Guidelines for Co-Processing Fuels and Raw Materials in Cement ManufacturingCement Sustainability Initiative (CSI)Cement Sustainability Initiative 1 Introduction 21.1 The Cement Sustainability Initiative 21.2 Background 21.3 Why a Version 2 (2013) of the CSI guidelines? 31.4 Contribution of co-processing to waste management 52 Cement manufacturing technology and co-processing ofmaterials derived from waste 62.1 What is cement? 62.2 Thermal characteristics of a cement kiln 72.3 Cement kiln suitability for processing waste 72.4 Turning waste into a source of raw material and fuel 82.5 Feeding points for waste materials into the cement manufacturing process 93 Selection of fuels and raw materials 103.1 Considerations for cement manufacturers 103.1.1 Kiln operation 103.1.2 Emissions 103.1.3 Clinker, cement and final product quality 113.2 Employee health and safety 124 Recommended techniques and practices for cement co-processing 134.1 Collection and transport of waste and by-products 134.2 Acceptance of alternative fuels and raw materials 144.3 Responsible use of biomass 154.4 Commonly restricted waste 154.5 Incinerator ash 164.6 Pre-processing 174.7 Kiln operation 184.8 Emissions control and monitoring 194.9 Communications and stakeholder involvement 195 Performance indicators and reporting guidelines 205.1 Key performance indicators 205.1.1 Air emissions 205.1.2 Energy KPIs 205.1.3 Raw material KPI 205.2 Reporting 215.2.1 Which installations are covered? 215.2.2 Reporting frequency 215.2.3 Performance values 216 Glossary 227 Acronyms and abbreviations 248 Elements and compounds 24Appendix: Guidance for co-processing 25Contents21 Introduction1.1 The Cement Sustainability Initiative (CSI)Cement is the most widely used building material in the world, with nearly 450 kilograms of cement being consumed yearly per capita. Making cement is an energy- and resource-intensive process, with both local and global impacts. Recognizing this, several cement companies initiated the Cement Sustainability Initiative (CSI) in 1999 as a member-sponsored program of the World Business Council for Sustainable Development (WBCSD).Today, the CSI is a global effort by 24 major cement producers with operations in more than 100 countries who believe there is a strong business case for the pursuit of sustainable development. Collectively these companies account for about one-third of the worlds cement production and range in size from large multinational companies to smaller local producers.General information on the CSI may be found on the project website: wbcsdcement. 1.2 BackgroundThe growth of the world population and the increase in average income are the main drivers behind the projected increases in waste generation worldwide. In parallel, various forms of waste are increasingly considered as resources that should be used in industrial processes. In order to avoid the loss of valuable resources and to safeguard precious land, the landfilling of waste is increasingly being prohibited or viewed as an option of last resort. While improvements to landfilling practices are being pursued in many developing countries, awareness is increasing that landfilling should be considered a temporary measure while developing a more resource-efficient waste management solution.Simultaneously, the need for construction materials, such as cement, is rising due to population increases, growing economies and the trend towards urbanization. Cement production takes place worldwide, and in general close to where people are living and producing waste. This provides a local option for waste management. Concrete is a sustainable product (long-lasting, energy efficient in buildings, recyclable) even taking into account the energy-intensive component of cement in its production.Considering increasing waste production on the one hand and the resource demands of the cement process on the other hand, cement companies started in 1979 to look at waste as a source of raw material and energy. Step by step, the use of waste by cement companies is now making a considerable contribution to the waste management system in many countries. The use of cement kilns for waste recovery termed co-processing should be situated in the waste hierarchy in between recycling and energy recovery. Where waste materials cannot be managed technically or economically by prevention and reduction, reuse and recycling, the cement manufacturing process provides a more ecologically sustainable solution compared to landfill or dumping, thanks to full energy and material recovery in the process (see figure 1, section 1.4).Cement plants play a vital role in communities, conserving natural resources by utilizing waste for its production while at the same time recovering the energy content of the materials. Co-processing is a term used to refer to the use of suitable waste materials in manufacturing processes for the purpose of energy