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
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