This document discusses co-processing waste materials in cement kilns, with a focus on concepts, initiatives, and case studies in Southeast Asia and the oil and gas sector. It provides an overview of co-processing, definitions, benefits, guidelines developed by Holcim and GTZ, and legal frameworks. Case studies from Indonesia describe Geocycle projects with Chevron, Star Energy, Montd'Or Oil, Pertamina, and Medco handling various oil and gas wastes, including drilling cuttings, contaminated soils, and hazardous chemicals, totaling over 15,000 metric tons. Updates on co-processing initiatives in India are also briefly outlined. The presentation aims to promote co-processing as an environmentally beneficial

1. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Co-processing in
cement kiln
Concepts and
in Oil and Gas Sector
John Jones
Regional Operations Director
Geocycle Asia

2. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Overview
• Concepts and Benefits of Waste Co-processing
• Challenges During Waste Co-processing
• Initiatives on Co-processing: South East Asia Experience
• Case study of Oil & Gas sector from Indonesia
• Recognition of the initiatives of Geocycle

3. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Waste Management Hierarchy
Main drive: LCA
3R+C
Co-
processing
Recycling
Technology
Society
Industry
A
Industry
B
* GIZ Guidelines on Co-processing of waste materials in Cement Production

4. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
What is Co-processing?
Co-Processing is…
…the disposal of waste materials in RII’s (Resources Intensives Industrial processes)
such as cement, lime, steel, glasses, power generation etc.*
* GIZ Guidelines on Co-processing of waste materials in Cement Production

5. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Advantages of Co-processing in Cement Kiln
 High temperatures and long residence time
In all cases more than 3” > 1100 C
 Self cleaning process
Lime represent > 60% in mass
 Double valorization: organic and minerals
Organic totally destroyed
Ash incorporated in the final product
 Reduction of global emissions
No additional emission if A.F.R. used - Global CO2 is reduced
 Existing, local industry

6. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Reduction of GHGs
Co-processing and
Incineration
Reduction in GHG
Emissions
Co-processing and Landfill
Prevention of Methane*
Emissions
* Methane has 21 times more global
warming potential than CO2
Co-processing is THE alternative to save our environment and
improve industry ecological footprint

7. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Co-processing: Moving to an UN Legal Frame
• Presentation of the co-processing concept at
the CoP Bali June 2008
• 2008-2011: SBC in charge to develop 4 new
technical guidelines for waste management
(used tires/e-wastes/ Hg/co-processing)
• Chile volunteered to draft a project, on the
web since Dec 2009
• Draft to be reviewed at the COPWG on May
10, 2010
• Final proposal presented and ratified at the
COP October 2011 Cartagena, Colombia

8. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Co-processing Guidelines
 Holcim and GTZ through a Strategic alliance
 Proposed international guidelines for the co-processing
of waste materials in the cement production
 Secured the public acceptance of these guidelines
 Finalized them in July 2006
Guidelines available in English, Spanish, Portugese, Chesk, Slovak, Hungary,
French, Chinese and Russian
 From those guidelines, specific legal
frames on co-processing are under
implementation in around 15 countries
 More advanced: Mexico, Salvador,
Colombia, Ecuador, Brazil, Chile,
China, Phillipines, …
 SA: new policy signed April 26 - 2009

9. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Co-processing guidelines….
CPCB Guidelines on Co-Processing February 2010
Co-processing is recognized by
government authorities in other South Asia
Countries
• Indonesia
• Sri Lanka
• Thailand
• Vietnam

10. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Waste & Sustainability: The Challenge

11. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Waste Pre-processing Activities

12. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Holcim’s Global Waste Co-processing Network
• Co-processing
activities in 39
countries with over
4500 customers
• 28 pre-processing
facilities
• More than 7 mil. tons
of AFR co-processed
in 2009
• Treated about 20,000
waste streams

13. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
The Geocycle Asia approach

14. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Waste handled

15. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Case study: Geocycle Indonesia
Total Services Solution Projects
–Oil and Gas Sector -
• Chevron Pasific Indonesia Riau – Cement Drilling Cutting and General Waste
Handling
• Chevron Geothermal, Gunung Salak – General waste Handling
• Medco JOB Tomori, Sulawesi – Drilling Cutting Handling
• Medco E&P Indonesia, Palembang – Contaminated Soil Handling
• Arun NGL, Aceh – Sulfinol Handling
• Star Energy Geothermal Wayang Windu - Drilling cutting Handling
• MontD’Or Oil Tungkal Jambi - General Waste Handling and Pit Cleaning
• Badak NGL Kalimantan - General Waste Handling
• Pertamina Plaju, Palembang – Contaminated Soil Handling
• Pertamina ONWJ, Marunda – Liquid and General Waste Handling
• Pertamina Geothermal Energy - Drilling Cutting Handling

16. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Chevron Pacific Indonesia
• Geocycle is awarded 2 years contract to handle Hazardous Waste
Disposal at Chevron Pacific Riau (06 Feb 2012 – 06 Feb 2014)
• This is the third contract between Geocycle and Chevron since 2010
• Waste materials include : Cement drill cutting, chemical waste, oily
rags, ash incinerator, used oil, etc.
• Total volume on contract is 3410 MT
• Scope of work :
 Handling and repacking
 Weighing
 Loading to shipping container
 Transporting (land and sea) - Interisland
 Co-processing in Cement Kiln

17. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Star Energy Geothermal
• Geocycle is awarded one year contract to handle Drilling Cutting from
Star Energy Geothermal
• Total volume on contract is 4550 M3
–Scope of work :
 Supervision
 Loading to Dump Truck
 Transporting
 Co-processing in Cement Kiln

18. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Clean Up Project – Montd’or Oil Tungkal Ltd Jambi
• Geocycle is awarded for 1 year contract to do site clean up
for MontD’Or Oil Tungkal, Ltd
• Waste materials include : oil sludge, contaminated soil
and some general waste

19. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Pertamina Geothermal Energy
• Drilling Cutting Handling for Pertamina Geothermal Energy
• 700 M3 of material from Pertamina Geothermal Energy was
transported to HIL
• Scope of work :
 Supervision
 Loading to Dump Truck
 Transporting
 Co-processing in Cement Kiln

20. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Pertamina–Medco E&P Tomori
• Geocycle is just recently awarded 2 years contract (execution starts on September 2013) to
handle Waste Management Disposal for Pertamina-Medco E&P Tomori
• Waste materials include : Drilling Cutting, Waste Oil and Chemicals
• Total volume on contract is 9000 MT
• Total Revenues of this contract is 4 Mio USD
• Scope of work :
 Handling and repacking
 Waste Water Treatment on Site
 Weighing
 Loading to shipping container
 Transporting (land and sea) - Interisland
 Co-processing in Cement Kiln

21. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Updates of India so far….
Geocycle has been co-processing RFCCU spent catalysts from Barauni and Panipat Refineries at
its cement kilns at Chaibasa and Gagal respectively
• Geocycle has the necessary approval from CPCB for co-processing of hazardous RFCCU spent
catalyst (category 4.1, schedule 1)
• Recently participated in the tender for disposal of Oily sludge from Haldia refinery at its cement kiln at
Chaibasa (under TC evaluation by IOCL)
• Have assessed the feasibility of the following waste streams:
• Oily sludge from Barauni Refinery for disposal at Chaibasa Cement Works, Jharkhand
• ETP Sludge, Chemical Sludge & TB Sludge from Panipat Refinery for disposal at Cement
Works, located in Rajasthan
• Activated Carbon from Mathura Refinery for disposal at for disposal at Cement Works, located in
Rajasthan
• Undertaken a successful trial run of Drill Cutting waste from Cairns India and Lakheri Cement
Works

22. Technical Session # (
Topic : Co-processing in cement kiln Concepts and in Oil and Gas Sector
Thank you -
Dhanyawad
Shukriya
Terima Kasih
Bohoma istuti
Khorb Kun Krup
Cám ón
Salamat
Xie Xie
Contact for further queries
John Jones
Regional Operations director
Geocycle Asia
John.jones@holcim.com