Taking Action on Materials: Global

Examples of By-Product Synergy

Professor Marian Chertow, Yale University

Presentation - US Business Council for Sustainable Development

July 17, 2013

Outline for Today Introduction and Vocabulary for Industrial

Ecosystems/Symbiosis/By-Product Synergy

Examples China – Tianjin Economic-Technological

Development Area (TEDA) India – Nanjangud Industrial Area, Mysore Korea – Korean Industrial Complex

Corporation (KICOX)

Industrial ecology is concerned with managing the physical resources of our

modern technological society

“In an industrial ecosystem, the consumption of energy and

materials is optimized, waste generation is minimized, and the

effluents from one process serve as the raw material for another”

R.A. Frosch, and N. Gallopoulos, Strategies for Manufacturing, Scientific American, 260 (3), 144, 1989The first great article of industrial ecology…

Sludge(treated)

Liquid Fertilizer

Farms

Cement;roads

Fishfarming

Water

Water

Water

Fly ash

Heat

ScrubberSludge

Gas

Steam

Ste

am

Sulfur

A-S Bioteknisk Jordrens

Sludge

Ste

am Coo

ling

wat

er

Statoil Refinery

LakeTissø

Boi

ler

wat

er

Yeast slurry Recovered nickel and vanadium

The Industrial Ecosystem of Kalundborg, Denmark

Energy E2 PowerStation

Pharmaceutical

Municipality of Kalundborg

District heating

Wall-board PlantSludge(treated)

Sample Benefits of Industrial Symbiosis/ By-Product Synergy to Kalundborg Participants Water savings

Oil refinery – 1.2 million cubic meters Power station – total consumption reduced by 60% System:

Ground water 2 million cubic meters/year (530 million gallons) Surface water 1 million cubic meters/year (265 million gallons)

Input chemicals/products 170,000 tons of gypsum 97,000 cubic meters of solid biomass (NovoGro 30) 280,000 cubic meters of liquid biomass (NovoGro)

Wastes avoided through interchanges 50,000-70,000 tons of fly ash from power station 2800 tons of sulfur as hydrogen sulfide in flue gas from oil refinery 240,000 tons CO2 reduction annually

Industrial Symbiosis

Industrial symbiosis engages traditionally separate industries in a collective approach to competitive advantage involving physical exchange of materials, energy, water, and/or by products

The keys to industrial symbiosis are collaboration and the synergistic possibilities offered by geographic proximity.

M. Chertow 2000

Annual Review of Energy and Environment(Also Wikepedia)

Jurong Island, Singapore

UK

EU, Vienna, Austria

Monfort Boy’s Town, Suva, Fiji

Tianjin Economic-Technological Development Area: TEDA as a Salt Pan in 1984

Tianjin Economic-Technological Development Area (TEDA) - 2006

Summary of all symbiotic exchanges identified in TEDAResource exchanged

I-I exchange

(%)

I-E exchange

(%)

Subtotal (%)

Average distance

(km)

Energy 5 (6%) 2 (3%) 7 (9%) 2.9

Water 12 (15%) 0 (0%) 12 (15%)

3.5

Material 16 (20%) 46 (56%) 62 (76%)

28.2

Subtotal 33 (41%) 48 (59%) 81 (100%)

India

Nanjangud

20km

Nanjangud Industrial Area, Karnataka

45 facilities – 900,000 tons of potential discards

Profile of industrial enterprises in NIA A sugar refinery and a coffee/beverage

producer account for ~60% production volume

Printed circuit boards, paper, textiles, automotive parts, distillery

Micro-enterprises: granite cutters, oil producer, food processors

Surrounded by a large agricultural community

Industrial food web in

Nanjangud Industrial AreaMysore, India

Final disposition of all materials generated by NIA facilities in Mysore, India

2015 ~ 2019

5 EIP pilot projects

(US$ 17 million)

2010 ~ 20142005 ~ 2009

Phase 1 Phase 2 Phase 3

Diffuse EIP concept to 8 industrial parks

(US$ 68 million)

2 to 3 new EIP

(US$ 6.8 million)

EIP master plan for South KoreaKorea Industrial Complex Corporation

CategoryUlsan Mipo

Onsan Total

Food 8 - 8

Textile 5 - 5

Wood / Papers

14 3 17

Petrochemicals

135 63 198

Non ferrous 29 9 38

Steel 132 66 198

Machinery 13 21 34

Electrical, Electronics

84 7 91

Transport Equipments

223 70 293

Others 27 7 34

Services 93 29 122

Total 763 275 1,038Source : KICOX (As on Apr. 2011)

Overview of Ulsan National Industrial Parks

Overall Objectives for Ulsan National Industrial Parks

Environmen-tal Quality Improve-ment

Zero Emission via Resource Circulation

Enhancement of Industry Competitive-ness

Pollution reduction

Cascading Zero-Emission via Resource recycle

Cost Reduction and Enhanced competitiveness

New business

Harmony with

Community

Eco-Polis

Ulsan

Sustainable

Society

Economic benefit : 6.6 million US$/yr (Steam selling and B-C replacement)

Environmental benefit: Reduction of 63,643 tons CO2/yr, 1691.5 ton /yr air pollutants

CO2 generation

CO2 reuse

BOILER

PROCESS

Outside steam

CO2 generation

Cogeneration Plant & BOLIER PROCES

S

Outside sale

STEAM supply

Air emission

STEAM Supply

CO2 Supply

Implementation: Top-down IS network

Thank you and Next!

Peter Laybourn, Chief Executive, International Synergies Limited , May 27, 2013

Chinese EIP standard Added industrial value per capita, and rate of growth of value Eco-efficiencies (per added industrial value)

Energy consumption Freshwater consumption Wastewater generation Solid waste generation COD emissions

Reuse ratios Industrial water Middle water Solid waste

Shared services/utilities Treatment percentage of wastewater Availability of common waste collection, wastewater treatment

systems Management systems

Environmental management system Availability of information management system

Public relations Release of public environmental report Public satisfaction with environmental quality

Source: Geng et al, 2009

Kalundborg as an Adaptive System Changes in footprint: Refinery doubles in size

with North Sea oil claims

Changes in flows: Power station switches fuel to meet regulations for CO2 reductions

Changes in organization: Pharmaceutical operation splits into two companies to separate biotech operations; an international company buys out the Danish gypsum board company

The Symbiosis Activities Kalundborg Symbiosis Institute 26

Kalundborg Symbiosis Institute

spread over ~ 7 km