Co-Processing  To reduce dependence on primary
resource markets
Co-processing is the use of waste as raw
material, or as a resource of energy, or
both to replace natural mineral resources
(material recycling) and fossil fuels such
as coal, petroleum and gas (energy
recovery) in industrial processes, mainly in
energy intensive industries such as cement,
lime, steel, glass and power generation.
Waste materials used for co-processing are
referred to as alternative fuels and raw
materials.
Concept of Co-processing
Co-processing is a proven sustainable
concept that reduces demands on natural
resources, reduces pollution and landfill
space, thus contributing to reducing the
environmental footprint. Co-processing is
also based on the principles of industrial
ecology, which considers the best features
of the flow of information, materials, and
energy of biological ecosystems with the
aim of improving the exchange of these
essential resources in the industrial world.
Benefits of Co-processing
 To conserve natural resources of
energy and materials
 To reduce emissions of greenhouse
gases in order to decrease global
warming and demonstrate a
positive impact on integrated
environmental indicators, such as
the ecological footprint
 To reduce the environmental
impacts of the extraction (mining
or quarrying), transporting, and
processing of raw materials
 To save landfill space and reduce
the pollution caused by the disposal
of waste
 To destroy waste completely,
eliminating potential future
liabilities.
 To dispose waste with minimum
environmental impact
Co-processing contributes to the industrial
competitiveness, is a complementary
technology to concepts such as cleaner
production or recycling and should be
considered as a treatment alternative within an
integrated waste management concept. It is
usually more cost effective than building new
waste treatment capacities thereby reducing
waste management cost to society.
Potential of Co-processing
The global industrial demand for energy is
roughly 45% of the total demand and the
requirements of the energy intensive
industries (EII) are more than half of the
total industrial demand, at 27% Worldwide.
Wastes suitable for Co-processing have an
energy potential equivalent to nearly 20%
of the fossil fuel energy used by the EII and
coal-fired power plants. By 2030, the
thermal substitution rate of waste could rise
to nearly 30%. In the EU-25 countries of
Europe, the available energy potential in
waste currently represents nearly 40% of
this demand, and this is expected to rise to
almost 50% by 2030. Co-processing offers
a significant potential for the reduction of
greenhouse gas emissions from fossil fuels.
 Types of Co-processing
Co-processing and reduction of
greenhouse gases
 The industry produces 5% of global
man-made CO2 emissions
worldwide. Half of this is a result
of the chemical process involved in
the transformation of limestone into
clinker, 40% is a result of burning
the fuel. The remaining 10% is split
between electricity use and
transport.
 There are three main techniques
available to the industry in
reducing net total and per tonne
CO2 emissions:
I. Maximize the efficiency of the
manufacturing process and
associated equipment to use
fuels and materials as
efficiently as possible.
II. Reduce the amount of fossil
fuel used in the process by
replacing it with biomass and
wastes that would otherwise
have been burned without
energy recovery and other
materials having lower carbon
content.
III. Replace a proportion of the
clinker in cement with
alternative materials (which
do not require thermal
processing), reducing the
CO2 emissions per tone of
cement produced.
IV. Without co-processing the
wastes would have to be
incinerated or land filled
with corresponding
greenhouse gas emissions.
V. In 2006, the percentage of
energy gained by the use of
waste as a fuel in the EU
stood at about 18%, resulting
in a reduction of 8 metric
tones of CO2 emissions each
year whilst saving about
5metric tonne of coal.
Position of Co-Processing in Waste
Management Hierarchy
Co-Processing a win-win situation for:
i. Industries (Profit):
A cost-effective substitution of
natural resources thereby
improving the competitiveness of
the industry.
ii. Ecology (Planet):
Environmentally sustainable waste
management and important saving
of natural resources.
iii. Society (People):
A long term and sound solution
for the treatment of different types
of waste produced by society.
European Union recognizes
co-processing as a resource
efficient solution
The co-processing of waste has been
officially recognized by the European
Commission as a resource efficient
best practice under its flagship
initiative for a resource-efficient
Europe under the Europe 2020
strategy.
‘Co-processing’ is a
complementary technology to
concepts such as
‘Cleaner Production’
or ‘Recycling’ and should be
considered as a treatment
alternative within an integrated
waste management concept.
Practical Example of Co-Processing
Cement production consumes large
amounts of both raw materials and fuel
and produces substantial CO2 emissions.
