Displaying items by tag: Alternative Fuels

Thailand: Executives from 50 administrative bodies in Nakhon Ratchasima Province have discussed how to dispose of 638,060t of accumulated garbage. A report on 'proper and practical methods' for disposal of the rubbish must be sent to the Office of Natural Resources and Environmental Policy and Planning by 30 July 2015.

The Comptroller-General's department has calculated that Nakhon Ratchasima will need US$6.19m in the 2016 fiscal year to dispose of the accumulated trash. Ranongrak Suwanchawee, president of the Nakhon Ratchasima Provincial Administrative Organisation, said that officials had agreed to transport and dispose of the garbage at a TPI Polene cement plant in Saraburi Province. This meant 29,000 trips to carry the trash in trucks plus the digging and levelling of a tip. The organisation has estimated that Nakhon Ratchasima would need a budget of about US$7.33m, slightly more than the department calculated.

India: In an update to news on 16 June 2015, which stated that US$49.8m or 27,420t of Nestlé's Maggi noodles has been recalled in India and are now being used as an alternative fuel at five Indian cement plants, local media has reported that Nestlé has paid Ambuja Cements US$3.14m for the service.

Canada: McInnis Cement and the St Elzear Forestry Cooperative Association (ACF) have signed a cooperative agreement to study the feasibility of using forest biomass as an auxiliary fuel for the cement plant under construction in Port-Daniel-Gascons.

The utilisation of forest biomass as an alternative fuel would enable the McInnis cement plant to reduce its emissions of greenhouse gases (GHG). McInnis Cement has provided the equipment necessary for the use of alternative fuels at its new cement plant.

"We are pleased to establish this collaboration with the region's forest industry in line with our GHG reduction plan," said Christian Gagnon, president and CEO of McInnis Cement. "Any operations that result from this agreement will be reviewed by the Environmental Committee, whose work began in April 2015," he added.

Forest biomass is a fuel source in abundant supply in Gaspé. McInnis Cement requires a local long-term quality source of supply at competitive costs. The St Elzear ACF is able to supply forest residues, wood chips, sawdust, shavings and bark.

"By studying the possibilities together, including from the outset the client's needs and the capabilities of potential suppliers, we are putting all the pieces in place to make this project a reality," said Sebastien Roy, executive director of the St Alzear ACF. "The success of a fruitful partnership between McInnis and our organisation would be a big boost to our industry. The situation is complex since, beyond availability, supply sources need to be guaranteed over the long-term and quality and prices must remain competitive, including product transportation and processing costs."

Egypt: According to Reuters, Arabian Cement Company has commissioned new alternative fuel processing machinery at its plant in Suez.

The state-of-the-art FLSmidth HOTDISC^TM allows Arabian Cement's plant to rely completely on coal and alternative fuels to run its operations. Moreover, it enables the plant to operate its kilns using alternative fuel materials directly, without the need to pre-treat them. Arabian Cement now has a designed fuel mix of 70% coal and 30% alternative fuels. The alternative fuel that will be used will be a mixture of agricultural wastes, municipal sludge and refuse-derived fuels (RDF). Alternative fuel use is expected to result in around 60,000t/yr of reduced CO₂ emissions.

Egypt/Sudan: According to Daily News Egypt, Qalaa Holding for Investment has signed an agreement with Financial Holding International (FHI) to sell FHI some of Qalaa's units. This is in line with Qalaa's aim to exit from some of its non-basic businesses and to reduce its consolidated debts of US$105m.

Qalaa will sell FHI its stakes in MENA Homes, Grandview and Dina Farms Land Companies, which will be separated from Dina for Agricultural Investments. In return, Qalaa will buy FHI's stakes in several affiliated companies, including cement producer ASEC Holding, as well as Taqa Arabia and Mashreq Petroleum in the energy sector. Qalaa will also buy FHI's stakes in Nile Logistics International in the Transport and logistics sector, Dina Farms Supermarkets in the retail sector and United Company for Foundries (UCF) in the metallurgical industry sector. The deal is expected to be finalised by December 2015, after the customary conditions and requirements are met.

Abdallah El-Ebiary, managing director of Qalaa's cement division, said that the cement sector is a main strategic area for Qalaa and that it has no intention of exiting it, nor the transport and energy sectors. He added that FHI plans to build a new pulveriser mill at the ASEC Cement plant in Minya, Egypt within the company's plan to convert to alternative energy due to the energy deficit and gas crisis. The cost will be US$30.2m and it will be built in the fourth quarter of 2015. "The company's strategy for the next period is to diversify to new and cheap energy sources instead of the traditional and unavailable sources. The investment cost is at US$30.2m, with US$1.31m for a pulveriser mill and US$11.8m for alternative fuel production," said El-Ebiary.