and resource recovery and the resultant reduction in the use of conventional fuels and raw materials through substitution. The co-processing of waste by cement plants is a service that the cement plants can provide to their communities for the mutual benefit of both the plants and the communities: the cement plant can receive a reliable local supply of fuel or material that replaces natural resources; the community can benefit from a more ecological local solution that avoids the large capital expense of incinerators and waste-to-energy plants or the resource inefficiencies associated with landfills.1Introduction31 Introduction1.3 Why a Version 2 of the CSI guidelines?Producing cement consumes both large quantities of 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 conventional fuels and virgin raw materials needed, and thus reduce the overall environmental impact of the operations. These alternative materials can be either waste or by-products from other processes. While there are benefits to be gained from using such materials in the cement industry as alternative fuels or raw materials, some waste streams are not suitable for this purpose. In keeping with this understanding, CSI member companies committed under the CSI Agenda for Action, published in 2002, to using waste materials only where it can be done safely, without harm to employees, neighbors and the environment or manufacturing process, and by maintaining the high quality of products. Building upon the principles of respecting the waste hierarchy, industrial ecology, and careful integration into local resource management infrastructures, in 2005 the CSI published its first set of guidelines for the responsible use of conventional and alternative fuels and raw materials in cement kilns.This revised version of the Guidelines for Co-Processing of Fuels and Raw Materials in Cement Manufacturing provides a technical overview of key issues and guiding principles relating to the responsible selection and use of fuels and raw materials in the cement industry, in view of technology developments and the evolution of stakeholder expectations in recent years. This guidance draws on the experience gained since the first guidelines were published. It is not meant to be an all-encompassing compendium on the use of waste in the cement manufacturing process, but rather outlines the most important principles and procedures which must be undertaken in the responsible use of co-processing in cement manufacturing.These guidelines should therefore be used in conjunction with other internationally recognized guidance documents, most notably: United Nations Environment Programme (UNEP) Basel Convention Technical guidelines on the environmentally sound co-processing of hazardous waste in cement kilns1 The guidelines issued by the Conference of the Parties to the Stockholm Convention2 European Commission Reference Document on Best Available Techniques (BREF)3 Other cement manufacturing specific guidance documents such as the Holcim- GTZ Guidelines4and SINTEF reports5provide other useful information on co-processing in the cement industry.6The largest volume substances emitted during the production of cement are particulate matter (dust), oxides of nitrogen, sulphur dioxide, carbon dioxide and carbon monoxide. Trace quantities of volatile organic compounds, acid gases, some trace metals, and organic micro pollutants may also be emitted. While cement kilns typically operate at steady conditions (excluding startup and shutdown), naturally occurring changes in raw materials and fuels composition can produce small day-to-day variations in emissions.Target audienceThese guidelines provide a practical reference for cement companies and their stakeholders, helping them understand and identify responsible and sustainable approaches to the selection and use of fuels and raw materials.We aim for the guidelines to be equally helpful to all cement companies and public bodies and widely distributed and used, particularly in countries and regions where specific requirements have not yet been fully identified. However, these guidelines are not meant to, and cannot,replace or supersede local, national or international requirements which must be followed.Prior to finalizing these revised guidelines, the CSI consulted various stakeholder groups from industry, non-governmental organizations (NGOs), academia and regulatory bodies to solicit feedback on the quality and consistency of the document. Very valuable input was received and has been integrated as much as possible. We would like to thank all those who have taken time to respond to us with their specific comments. They have 1 UNEP Basel Convention Secretariat. Technical Guidelines on the Environmentally Sound Co-processing of Hazardous Wastes in Cement Kilns. Available from basel.int/TheConvention/Publications/TechnicalGuidelines/tabid/2362/Default.aspx.2 Secretariat of the Stockholm Convention on Persistent Organic Pollutants. 