Sasol ChemCity's ED Opportunities in Waste Management
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Sasol ChemCity’s ED Opportunities in
Waste Management
Rivash Panday, Marcelle Hunt, Elaine Prosper & Rantle Mafata
March 2011
Overview 1. Factors Driving Industry Change Resulting in ED Opportunities 2. Focus Areas in the Field of Waste Management 3. Projects
1. Factors Driving Industry Change Resulting in ED
Opportunities
Global warming – Industry to look at cleaner technologies. Reduce, reuse and
recycling opportunities with disposal being the last resort. This will reduce waste
to landfill and create ED opportunities resulting in job creation
Waste Act – Forcing industry to develop and implement Waste Management
Plans. Result in ED and job creation.
Eskom Electricity Crisis – Use waste as a resource to generate electricity.
Water Shortage – Look for ways to treat and recycle water i.e. the use of grey
water for irrigation.
Governments drive to create jobs – Force social development opportunities like
waste collection and recycling.
Housing shortage – Use alternative building materials to construct affordable
houses as apposed to cement built houses.
Organic farming – drive to stop the use of inorganic fertilisers and pesticides.
Green waste composting, vermicomposting, Activate Sludge Pasteurisation
(ASP).
2. Focus Areas in the Field of Waste Management
Recycling
-Municipal solid waste
- waste tyres
- wood waste
Organic Waste
Water Treatment
-Sasol waste streams
- Mine water
- waste tyres
-Sewage
- Fine coal & discards
Waste Group Projects
Biological Waste
Inorganic Waste
- Green Waste
- Fly ash
- Sewage Sludge
-Gypsum waste
- Manure
3. Projects
55% of projects have to be Sasol Linked
At least 1 project each in the Govan Mbeki and Metsimaholo
Municipalities.
12 Media Hits.
3.1. Waste Tyre Beneficiation
TPT visited China to investigate optional polishing stages as an add-on
to TPT’s waste tyre pyrolysis process.
As part of the technology review of Chinese technology, TPT was
introduced to Rubber Crumbing facility.
Rubber crumb produced was exported to SA, as stringent SA
specification for bitumen rubber production was met.
Quantity exported to SA = 500 tons to Tosas for use in Bitumen
Rubber Asphalt
Project Timeline Capital Expenditure
Order placement and 30% deposit
completed Dec 2010. Office Equipment
Working capital (1 month)
R 200 000
R 1 400 000
Complete the manufacture, Civil
Electrics
R 500 000
R 500 000
equipment testing prior to export, Site Infrastructure (Fire R 1 500 000
control, storage)
and exportation of equipment to Crumbing plant R 6 800 000
South Africa, due 25 April 2011. Shipping, & Taxes R918 445
TOTAL CAPEX R 11 818 445
Completion of the Environmental REQD
Impact Assessment
Installation and Commissioning the
plant and equipment, due 25 May
2011.
Issuing of applicable permits, due 25
May 2011.
Commence full scale operation, 01
June 2011.
3.2 Using Sasol FA in Alternative Housing Tower Technology (Pty) Ltd has developed a building system that uses a cement foam that can incorporate Slag, Gypsum and Fly Ash in the manufacture of panels that is used in alternative housing. Agrément Certification (Agrément Certificate 2009/368: Alternative Steel Frame Building System) and SABS approval has been obtained for this technology. ChemCity is currently supporting Tower Technology in establishing a panel manufacturing factory targeting the commercial market. This project is also supported by FNB Housing who has funded a program to construct 3 houses at Cosmo City to test market acceptance. There is therefore an opportunity for Sasol Facilities Management to consider alternative building Houses from Sasol’s waste material with the objective of establishing affordable housing.
3.2.1 Advantages of Tower Technology’s
Alternative Building system
- Logistics i.e 4 houses can be loaded on a superlink.
- Savings on Site managers which is 25% of conventional housing costs.
- Plumbing and electrical are prefitted in the panels.
- Wasteage costs since panels are manufactured in a controlled
environment.
- Labor costs due to ease of installing the panels.
3.2.2 Price
Tower have priced their houses in Cosmo City and the complete
(including finishes, kitchen & stove) 52 m2 good quality, well built house
complying to all Agrément and SABS standards was R195,000
(R3750/m2) including VAT, professional fees and delivery - excluding
the stand.
With the stand at R96,000 the client can buy a house for less than
R300,000.
Other developers start selling at R350,000 in the same area.3.2.3 Tower Technology’s Building System 1
Electrical Panel
Gable Panels
Plumbing Panel3.2.4 Cement incorporating Fine Ash Foam
Foam Filling Leveled PanelPlastering Curing
3.2.5 Construction
3.2.6 Completed House
Final Sasol Fine Ash Alternative Houses
3.3. Cement Fibre Extrusion Incorporating Sasol
Fine Ash
Norverte Technology has patented a
cement Fibre extrusion technology.
The formulations is mainly
composed of 5-10% cement
depending on the reactivity of the
recyclable resource being used, fly
ash from 50-80%, hybrid 01
extrusion additive of 2-3%, fibrous
wastes can also be used eg. Waste
pulps.
Currently operating a small scale
unit at the Everite and have
aspirations to expand.3.3.1 Sasol Fine Ash Products using Norverte’s
Technology3.4. Beneficiating Secunda Coarse Ash
Synfuels produces approx 13 million tons of coarse ash per annum
Environmental and regulatory issue
Untapped market for use in
Road building
Brick manufacturing
Alternative Housing
Concrete
Cement
Roof tiles
Other
Initial indications are that market penetration of at least 18% within 120
km radius of Secunda could be achieved in road building, brick
manufacturing, concrete and cement
This translates to 400 000 t/month or 5 mill tpa
Opportunity for enterprise development – local economic upliftment and
job creation3.4.1. Premamix
Premamix is a product derived from the reconstitution of Coarse ash
and fine to produce an aggregate substitute.
Premamix presents advantages to be used in the following markets:
(1) Roads
(2) Brick Making
(3) low strength concrete and cement products
Advantages:
- Reduce cement content in bricks and concrete by 20 – 45%.
- It’s density is 35% less than normal aggregates.
- The only road material with which labour intensive construction can be
done economically.
Conframat is willing to provide guarantees for 250,000 tons/month of
Coarse Ash for use as Premamix.3.5 Anaerobic Digestion of Biosolids Anaerobically digest chicken and cattle manure using a Covered in-ground reactor (Cigar) to generate biogas which will be converted to electricity.
Digestion of the Effluent Effluent is pumped to digestor through a manifold system.
Support Provided by ChemCity:
- Environmental Impact Assesment – EIA
- Financial model Development
- Legal support in finalizing contracts
- Project Management
- Drafting of the business plan
- Assistance with negiotiations for a Power Purchase Agreement.
Status:
- Secured funding in principle of R47 million provided that a PPA is in
place from DBSA & E&Co.
- PPA discussions in final stages with a leading German car
manufacturer.
- Busy with wheeling agreement with Tswane Municipality.3.6 Vermicomposting
Assistance Provided
- Feasibility studies
- Business plan
- Grant funding approx R500,000
- Marketing
- Branding
- Entrepreneurship Training -
Raizcorp
Status
- Setting up facility in Nigel.
- Funding proposal submitted to Sasol
CSI to establish facility in SasolburgQuestions? THANK YOU
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