Qalaa also plans to increase the production capacity of its Takamol cement plant in Sudan from 430,000t/yr to 800,000t/yr in 2016. Qalaa aims to establish a new coal mine for the plant. The plant is 51% owned by ASEC Cement and 49% controlled by the Sudanese Social Security Investment Authority (SSIA), the entity that manages all pension funds in Sudan.

Philippines: According to the Philippine Daily Inquirer, on 24 June 2015 the Pasig City government brought online what it described as, 'The country's largest facility for turning rubbish into fuel, capable of processing 600t/day of trash.'

The plant, which is Pasig City's joint project with the IPM Construction & Development Corp (IPM) and the Metro Manila Development Authority (MMDA), can process almost all of the city's daily waste production into refuse-derived fuel (RDF). Pasig City mayor Maribel Eusebio said that the plant would produce fuel pellets from the waste, which would then be supplied as an alternative fuel to cement plants. The RDF is majority-owned by Basic Environmental Systems & Technologies (BEST), a subsidiary of publicly-listed Minerales Industrias Corp, as well as France-based Lafarge Industrial Ecology International.

The plant mechanically segregates waste, selecting garbage with high thermal value that will be shredded, made into pellets and wrapped into bales. The plant is expected to convert 25 – 35% of the processed waste into alternative fuel for cement kilns. "The plant addresses serious concerns on increasing municipal solid waste and disposal," said Eusebio. "The RDF plant also complies with the waste diversion requirement of Republic Act No 9003 or Ecological Solid Waste Management Act of 2000. It also addresses climate change issues associated with how municipal wastes are managed."

The use of RDF in lieu of coal addresses the twin issues of solid waste management and climate change. "This is the largest RDF plant in the Philippines to date," said Isabelita P Mercado, president of IPM, which operates and manages the plant. "This is also a pioneering endeavour to save the environment by reducing our dependence on fossil fuel."

This week brought the news that, following testing by the Food Safety and Standards Authority of India (FSSAI), some 27,402t or US$49.8m of Nestlé's Maggi noodles had to be recalled from the market due to allegedly high levels of lead. But what do you do with 27,402t of noodles deemed unsafe for human consumption?

The solution was incineration. Five cement plants will take 40 days, which started on 9 June 2015, to consume all of the noodles as an alternative fuel. "This was the most environment-friendly solution to destroy the recalled noodles," said Luca Fichera, executive vice president of Nestlé's supply chain in India.

India's fuel supply is notoriously unreliable. Coal is the dominant fuel used for cement and power production in India, however, supplies have been inconstant in terms of both quality and quantity for some time now. To shore up the coal supply, the government cancelled, reallocated and auctioned 214 of the 218 coal blocks in India, starting in September 2014. According to local media, Coal India, which still operates most of the blocks, is now expected to increase its coal production capacity by as much as 60Mt in 2015, following 7% production growth in the 2014 - 2015 financial year. However, there is still a major coal shortage in the country and recent reports by India's coal ministry suggest that the new coal linkages will increase coal costs. The new coal linkage process will see sales go via an auction system instead of a static price. Coal costs for cement producers are expected to rise by as much as 25% as a result.

Given India's long-standing fuel supply problems, its cement producers may wish to learn from the use of Nestlé's Maggi noodles as alternative fuels in cement plants. Instead of viewing the coal shortage as a challenge, it might instead be considered an opportunity to increase alternative fuel use, reducing costs and moving to more environmentally-friendly cement production. In addition to the standard industrial, municipal and household waste, among others, India might look to use some of the large quantities of waste biomass that must surely be produced from its agricultural sector. Like the game, 'Hungry, hungry hippos,' India's cement plants could consume a wide variety of nearby wastes in place of coal.

India: Some US$49.8m, which equates to 27,420t, of Nestlé's Maggi noodles has been recalled in India and is now being used as an alternative fuel at five Indian cement plants. Nestlé said that the recall process is one of the largest in the history of India's food industry.

"The recall of Maggi noodles from the market is an immensely complex mammoth activity, the largest in the history of Nestlé," said Luca Fichera, executive vice president of the supply chain in India. "The trust of our consumers is extremely important for us and despite the enormity, we are focused on completing this efficiently and as fast as feasible."

The recall started on 5 June 2015. Of the total to be consumed by cement plants, some US$32.7m was recalled from the market, while US$17.1m was removed from Nestlé's factories and distribution centres.

The Indian cement plants have been consuming the noodles as alternative fuels since 9 June 2015. "This was the most environment-friendly solution to destroy the recalled noodles: To convert them into fuel," said Fichera. It will take 40 days to destroy the 27,420t of noodles at the five cement plants.

