interim meeting of the project on low-carbon city planning ... · ・b3 waste are mainly treated by...

© 2013 AMITA CORPORATION All Rights Reserved.1

Interim Meeting of the Project on Low-Carbon City Planning in Surabaya, Indonesia

November 20, 2013

AMITA CORPORATION


Business Concept ～Waste Reuse in Cement Plant～

CaO SiO2 Al2O3 Fe2O3

Virgin raw material

100% Recycle (Reuse)※CRM is used as alternative SiO2&Al2O3

Waste

CRM

Mine

Waste GeneratorCement plant

Landfill

AMITA

Incinerator

Alternative raw material

Coal

SlurMix ®


【1】Baseline Survey・ Cement production・ Waste consumption rate in cement industry・ Energy consumption amount, Energy consumption rate,

CO2 emission amount

【2】Market Survey・ Generation amount of each industrial waste・ Simulation of the products・ Treatment cost of each industrial waste・ Relevant environmental regulation

【3】Feasibility Study・ Initial cost of intermediate treatment plant for cement raw material・ Government support・ Project finance （JBIC, JICA, etc.）

Survey items


【1】Baseline Survey (Achievements)・ Cement production・ Waste consumption rate in cement industry・ Energy consumption amount, Energy consumption rate,

CO2 emission amount

Survey items

Semen Gresik/ TubanProduction 2,880,000t/ year

Kiln 4 (SP)

Waste recycling Paper sludge ash, Fly ash, Bottom ash, Heavy oil sludge, Waste grease, Cu slag,

BF slug, Waste rubber, Tobacco filter, RDFBiomass byproducts recycling Coco peat, Rice husk

Energy substitution ratio Biomass 3%


Indonesia JapanPopulation 230,000,000 128,000,000

Area 1,910,931 km2 377,930 km2

Industrial waste generation 7,000,000 t / year 400,000,000 t / yearCement production 55,000,000 t / year 57,579,000 t / year

Waste recycled amount by cement industry

? t / year 44,400,000 t / year

Waste consumption rate in cement industry

? kg / cement 1t 469 kg / cement 1t

Waste Utilization in Indonesia and Japan

Findings・ Indonesian cement makers are utilizing mainly agricultural by-products,

not much industrial by-products.・ Indonesian cement industry has huge capacity to accept industrial by-

products.


【1】Baseline Survey (Future plans)・ Visit other cement companies as much as possible.・ Analyze each companies status and figure out the potential ability

for recycling.・ Study Waste Acceptance Criteria of all cement companies.

www.asi.or.id/


【2】Market Survey (Achievements)・ Generation amount of each industrial waste・ Simulation of the products・ Treatment cost of each industrial waste・ Relevant environmental regulation

Survey items

Company A Company B Company C Company DProduct Musical

productsStationary

goodsMetal Food products

Waste and

amount

・Waste water treatment

sludge: 25t/ day・Blass grinding scrap: 5t/ day

・Waste plastics: 2t/ month

・Waste oil: 2t/ month

・Dust: 12t/ month

・Waste water treatment sludge:

5t/ day・Coffee sludge:

25t/ dayCost Unknown Rp. 5,500/ kg Rp. 2,000-2,700

/kgRp. 130/ kg


Company E Company F Company G Company HProduct Auto-parts Food products Auto-parts Pharmaceutical

Waste and

amount

・Ash: 2t/ month・Waste glass:

1t/ month

・Waste oil: few drums/ month

・Waste oil: 0.2t/ month

・Waste plastics: 0.2t/ month

・Canteen waste: 6t/ month

・Waste water treatment sludge:

2t/ monthCost Unknown Rp. 600,000/

drumRp. 350,000/

drumRp. 600,000/

drum

Findings・ Metallic scraps and plastics are usually sold to recyclers.・ Organic waste are also sold as raw material for animal feed and fertilizer.・ B3 waste are mainly treated by PPLi (P.T. Prasadha Pamunah Limbah

Industri) and TLI (PT. Teknotama Lingkungan Internusa).・ Companies in Surabaya region are burdened with high transportation

cost of B3 wastes.・ Most of wastes are not utilize as raw material for cement industry.


【2】Market Survey (Future plans)・ Visit other waste generator as much as possible.・ Collect information from Japanese companies by using attached

questionnaire.・ Simulate chemical composition of CRM (Cement Raw Material)

made of industrial wastes.・ Survey market price of treatment cost.・ Study relevant environmental regulation.


Survey items

【3】Feasibility Study (Achievements)・ Initial cost of intermediate treatment plant based on Japanese plant.

(Estimation)SlurMix® plant Rp. 25,000,000,000 (Treatment capacity: 10,000t/ year)CRM plant Rp. 13,800,000,000 (Treatment capacity: 24,000t/ year)


【3】Feasibility Study (Achievements)・ Government support

InformationKLH ・JICA support municipal waste management, not B3 wastes.

・Most of JICA projects are Yen loan projects.・There is a waste management law though, final judgment might depends on the person in charge.

JETRO ・JETRO does not have enough information about B3 wastes.・1,400 Japanese companies in Jakarta and many of them are automobile related industries.・Minimum wage has been raised for 40%.・JETRO will support making questionnaire to the Japanese companies.

【3】Feasibility Study (Future plans)・ Visit relative agencies. （JBIC, JICA, etc.）


Assumption: Constructing SlurMix® plant in Surabaya

・Production of SlurMix®: 10,000ｔ/ Year

・Calorific value of SlurMix®: Ave. 3,349kcal/kg→ 10,000t× 3,349kcal/kg =33,500,000kcal/kg

・Ave. calorific value of coal is 6,354kcal/kg→ 5,270t of coal

・CO2 emission of coal is 2.33t/coal ton→ Cement manufacture could save about 12,280ｔ -CO2/ Year by

using SlurMix®.

Reduction of CO2


Assumption: Constructing CRM plant in Surabaya

・Production of CRM: 24,000ｔ/ Year

・Calorific value of CRM: Ave. 1,800kcal/kg→ 24,000t×1,800kcal/kg =43,200,000kcal/kg

・Ave. calorific value of coal is 6,354kcal/kg→ 6,800t of coal

・CO2 emission of coal is 2.33t/coal ton→ Cement manufacture could save about 16,000ｔ -CO2/ Year by

using CRM.

Reduction of CO2


Survey Items Jul Aug Sep Oct Nov Dec Jan FebBaseline Survey・Cement production・Waste consumption rate in cement industry・Energy consumption amount,energy consumption rate, CO2emission amount

Market Survey・Generation amount of each industrial waste・Treatment cost of each industrial waste・Relevant environmental regulation

Feasibility Study・Construction cost of intermediate plant for cement raw material・Government support・Project finance （JBIC, JICA, etc.）

Schedule

interim meeting of the project on low-carbon city planning ... · ・b3 waste are mainly treated by...

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