ENVIRONMENTAL IMPACT ASSESSMENT REPORT FOR THE FOR THE PROPOSED IMPLEMENTATION OF AN ALTERNATIVE FUELS AND RESOURCES PROGRAMME FOR KILN 5 AT THE HOLCIM SOUTH AFRICA ULCO PLANT, NORTHERN CAPE PROVINCE Compiled by Bohlweki Environmental (Pty) Ltd PO Box 11784 Vorna Valley MIDRAND 1686 In association with the following specialists Dr D Baldwin and Ms M Chettle Dr L Burger and Ms R Thomas Environmental & Chemical Consultants Airshed Planning Professionals Mr F Joubert Ms C Herrera Sustainable Law Solutions Stewart Scott International Environmental Impact Assessment Report for the proposed Alternative Fuels and Resources Project at the Holcim South Africa Ulco Plant, Northern Cape Province EXECUTIVE SUMMARY 1. INTRODUCTION Holcim (South Africa) (Pty) Ltd, formerly known as Alpha (Pty) Ltd, is one of South Africa’s key producers of cement, stone and ready mixed concrete for the construction industry. Holcim South Africa currently operate three cement plants in South Africa, one of which is the Ulco plant, located approximately 80 km north west of Kimberley in the Northern Cape Province. At Ulco plant, limestone (source material) and coal (fuel) are currently the primary raw materials utilised in the manufacture cement. Ulco plant is situated on a limestone deposit that is mined and milled as feedstock to the plant. The coal that is utilised in its kiln as the main energy source for converting the limestone raw meal into clinker (the base feedstock for cement) is transported to the plant by rail. Holcim South Africa are considering implementing the global trend of replacing a portion of the fossil fuel (coal), used as the primary energy source, with alternative waste-derived fuels. That is, the introduction of an Alternative Fuels and Resources (AFR) programme is proposed for the Ulco plant. The AFR programme aims to reduce traditional fossil fuel usage at the existing plant by up to 35% or more through the replacement of coal with alternative waste-derived fuels and raw materials. These alternative fuels would be sourced from selected waste products and by-products generated from selected existing industrial and domestic sources. 1.1. Motivation for the Proposed Project The process of cement manufacture is energy intensive. The average energy required to produce 1 000 tons of cement clinker is approximately 130 tons of coal. As a result, Holcim South Africa currently requires approximately 350 000 tons of coal per annum to operate their kilns across the country. The Holcim commitment to promoting development that is sustainable and at the least cost to future generations has resulted in a drive to substitute a portion of the traditional non-renewable fossil fuel (coal) used in the production of cement clinker with suitable alternative waste-derived materials/fuels. This has resulted in the need to identify alternative renewable fuel sources which would provide similar energy (i.e. calorific value) when burnt to that provided by coal, would not be detrimental to the process in the kiln or the product produced, and would be less costly than coal in the long-term. Executive Summary i 09-Nov-04 Environmental Impact Assessment Report for the proposed Alternative Fuels and Resources Project at the Holcim South Africa Ulco Plant, Northern Cape Province The use of alternative fuels and raw materials selected from waste products and by-products generated from industrial and domestic sources addresses this need, as much of this waste is chemically similar to coal. The use of this waste as a fuel presents the opportunity to reduce the environmental impacts of using a non-renewable resource (coal) in the cement clinker manufacturing process, as well as to reduce the amount of waste material that would traditionally be disposed of to landfill or incinerated. The utilisation of AFR in the cement industry is consistent with initiatives of National Government, particularly the National Waste Management Strategy (NWMS) which focuses on waste prevention, waste minimisation and the re-use of waste materials. The practice of employing alternative fuels in cement plants promotes materials recovery and recycling by the recovery of the energy, as well as the mineral components, from waste. The use of waste-derived fuels in a cement kiln reduces fossil fuel use, and maximises the recovery of energy, without any significant change in emission levels. The use of alternative fuels is a well-proven and well-established technology in the European, American (both North and South) and Asian-Pacific cement industries. Experience at international plants has shown that alternative fuels can successfully replace traditional fossil fuels with no adverse impact on the environment, safety or health of employees and communities, or on the quality of the final cement product. 