2007. Guidelines on Best Available Techniques and Provisional Guidance on Best Environmental Practices Relevant to Article 5 and Annex C of the Stockholm Convention on Persistent Organic Pollutants: Cement Kilns Firing Hazardous Waste. Expert Group on Best Available Techniques and Best Environmental Practices, United Nations Environment Programme. Available at chm.pops.int/Implementation/BATBEP/Guidelines/tabid/187/Default.aspx.3 European Integrated Pollution Prevention and Control Bureau. 2010. Reference Document on Best Available Techniques in the Cement, Lime and Magnesium Oxide Manufacturing Industries. European Commission, Joint Research Centre, Institute for Prospective Technological Studies. Available at eippcb.jrc.ec.europa.eu/reference/BREF/clm_bref_0510.pdf.4 Holcim-GTZ. 2006. Guidelines on Co-processing Waste Materials in Cement Production. The GTZ-Holcim Public Private Partnership.5 SINTEF. 2009. Requirements for Co-processing of AFR and Treatment of Organic Hazardous Wastes in Cement Kilns. SINTEF. 2009. Guidelines for Co-processing. Published in Proceedings of «China International Conference on the Utilization of Secondary Materials and Fuel in Building Materials Industry”.6 Further reference information can be found on the CSI website: wbcsdcement/index.php/key-issues/fuels-and-materials.helped us to improve the quality of this document. 4PrinciplesWith the aim of assisting cement companies in designing their own strategies to contribute to sustainable development, the first version of the CSI guidelines introduced principles for member companies on how they would select and use fuels and raw materials in the future. The principles introduced in 2005 are still valid and are repeated and enhanced below: Maintain an economically vibrant industry, delivering profit to shareholders, rewarding employees, and contributing to local communities through employment, taxes and community activities. Comply with laws, regulations and standards relating to safety, health, environment and quality where they currently exist, and contribute to the improvement of the regulations and policies dealing with waste management in the country. Continue to deliver high-quality, competitively priced goods and services that meet our customers needs and the strictest product standards. We will develop new cement products in response to societys changing social, environmental and economic needs. Make the health and safety of those involved in and affected by the production of cement paramount in decision-making. Design installation, transport, handling and operating procedures to protect the health and safety of employees, contractors and local communities. Be recognized as attractive employers and work to build relationships of trust with the communities in which we operate. Evaluate our choices within the broader context of sustainable resource management. We will seek to recover the mineral components and energy content of waste and by-products of other industrial, agricultural or municipal processes in our operations to replace conventional fuels and raw materials where possible and appropriate. Be involved in the waste management infrastructure of the countries in which we operate. We will be prepared to respond quickly to changes in the supply of waste and by-product resource streams, in particular where more sustainable options for their use emerge. Seek to use alternative fuels and raw materials as efficiently as possible by using the recommended co-processing techniques and practices, and by continuously improving our process management systems. Use common principles for monitoring, managing and reporting impacts in key areas, in particular health and safety, carbon dioxide and other airborne emissions, and material substitution rates. Continuously monitor and improve our safety, health, environment and quality management practices, and train employees in the policies and procedures relevant to their roles. We will pay particular attention to maintaining strong management practices in countries where few health, safety, environment or quality regulations currently exist. Engage in constructive dialogue with stakeholders, and make decisions regarding the use of conventional and alternative fuels and raw materials in an open, transparent and accountable way. Collect data to continuously improve our understanding of the impacts of our operations and report regularly on our performance.1Introduction51.4 Contribution of co-processing to waste managementGovernments, municipalities, companies and agricultural organizations that are faced with decisions on how to manage their waste are guided by the waste hierarchy in conjunction with economic value. Co-processing of waste in the cement industry is an advanced and innovative recovery process whereby energy is recovered and the non-combustible part