast Furnace
Slag

Silica Fumes
The cement process is by
nature a top-flight treatment
solution
 Full destruction of organic waste compounds
- high temperature, long residence time
 High efficiency gas cleaning inherent to process
 No residue (ash) since minerals get combined
Traditional incineration :
2 sec. - > 1200 °C, as the most
stringent requirement for high
chlorine content wastes
up to 25 % of slag to get rid of
15 m
up to 5 % of hazardous fly ashes
Efficiency
of co -&processing
Cement
industry
A.F.R.
Meal temp 100 Deg. C
Cap. 8000 t/d
Mat. 100C
Raw Meal
Gas 400C
Mat. 400C
Gas 600C
A. F. R.
Gas 1200C
Gas > 2000C
Preheater
Tower
Precalciner
Kiln
Gazes self-cleaning
Gazes self-cleaning
(CaO)
(CaO)
Cooler
Clinker
No ash
No ash, No Wastes,..etc
All mineral in final product
All mineral in final product
Material Inlet temp. 900 Deg. C
Material temp.1450 Deg. C
Clinker temp.150 C - Cap. 5000 t/d
The recycling of waste in a cement kiln
PROCESS
 No impact on products
 No impact on the process
 No impact on emissions
 No impact on health
• Particles
• HCl
• SO2
• NOx
• CO
• Heavy metals
• Dioxins et furans
• CO2
EMISSIONS
No difference
No difference
No difference
Possible reduction
Slight increase but manageable
No difference
No difference
Strong reduction
A very broad range of waste
* Biomass





Rice husks, coffee husks,
Palm Kernel shells,…
Sewage sludge
Animal meal
Crops for fuel
wood,…
* Municipal waste

Refused Derived
Fuels,…
* Used tires, used oils
* Hazardous waste






Solvents
Paint sludge, inks,
varnish
Hydrocarbon waste
(tank bottoms,
slops,…)
Cutting oils
Chemical waste water
Catalyst,…
* Non hazardous industrial and commercial waste

Shredded Plastic, production waste,
packaging waste,…
Preparation of packaged chemical
World Leader
wastes for direct incineration
in Cement
EcoCem Industrial Ecology in UAE
UAE: “A country moving fast and strong towards renewable
energy sources”
LAFARGE EXPERIENCE OF WASTE STREAMS
•
•
•
•
•
•
•
•
•
•
Used Oils
Other Hydrocarbons - Sludge of hydrocarbons - Drill cutting
Tyres – Solid or Chips
Sewage Sludge
Solvents
Spent Pot Liners
Spent Blasting Grit
Saw dust & Wood Chips.
Expired chemicals
More than 30 types of ARM
World Leader
in Cement
A long term commitment
to Sustainability
Lafarge has a well balanced geographical portfolio,
present in 79 countries and on every continent
A World leader in Cement # 1 (the biggest) - # 2 in Gypsum
Operate in 79 countries - Employ >70,000 people
Industrial sites worldwide >2,500 - Turn over 18 billion Euro
Western Europe
Workforce: 17,900
Sales: 6,021 M€
Central
and Eastern Europe
Workforce: 8,600
Sales: 1,761 M€
North America
Workforce: 14,200
Sales: 4,270 M€
Asia
Workforce: 20,900
Sales: 2,029 M€
Latin America
Workforce: 4,400
Sales: 968 M€
Africa
Workforce: 11,200
Sales: 2,373 M€
Middle East
Workforce: 6,400
Sales: 1,611 M€
Lafarge experience since 1970 in Industrial
Ecology in more than 36 countries, 88 plants
Ecovesta: 100%
Scori: 25%
Delvanis: 51%
BEB: 80%
ThermoTeam: 25%
Ecosolution: 100%
Energa: NC
Sapphire: 100%
EcoProm Effect: 51%
EcoGest: 100%
Scori: 14%
Valren: 50%
Coderes: 51%
Systech: 100%
EcoGest: 100%
EcoGreen: 80%
Recy Eco: 51%
BeoEkoKorak: 100%
Ecocem: 49%
Ecocim : 45%
Ecocem : 100%
Jordan..: 100%
EcoCem Consult: 100%
EcoCem Ind Ecology: 49%
Morelastic…: 82%
Eco-Processa: 50%
Ceprocem Services: 100%
ResourceCoAsia: 20%
Eco2 : 50%
 31 companies, 12 companies controlled 100% including LIEI
 275 employees for IE plus subcontractors
MundoVerde: 20%
Lafarge vision
• Being sustainable
The production of one ton of
cement necessitates non-renewable
raw materials and generates CO2
emissions.
Replacing a part of fossil fuels with
alternative fuels offers a response
to this double environmental
challenge and provides an
economically viable waste
treatment option to local
communities.
Ambitions 2020
50% of non fossil fuels (30%
biomass)
Alternative Fuels consumption
In Lafarge group
% substitution Alternative Fuel Lafarge
16,0%
15,0%
14,0%
13,0%
12,0%
11,0%
10,0%
9,0%
8,0%
2002
2003
In 2012
2004
2005
2006
2007
2008
2009
2010
2011

3.2 MT of Alternative Fuels

400 kT of Tyres

800 kT of Refuse Derived Fuel
2012
Open new horizons for the recycling the wastes
of IR & Construction Material
Bassem Nassouhy, PhD, MBA
QHSE & Business Development Manager
[email protected]
+971 555 438 506