Co-processing

Co-processingis the use ofwasteas raw material, or as a source of energy, or both to replace natural mineral resources (material recycling) andfossil fuelssuch as coal, petroleum and gas (energy recovery) in industrial processes, mainly in energy intensive industries (EII) such ascement,lime,steel,glass,andpower generation.Waste materials used for Co-processing are referred to as alternative fuels and raw materials (AFR).

Concept of Co-processing

Co-processing is a provensustainable developmentconcept that reduces demands on natural resources, reduces pollution and landfill space, thus contributing to reducing theenvironmental footprint.Co-processing is also based on the principles ofindustrial 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.

Figure 1: Types of Co-processing

In summary, the benefits of Co-processing are:

to conserve natural (non-renewable) resources of energy and materials,
to reduce emissions of greenhouse gases in order to slow global warming and demonstrate a positive impact on integrated environmental indicators, such as theecological footprint,
to reduce the environmental impacts of the extraction (mining or quarrying), transporting, and processing of raw materials,
to reduce dependence on primary resource markets,
to save landfill space and reduce the pollution caused by the disposal of waste, and
to destroy waste eliminating potential future liabilities.

Co-processing contributes to the industrial competitiveness, is a complementary technology to concepts such ascleaner productionorrecyclingand should be considered as a treatment alternative within an integrated waste management concept. Some EII offer co-processing as asustainable waste managementservice. It is usually more cost effective to adapt existing facilities of EII than building new waste treatment capacities thereby reducing waste management cost to society.

The waste management hierarchy (see figure below) shows that Co-processing is a recovery activity which should be considered afterwaste preventionand recycling; Co-processing ranks higher in this hierarchy in comparison to disposal activities such as landfilling or incineration.

Figure 2: Waste Management Hierarchy

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 theEU-25countries 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.

The EU cement industry already uses more than 40% fuels derived from waste and biomass in supplying the thermal energy to the grey clinker making process. Although the choice for this so-called alternative fuels (AF) is typically cost driven, other factors are becoming more important. Use of AF provides benefits for both society and the company: CO₂-emissions are lower than with fossil fuels, waste can be co-processed in an efficient and sustainable manner and the demand for certain virgin materials can be reduced. Yet there are large differences in the share of AF used between the European Union (EU) member states. Clearly, the societal benefits can be enlarged if more member states increase their AF share. In this study Ecofys assess the barriers and opportunities for further uptake of AF in 14 EU member states. Ecofys found that local factors constrain the market potential to a much larger extent than the technical and economic feasibility of the cement industry itself. In this summary they present the overall findings. The detailed assessments are available in separate cases studies.Source

Roughly 60% of the waste that could be used for Co-processing is biomass and thereforecarbon neutral.In this way Co-processing offers a significant potential for the reduction ofgreenhouse gas emissionsfrom fossil fuels. Furthermore, diverting industrial waste streams from landfills and incinerators without energy recovery contributes to reducing overall CO₂emissions when used to substitute fossil fuels through Co-processing (as illustrated in the figure below).

Figure 3: Reduction of Emissions through Co-processing

Other factors that must be considered when Co-processing waste include product quality standards, permitting aspects, and transparent communication in order to gain public acceptance.

Examples of waste that can be co-processed

Used tires
Various solid waste in plastic barrels
Shredded solid waste

Contaminated paper
Medical waste (pharmaceutical phial)
Rice husk

Contaminated glass bottles
Impregnated sludge
Paint sludge

Coprocessing in Pharmaceutical Excipients Development

Coprocessing is the combination of two or more excipients to form materials (coprocessed excipients) of superior functionality and limited unwanted effects. Co-processing is a tool that is employed by pharmaceutical excipients manufacturers and formulation scientists to develop materials with superior performance. Coprocessing is fundamentally based on particle engineering that allows modification of Critical Material Attributes (CMA) of the primary excipients. These modifications are reflected in the resulting coprocessed material as enhanced functionality. The primary excipients are established pharmacopoeial materials.

External links

Co-Processing Waste Materials in Cement ProductionOn this website you will find various digital documentations related to the topic "Co-Processing Waste Materials in Cement Production".
The Deutsche Gesellschaft für Technische Zusammenarbeitfosters the international collaboration for sustainable development.
The World Business Council for Sustainable Developmentprovides a platform for companies to explore sustainable development, share knowledge, experiences and best practices, and to advocate business positions on these issues in a variety of forums, working with governments, non-governmental and intergovernmental organizations.
The Cement Sustainability Initiative (CSI)was formed to help the cement industry to address the challenges of sustainable development. The business leaders of a group of major cement companies lead the initiative.
The United States Environmental Protection Agency (EPA)leads the nation's environmental science, research, education and assessment efforts. The mission of EPA is to protect human health and the environment.
Energy from WasteProduction of energy through the incineration of waste

Downloads

https://web.archive.org/web/20090510083738/http://www.coprocem.com/literature-var-2Literature on various aspects of Co-processing in EII
https://web.archive.org/web/20110708191924/http://www.coprocem.com/trainingkit/pages/home.htmlA training kit on Co-processing waste materials in cement production
https://cembureau.eu/media/2lte1jte/11603-ecofys-executive-summary_cembureau-2017-04-26.pdfStatus and prospects of co-processing of waste in EU cement plants

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