Cement Industry and the

AF Challenge
1

Dr Shadia Elshishini
Prof Chemical Engineering Cairo Univ
MSEA Advisor

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 MoE Policy
2

Achieve

Sustainable Development

By Working together with an industry that is:

Committed to Environmental Protection

Assumes Corporate Social Responsibility

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 EEAA Mandates Regarding Waste
3

Setting the national strategy for waste management

Propose economic mechanisms to encourage different
activities and procedures for the prevention of pollution
Implement pilot projects for the preservation of natural
resources and the protection of the environment from
pollution.
Participate in laying down plans to protect the country
from leakages of hazardous substances and waste
causing environmental pollution.

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 Type of Wastes
4

Persistent Organic Pollutants, POPs regulated under

Stockholm Convention
Hazardous Industrial wastes: e.g. catalysts, Petroleum
oily sludge, waste from pesticide production, PVC waste
Spent mineral oils: only about 20% are recycled
Waste from pharmaceutical industry including expired
drugs
Hospital wastes
Agricultural waste AW and municipal solid waste MSW
Used tires
Fly ash ..

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 Amount of waste
5

CKD: For a clinker production of about 50 m t/y By-pass dust will

reach 1 m t/y
Fly ash: 5 m t/y for 20 GW Power Plants
Gypsum and Phosphogypsum

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 HZ waste management
6

HZ waste regulated by Law 4 and its amendments

In June 2005, an industrial hazardous waste management center was
established, as a joint effort between EEAA, Alexandria Governorate
and the Ministry for Foreign Affairs of Finland, in Naserya, Alexandria.
The center is designed for treatment of inorganic hazardous waste.
In 2011, the first facility for treatment of mercury in waste fluorescent
lamps was established, at Naserya, as a result of cooperation between
the Governments of South Korea and Egypt.

Organic waste? Inorganic waste, Destruction of POPs?

landfill full ?

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 7

Incineration in Cement kilns

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Alternative Fuel or Raw Material (AFR)
8

AF

ARW

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Limit values of Heavy Metals in AFR
9

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 Element Limit Value kg/t cl

10

Limit values in Input

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 11

Hazardous wastes

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 Types of HZW not allowed in cement kilns
12

According to Basel Convention guidelines for HZ incineration

The following wastes should not be co-processed in cement kilns:
Radioactive or nuclear waste
Electrical and electronic waste (e-waste)
Whole batteries
Corrosive waste, including mineral acids
Explosives
Cyanide bearing waste
Asbestos-containing waste
Infectious medical waste
Chemical or biological weapons destined to destruction
Waste consisting of, containing or contaminated with mercury
Waste of unknown or unpredictable composition, including unsorted
municipal waste.

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 HZW Allowed for Incineration in Kilns
13
Tank bottom sludges, acid alkyl sludges
Oil spills and acid tars from petroleum refining,
Natural gas purification and pyrolytic treatment of coal
Waste machining oils, waste hydraulic oils, brake fluids, bilge oils
Oil/water separator sludges, solids or emulsions
Washing liquids and mother liquors
Still bottoms and reaction residues from the manufacture, formulation,
supply and use of:
Basic organic chemicals, plastics, synthetic rubber, man-made fibres
Organic dyes, pigments, organic pesticides and pharmaceuticals; waste
ink; wastes from the photographic industry; tars
Carbon-containing wastes from anode manufacture (aluminum thermal
metallurgy)
Wastes from metal degreasing and machinery maintenance
Wastes from textile cleaning and degreasing of natural products;
Process wastes from the electronic industry

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 Banned Persistent Organic Pollutants (POPs)
14

National Implementation Plan (NIP) of Stockholm Convention on

POPs: destruction of PCBs and banned pesticides.
Lindane: potential to cause cancer and birth defects in animals.
220 t stored in Adabeya Port for destruction in cement kilns
through World Bank support.
International and National bidding process

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EEAA procedures for HZW incineration in Cement Kilns
15

EEAA is in the process of adopting new

Existing procedures: procedures for granting approvals for HZW
Start with small incineration:
amount of ARF 1. Perform Mass balance on main
Monitor pollutants in feed (RM + Fuel) to ensure
Increase amount that the proposed amount of AFR will
generate pollutants within the range
Monitor
proposed in previous slide.
Repeat to reach
2. Calculate pollutants in output (stack
max amount emissions, clinker, by-pass dust)
Repeat when through measurements. This is
changing ARF type performed once for fingerprinting the
kiln.
3. Monitor stack emissions
4. When using different types of HZ
preliminary approval will be given after
step 1, then step 3 is undertaken.

