phil johnson, international synergies ltd industrial symbiosis and the circular economy

© International Synergies LimitedVersion date 13 November 2013

Resource Efficiency

Industrial Symbiosis and the Circular EconomyWMG Innovation Feast11th December July 2014

Phil JohnsonBusiness Consultant

International Synergies Limited


Presentation Agenda

• International Synergies Limited

• What is Industrial Symbiosis?

• Real cost of waste

• Case study examples


1. International Synergies Ltd

“International Synergies strives to lead the worldin innovative industrial ecology solutions for a low

carbon, sustainable economy. ”


• Birmingham based SME with 20 employees

• Offices in Birmingham, Brussels and Belfast

• Specialists in industrial symbiosis – 15,000 companies havebeen engaged to date

• Clients from public and private sector and experience inAustralia, Belgium, Brazil, Canada, Chile, China, Denmark,Finland, Hungary, Italy, Mexico, Netherlands, Poland,Romania, South Africa, South Korea, Turkey, USA and UK

Introducing International Synergies Limited


International Synergies Limited and NISP:Recognition from all sectors

NISP is accredited by the European Commission as an Exemplar of Eco-Innovation through its Environmental Technologies Action Plan

2007

OECD declares Industrial Symbiosis “a la NISP” an “excellent example ofsystemic innovation vital for future green growth”

2010International Synergies received the Environmental Excellence Award forBest Carbon Reduction Programme for NISP

2010

NISP highlighted as 1 of 20 Worldwide Green Game Changing Innovationsin a report commissioned by the World Wide Fund for Nature (WWF)2010

British Expertise International Award for implementing the NationalIndustrial Symbiosis Programme on a Global Scale

2009

2013

International Synergies organises a Public Private Partnership on industrialsymbiosis for the Global Green Growth Forum (3GF)2013

2013 Peter Laybourn, Chief Executive, is short-listed for Edie.net’s SustainabilityLeader of the Year Award

Worldwatch Institute Europe, Best Practice Business Innovation in a LivingEconomy features NISP as exemplar

© Copyright International Synergies Limited – 2013.09.15


2. What is Industrial Symbiosis?


Symbiosis Definition:

‘An interactionbetween twodifferentorganisms living inclose physicalassociation to theadvantage ofboth’

Concise OxfordDictionary, 8thEdition


What is ‘Industrial Symbiosis’?

An industrial ecosystem where unused or residual resources ofone company are used by another. This results in mutualeconomic, social and environmental benefits.

Connecting Industry – Creating Opportunity


Linear system

ProductsNaturalResources

Waste

Transition towards acircular system

Natural Resources

Products

Products

Waste

to

Resource

Natural Resources

• Change the perception of industries• Enhancing business benefits and opportunities• Increase environmental benefits

Industrial Symbiosis Advances Sustainability


Industrial Symbiosis & The Waste Hierarchy

IS works to keep resources in the top 3 levels of the Waste Hierarchy

“The higher the level, the greater the cost saving”


3. NISP Achievements

(UK)


NISP INCREASES

Jobs

Sales

Learning

Profits

Innovation

New business

Inward investment

Knowledge transfer

Utilisation of assets

NISP REDUCES

Use of Virgin resources

Use of water

Hazardous waste

CO2 emissions

Transport

Pollution

Landfill

Costs

Risk

What NISP achieves …

NISP helps create real business opportunity


UK NISP delivered OutcomesApril 2005 – March 2012

METRICS Unit RESULTS

TO DATE

5YEARS Projection

with 20% decay

5YEARS Projection with no

decay

Landfill diversion T 9,074,493 21,863,907 45,372,465

CO2 reduction T 7,869,473 17,555,721 39,347,365

Virgin material savings T 11,679,029 33,262,089 58,395,145

Haz waste eliminated T 420,739 369,204 2,104,145

Water savings T 14,114,161 34,825,914 70,565,805

Cost savings £

£205,648,184 £411,546,215 £1,028,240,920

Additional sales £

£198,520,840 £351,614,047 £992,604,200

Other metrics

Jobs created Qty 10,000+ jobs have been directly created and

safeguarded

Jobs saved Qty

People trained in IS Qty 6,296

Private investment

£ £ 316,610,204


Foundries engaged - include

• Chamberlain & Hill

• Alucast

• Grainger & Worrall

• James W Shenton

• GPD Developments

• Brockmoor

• Darcast


4. European and Global Impact


Our International Experience

HungaryNISP HungaryKozep-Magyarorszag, Budapest

European Union Life+Climate KIC

TurkeyNISP TurkeyIskenderun Bay areaBP

South KoreaCo-operation on Eco-ParkDevelopment

ChinaTianjin Economic DevelopmentArea Industrial Symbiosis NetworkTianjinEuropean Union Switch Asia