The food safety regulator ordered Nestlé to withdraw the noodles after some samples were allegedly found to contain higher-than-permissible levels of lead. This was rejected by Nestlé, which said that its own independent tests suggested otherwise. Nestlé has since moved to the Bombay High Court, challenging the order. The court has issued notice to the Food Safety and Standards Authority of India (FSSAI), the regulator and other respondents and posted the matter for hearing on 30 June 2015. Nestlé has halted the production of Maggi noodles in its factories since 5 June 2015 and has withdrawn the product from the market.

India: According to the Economic Times, the waste from city kitchens will soon be recycled into refuse-derived fuel (RDF) at waste processing plants in Kalaburagi City, Karnataka. The RDF from the 10 upcoming waste processing plants in Kalaburagi will be given to cement companies for use as fuel and the biodegradable waste will be used as manure by farmers.

The joint initiative taken up by the Karnataka State Pollution Control Board (KSPCB) and Karnataka Urban Infrastructure Development & Finance Corporation (KUIDFC) has had agreements with cement manufacturers such as ACC, Vicat Sagar and UltraTech in Kalaburagi.

"Plastic-like material is a good alternative for fossil fuel as it can replace up to 20% of fossil fuel in terms of energy," said KSPCB chairman Vaman Acharya. The pact is yet to be signed and talks between the stakeholders is in the final stages. Transport costs for the RDF are estimated to be less than US$0.016/kg.

The idea to use RDF instead of fossil fuel in Kalaburagi cement plants was first conceived by Hasiru Dala, a Bengaluru-based non profit organisation working on waste management. It has provided 100t of combustible waste to Zuari Cements' plant in Andhra Pradesh in the past two months. Nalini Shekar, founder of Hasiru Dala, said that the material was not sold to the cement plant for a price, but Zuari paid for packaging and transportation. Households have been asked to segregate waste and hand it to BBMP garbage collectors to make the process easier.

Encouraging news from Egypt with the announcement that Lafarge Ecocem has taken on two refuse-derived fuels (RDF) contracts in Suez and Qalyubeya. The RDF plants will have production capacities of 42,000t/yr and 280,000t/yr respectively, after upgrades are built.

The move follows a deal Lafarge struck with Orascom in March 2015 to develop a waste management framework of municipal and agricultural waste. The plan is to achieve an average fuel substitution rate of 25% by the end of 2015. Around the same time Ecocem also signed a cooperation agreement with the German Development Cooperation (GIZ) and the Qalyubeya Governorate to upgrade a recycling plant in Qalyubeya to produce RDF. Part of the deal was intended to reinvest some of the revenue from RDF sales back into the region's waste collection infrastructure.

These production levels compare to SITA UK's new RDF plants in the UK, which has a more mature RDF market. There, the newly opened Malpass Farm plant is planned to produce 200,000t/yr and the Tilbury plant will have an output capacity of 500,000t/yr when it opens. However, the Malpass Farm plant mainly feeds one cement plant, the 1.3Mt/yr Cemex Rugby plant with a mean substitution rate of 61% in 2013. By contrast, Lafarge Cement Egypt runs the massive 10.6Mt/yr El Sokhna plant.

Co-processing at El Sokhna by Lafarge is of particular interest given the links with Egypt's unofficial household waste collectors, the Zabbaleen. Lafarge Egypt recruited and trained 140 Zabbaleen to gather waste material for RDF production. The strategy enabled Lafarge to gather continuous supplies of RDF and strengthen local stakeholder relations, as Lafarge's 2013 sustainability report puts it. Lafarge Egypt's substitution rate was 2.2% in 2012 with significant improvements made since then. The current target of 25% for the end of 2015 shows how much progress Lafarge has made.

Hisham Sherif of the Egyptian Company for Solid Waste Recycling (Ecaru) placed Egypt's municipal solid waste level at 20Mt/yr at a presentation given at the Global CemFuels Conference earlier in 2015. From this 4Mt/yr of RDF could be produced. Together with biomass derived fuel (BDF) Sherif reckoned that the country's cement plants could reach substitution rates of 30 – 40%. Problems though with increasing RDF rates in Egypt include legal complexities, institutional issues, poor services and monitoring and centralised planning with little regard for the country's unofficial waste pickers, such as the Zabaleen.

Lafarge Ecocem appears to be tackling each of these problems in turn as the deals with Orascom and the Qalyubeya Governorate show. However, spare a thought for Egypt's unofficial waste sector workers who are likely to lose their livelihoods as waste management becomes more formalised and personnel rates per tonne of waste collected tumble.

For more information on the Zabaleen, check out the documentary made about them in 2009, called 'Garbage Dreams'.