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Strict and simplified procedures
16

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Egyptian and EU stack emission standards
17

IED Annex VI Egyptian

Co-incineration Standards

Total Dust mg/Nm3 30 30-50

HCl mg/Nm3 10 10

HF mg/Nm3 1 1

NOxi prehater 500

mg/Nm3 450-600
NOx Lepol and long kiln <800 until 2016

Cd+Tl mg/Nm3 0.05 0.05

Hg mg/Nm3 0.05 0.05

Sb+As+Pb+Cr+Co+Cu+Mn
mg/Nm3 0.05 0.5
+Ni+V

Dioxins and furans mg/Nm3 0.1 0.1

SO2 mg/Nm3 50 (1) 400

TOC mg/Nm3 50 (1) 10

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 18

Non-Hazardous waste

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 MSW regulations and strategy
19

Article 37 of Law 4/1994: It is prohibited to throw, treat or burn garbage

and solid waste except in special sites designated for such purpose which
are far from residential, industrial, or agricultural areas, as well as from
waterways.
Article 39 of the ER of Law 4/1994: The solid waste collection
contractors shall be committed to the cleanliness of the waste containers
and trucks whose regular cleanliness must be a precondition for ensuring
safety and strength of the means of waste transport
In June 2000 MSEA/EEAA issued the National Strategy for Integrated
Municipal Solid Waste Management in which the roles of central
government and governorates are defined.
September, 2013, Integrated Solid Waste Management Sector (ISWMS),
established under MSEA to improve the solid waste sector in Egypt and to
implement the National Solid Waste Management Program (NSWMP)
supported by KfW and GIZ
A Waste Management Agency is proposed to be established under MoE

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 MSW management options
20

The collected municipal solid waste in most Egyptian

governorates fluctuate between 50 - 75% of the generated
amounts, about 85% of these amounts ends up in open
dumps causing adverse environmental and health impacts
Historical accumulations reach 5-7 million tons
Different Options are studied:
Plasma arc technology
Waste to Electricity

Composting

RDF production

Gasification

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 Plasma Arc Technology
21

Ionized gas
at high temp
capable of
temperature
capable of
conducting
electrical
current

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 Plasma Arc Characteristics
22

Temperatures 4,000C to over 7,000C

Hazardous & toxic compounds broken down to elemental
constituents by high temperatures
Acid gases readily neutralized
Organic materials Gasified to syn gas (H2 & CO) or melted
Residual materials (inorganics, heavy metals, etc.)
immobilized in a rock-like vitrified mass which highly
resistant to leaching
Current project ln Japan: Gasification of 300 TPD of MSW
and Generates up to 7.9 MW of electricity (4.3 MW to grid)
Tipping fees of $30/ton make it profitable

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Waste to Electricity
23

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 Biofuel from agricultural waste
24

Agricultural waste is a renewable energy source and a valuable

resource mainly in the production of bioethanol and bio diesel

E-CHEM is interested in the project but main obstacle is collection

Yields can reach 200 l/t

30 MT/y -> 6000 Ml/y
US goal for the
next 10 years:
20% cut in Production in 2012 in Million gal/y
gasoline North & Central America 13,768
consumption by Brazil 5,577
investing in biofuel
Europe 1,139
China 555
Canada 4,490
DOE to spend
Billions US$ Australia 71

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 25

Compulsory vs Voluntary
Use of AFR in Cement kilns

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 Problem Definition
26

Role of Cement Plants in the WM system (voluntary action)

Service providers: replacing municipalities role in managing MSW
(incinerators) entitled to gate fee
Commodity buyers: For MSW to be a commodity on the market
characterized as fuel (CV) and priced
Enforcement tools:
1. Requiring % of RDF in Fuel Mix
2. Adopting the more stringent standards for EU co-processing
3. CO2 reduction by amount equivalent to that caused by coal
combustion

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 Preliminary Feasibility on RDF
27

Composition

Revenues

Gate fee sensitivity

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 Conditions for Compulsory Actions
28

To be able to adopt enforcement tools 1 & 2:

RDF should be available to all cement plants at a cost-
effective price and with a steady supply.
Prohibit monopoly of RDF suppliers and control price

The new Executive Regulation requests that:

Cement Companies present annual performance reports
including the fuel mix.

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 CO2 Reduction Required by New ER
29

Cement companies will commit to reducing CO2 by an

amount equivalent to the increase caused by switching to
Coal
Different measures could be used:
Use alternative fuels
Participate in Projects for renewable energy

Produce green cement which uses less clinker and more

additives

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30

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