ChinaPilot Project – Circular EconomyYunnan ProvinceDefra – SustainableDevelopment Dialogues

RomaniaECOREGSuceavaEuropean Union Life+

MexicoNISP MexicoToluca Lerma

Defra – SustainableDevelopment Dialogues

South AfricaWestern Cape Industrial

Symbiosis ProgrammeWestern Cape

Provincial Government

PolandEUR-ISWroclawClimate KIC

BelgiumNationalessenscia

BrazilBrazilian Industrial Symbiosis Programme

Minas GeraisParana

Rio Grande do SulDefra – Sustainable

Development DialoguesAl-Invest

ItalyRomeENEA

NetherlandsLimburgProvince of Limburg

SlovakiaReducing Production Wasteby Industrial SymbiosisBratislavsky krajERDF

United KingdomNISPEngland, Scotland, N. Ireland & WalesDefra, Scottish Government, InvestNorthern Ireland, Welsh Government

FinlandNationalMotiva/SITRA

South AfricaSouth Africa Industrial

Symbiosis Pilot ProgrammeGauteng Province

Defra – SustainableDevelopment Dialogues

ChinaIntro of IS to Jiangsu ProvinceJiangsu ProvinceUK SPF Fund


Why Industrial Symbiosis?

3. The real cost of waste


Landfill tax

0

10

20

30

40

50

60

70

80

7 710 11 12 13 14 15

1821

24

32

40

48

56

64

72

80

Landfill Tax - £ per Tonne

£ per tonne


Resource Streams


Segregation

Waste Value per tonne*

Mixed paper and board £88

Paper £118

Old corrugated containers £110

Plastic bottles £280

Ferrous metals £200

Non Ferrous metals £1000- £5000

*values will change


Waste hierarchy: Prospectingfor Value

Prevention

Reuse

Recycle

Recovery

Disposal

13%

77%

5%

5%

0%Analysis of 25% of synergiescompleted in 2010-2011% tonnage

NISP achieves 90% of itsbenefits at the top two levelsof the waste hierarchy


The environmental impact of waste


Hidden costs of waste

• Staff time for handling and collectingwaste

• Purchase of materials discarded

• Transportation to storage areas

• Provision of secure storage area

• Pre-treatment eg baling


The real costs of waste

• 5 – 10 times higher than disposal cost

• Up to 3 – 4% of turnover

• 1% of turnover can be saved


Do you do it?

• Does your organisation apply the hierarchy ?

• What do you do well?

• How could it be improved?


Ways to improve resource efficiency

Wastesegregation

GoodHousekeepi

ng

Materialexchange

Design outwaste

Reducepackaging

ImprovingResourceEfficiency


6. Model of delivery


ERDF offer

• SMEs with operating sites in the West Midlandsqualify for 12 hours of FREE business support

• Delivered in a number of ways:

• Site visit

• Waste audit

• Synergy facilitation

• Raising staff awareness session

• Resource Matching Workshop


LEARN HOW TO EFFECTIVELY MANAGE RESOURCES TO:• Map processes to characterise and quantify resource flows• Develop a systematic approach to segregation and collection• Achieve zero waste goals• Reduce disposal costs

International Synergies’ Approach toTraining

“A very concise and informativecourse, delivered in an easilyunderstandable manner.”Environmental Resource Group,2011

IMPROVE COMPLIANCE AND ENCOURAGE CULTURECHANGE:• Prevent waste arisings from workplace activity• Improve the management of unavoidable wastes

BENEFITS TO YOU:• Lower resource and disposal costs• Maximise value from waste• Improve environmental performance• Improve resource management systems• Foster a culture of more sustainable waste and resource

management


Building the IS Network

• Recruit new businessmembers

• Access a diverse range ofresources, sectors, businesssizes and locations

• Larger the network, thegreater the opportunity

• Currently 15,000+ industrymembers and growing (in UK)


Business Opportunity Workshops

• Facilitating the exchange ofinformation betweenbusinesses

• Tried and tested, interactivebusiness opportunity model

• Typically 50 – 60 organisationsin one room

• Can generate 300+ potentialsynergies from a facilitated ½day session


Facilitated Synergy: Role of Practitioners

• Identify ‘IDEAS’