The use of alternative fuels and raw
materials in cement manufacturing can
reduce the amount of fossil fuels and
virgin raw materials needed, and thus
reduce the overall environmental impact of
the operations. These alternative materials
may be either by-products from other
industrial processes, or waste streams such
as municipal solid waste, sewage sludge,
ETP sludge, discarded tyres and plastics.
In the State of Tamil Nadu in India, large
number of textile dyeing units are in
operation in Tiruppur, Erode, Namakkal
and Karur districts. These units generate
huge quantity of sludge from the treatment
of trade effluent, which is categorized as
hazardous waste needs to be disposed
properly. M/s. Ultra Tech Cement Limited,
Reddipalayam, Ariyalur District carried
out a trial run of co-processing of textile
dyeing industry ETP sludge in their
cement plant. The trial study reveals that
there is no significant variation in the
quality of stack emission, ambient air
quality, clinker composition, and the
physical strength of cement. There is no
leaching of heavy metals from the clinker.
This also conserves the raw material (lime
stone) consumption. Thus co-processing of
textile dyeing industry ETP sludge in the
cement industry is a sustainable
development concept based on the
principles of making one industry’s waste
another’s raw material.
 Initiatives taken by Government plants in the State on the importance of
Authorities on Co-Processing of Waste co-processing and an action plan targeting
10 % fuel requirements substitution in the
Waste Minimization through next three years.
Co-Processing is the concept on
“Utilization of Hazardous waste” as a Cement Plant Waste Co-Processed
supplementary resources or for energy during the year
recovery, or processing in line with Ambuja Cement Ltd., 1945.845 Tons During
Ambujabagarm 2009
Hazardous Waste (Movement, Handling &
Tal-Kodinar,
Trans boundary Movement) Rules, 2008. Dist- Junagadh
Central Pollution Control Board (CPCB) Sanghi Cement, 266.77 MT from
has been empowered to accord approval Sanghipuram, July-2009 to
for utilization of different categories and Tal-Abdasa, Dist-Kutch Mar-2010
type of Hazardous Waste. Subsequently Ultratech Cement, 11175.282 MT during
CPCB has developed guidelines in Kovaya, Tal-Rajula, 2009-2010.
Dist-Amreli
February-2010 for co-processing of
Total 15, 22.840 MT of waste has been
Hazardous Waste in cement kilns. Other
co-processed in cement kiln till
substances with high calorific value viz.;
tyres and plastic wastes, which are
July-2014 in Gujarat.”
otherwise treated as “waste” not in the References:
purview of “Hazardous Waste” can also be
 https://en.wikipedia.org/wiki/Co-
co-processed in the Cement Industry,
processing
Thermal Power Plant, Iron and Steel http://www.sweepnet.org/ckfinder/userfile
Industry through co-processing. s/files/events/Forum-beirut-
april2011/session5-Cementis.pdf
At present Gujarat Pollution Control  file:///C:/Documents%20and%20Settings/
Board has permitted a few Cement Plants Administrator/Desktop/session5-
to co-process different compatible Cementis.pdf
 http://www.cmaindia.org/cms/images/conf
hazardous Wastes. During the year erence/Technical-V/Mr-V-R-Ghadge.pdf
2009-2010 approx. 13000 MT of Waste  http://www.envirobiotechjournals.com/ar
ticle_abstract.php?aid=5161&iid=173&ji
has been co-processed in the cement d=4
Industries, which is a good initiative to  http://gpcb.gov.in/pdf/ENV_SOME_INIT
start with. GPCB has taken up this issue IATIVES_IN_GUJARAT.PDF
 http://gcpcgujarat.org.in/userfiles/file/Eve
on priority by conducting several meetings nts/Environment%20Laws%20and%20it
with stake holders for promotion of co- s%20Implications%20in%20Gujarat-
%20Shri_%20V_R_%20Gadge,%20GPC
processing of Hazardous Waste in cement B.pdf
kilns instead of disposal by Incineration.
A comprehensive database on such wastes GUJARAT CLEANER PRODUCTION CENTRE
that can be co-processed and incinerated in ENVIS CENTRE
the State is developed. Gujarat Pollution Block No. 11 & 12, 3rd Floor,
Udyog Bhavan, Sector-11,
Control Board has also sensitized the Gandhinagar-382017
Executive Authorities of the Cement Email id: gcpc-env@nic.in
Website: www.gcpcenvis.nic.in