1.2. Infrastructure Requirements for the Proposed AFR Programme Kiln 5 at Ulco Plant is capable of implementing the technology associated with the acceptance and use of alternative fuels as an energy source, together with coal. Coal will continue to form the primary energy source in Kiln 5. The AFR programme is aimed at substituting a portion of the total coal requirement. The proposed introduction of the AFR programme would require the continued storage of coal on the existing stockpile, as well as the creation of a second designated storage area/facility for an approximate 2-day supply of approved AFR. This AFR storage area would be required to comprise suitable storage tanks, silos and bunkers in close proximity to the kiln. Two AFR fuel storage areas are proposed to be established within the boundaries of the existing Ulco plant, i.e. an undercover storage area of approximately 300 m2 and an open storage area of approximately 2 000 m2. The proposed AFR storage areas are located adjacent to the plant within the plant footprint to allow for safe and secure feeding of the AFR material from the storage area to Kiln 5. The demarcated areas have been extensively disturbed through previous use for construction purposes. The sites are devoid of vegetation, and on level terrain. Executive Summary ii 09-Nov-04 Environmental Impact Assessment Report for the proposed Alternative Fuels and Resources Project at the Holcim South Africa Ulco Plant, Northern Cape Province The AFR storage facility would be required to be designed according to national construction, and fuel handling and storage requirements. This would include a bunded concrete base complete with stormwater containment and handling facilities, as well as monitoring and fire-fighting equipment. The storage area would be accessed by a levelled and sealed access road, and would include sufficient area to all for safe vehicle off-loading and manoeuvring, as required. It is proposed that initially the kiln would be in a position to utilise approximately 70 tons of AFR a day (represented by between 2 and 3 vehicle loads of AFR per day). It is proposed that the volume of AFR utilise per day could increase to approximately 240 tons per day. The acceptance and storage facilities would be required to be designed to safely handle and feed these volumes. A dedicated AFR on-site laboratory would be required at Ulco plant to conduct 'fingerprint' analyses on all AFR materials arriving at the operation to verify that the arriving material is consistent with the original waste acceptance criteria. Only after laboratory approval would the AFR waste stream be accepted for off- loading to the Ulco AFR storage facility. Any waste-derived fuels received which do not match the original 'fingerprint' criteria would be returned to the supplier and the incident reported. 1.3. Waste-derived Materials which can be utilised as Alternative Fuels Waste materials currently utilised by the global cement industry as alternative fuels include scrap tyres, rubber, paper waste, waste oils, waste wood, paper sludge, sewage sludge, plastics and spent solvents, amongst others. Similar waste materials are proposed to be used as AFR in South Africa, together with other wastes considered suitable (including industrial hydrocarbon tars and sludges). These wastes could potentially be sourced from a variety of existing sources from a variety of geographic locations. Only those waste-derived fuels that meet the stringent standards set by Holcim and approved by the authorities will, however, be considered and accepted for use in the kiln. International experience has proven that the use of alternative fuels is technically sound as the organic component is destroyed and the inorganic component is trapped and combined in the cement clinker, forming part of the final product. Cement kilns have a number of characteristics that make them ideal installations in which alternative fuels can be valorised and burnt safely. These include: • High temperatures – exceeding 1 400°C (flame temperature ~2 000°C) Executive Summary iii 09-Nov-04 Environmental Impact Assessment Report for the proposed Alternative Fuels and Resources Project at the Holcim South Africa Ulco Plant, Northern Cape Province • Long residence time – in excess of 4 seconds • Oxidising atmosphere • High thermal inertia • Alkaline environment • Ash retention in clinker – fuel ashes are incorporated in the cement clinker, and there is no solid waste by-product While many waste streams are suitable for use as alternative fuels or raw materials, there are others that would not be considered for process, public health and/or safety reasons. No materials that could compromise the environment, the health and safety of employees or surrounding