• Make introductions

• Facilitate negotiations

• Provide technical expertise

• Mine the network foranswers and opportunity

• Use their industry expertiseand knowledge

• Encourage and acceleratesynergy progress


ERDF project outcomes since 2010

• 154 Business Assists including 122 with SMEs

• 378,000 tonnes of CO2 saved

• 153 jobs safeguarded

• 81 jobs created


Industrial Symbiosis in Action

4. Case Study Examples


Case Study: Business Solutionfor Foundry Waste

• Links to foundries via Cast MetalFederation

• Identified ways to reuse spentfoundry sand to brick manufacture

• Sustainable solution rather thanlandfill

• Additional Sales - £200,000

• Landfill Diversion – 10,000 tonnes

• Cost Savings - £300,000

• Virgin Materials – 10,000 tonnes

• Jobs Saved - 42


Case Study: Foundry Sand reuse. M74Completion

Edgar Allen Foundry

80,000T of sand usedfor general Fill


Mapping a route to waste reductionBalfour Beatty Civils and Credential Environmental

• Balfour Beatty Civils were looking for asustainable option for diverting a canalwhile building a bypass around Selly OakHigh Street in Birmingham.

• Credential Environmental Ltd was ableto supply tyre bales for the diversion ofthe canal, saving the need for steelstructures and aggregates. The projectwas so successful that the bales werethen put to use as retaining wallsthroughout other areas of the site

• The synergy resulted in a cost saving toBirse Civils Ltd of £40,000.

• A CO2 reduction of 375 tonnes wasachieved, with a saving of 1,000 tonnesof virgin material and 6,000 tonnes ofwater.

• Credential Environmental benefitedfrom £9,000 in additional sales.

John Daft – Balfour Beatty Civils:“With their local knowledge and supply chainpartners NISP ensured the most practicaland sustainable engineering solution wasdelivered on time and within budget.”


• Tarmac Building Products was lookingfor alternative materials as fillmaterial in lightweight buildingblocks

• Witherley Services was managing alarge stockpile of blast furnace slagand looking for routes to market

The results include:

• 17,300 tonnes of material wasdiverted from landfill

• 1777 tonnes of carbon dioxidesavings & Cost savings for Tarmacversus expensive raw materials

Case Study: Firm Foundations for SuccessWitherley Services and Tarmac Building Products


Case Study: reuse

• Farrow & Ball use intermediate bulk containers (IBCs) in the manufactureof high quality paint and wallpaper

• Centrax Ltd needed IBCs for the collection and storage of waste from theirengineering operations

• The two companies were brought together by NISP

• This resulted in:• landfill diversion of 2 tonnes of waste material• 2 tonnes of virgin materials saved• cost savings of £1500


Case Study: Recycling potential in the PipelineBlack & Veatch and B&J Parr

Black & Veatch Water Europe had alarge amount of used sewerage pipethat had been removed from a projectin Stoke.

Rather than send to landfill, NISPintroduced them to B&J Parr who couldwash and pelletise the plastic before itwas melted and used to manufacturetheir recycled bags.

The results include:•Diversion from landfill: 4 tonnes•CO2 reduction: 51 tonnes•New Business sales for B&J Parr: £400


Case Study: Innovation in materials

Companies:• Mil-Ver Metals• Denso Manufacturing UK

Summary:• Hazardous waste generated from Denso

producing air conditioning units was collectedand reprocessed by Mil-Ver for use in itsmanufacturing process

Achievements:• Cost Saving £55,000 per year• Hazardous waste eliminated 15 tonnes per year• Carbon emissions reduced by 242 tonnes per year


Fruitful Collaboration

Terra Nitrogen: Industry producesderivatives of nitrogen and methanol.Waste:12,500 tonnes of CO2 released

to atmosphere, hot steam andammonia.

John Baarda: Tomato producer Additional production capacity

limited due to high costs of energy

Partnership

•Elimination of CO2 emissions

•Construction of a greenhousecapable of producing 300,000tomatoes per year

•Investment of £15M

•Creation of 65 new jobs

•Recovery of heat from steam


Phil JohnsonBusiness Consultant

International Synergies Limited

t: +44 (0) 121 433 2660dl: +44 (0) 121 433 2687

e: philip.johnson@international-synergies.comwww.international-synergies.com

@IntlSynergies@NISPnetwork

Thank You for Listening...

phil johnson, international synergies ltd industrial symbiosis and the circular economy

Technology

date clients

symbiosis definition

industrial ecosystem

exemplar of ecoinnovation

business benefits

livingeconomy features

public private partnership

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