1. 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

2. 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)
Scale
– more public infra
India – more private
KICOX - facilitator

3. Industrial ecology is concerned with managing the physical resources of our modern technological society
In this sense IE is foundational – how do we know even how to measure production and consumption without understanding our material and energy flows? Without knowing how much is available? Without 3

4. “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”
Start with a vision…
R.A. Frosch, and N. Gallopoulos,
Strategies for Manufacturing,
Scientific American, 260 (3), 144, 1989
The first great article of industrial ecology…

5. The Industrial Ecosystem of Kalundborg, Denmark
                           
                                                                                                     
                
                                                                                                     
The Industrial Ecosystem of Kalundborg, Denmark
Statoil Refinery
A-S Bioteknisk Jordrens
Liquid Fertilizer
Sulfur
Sludge
Steam
Municipality of Kalundborg
District heating
Water
Cooling water
Boiler water
Steam
Gas
Energy E2 Power Station
Lake Tissø
Water
Scrubber
Sludge
Wall-board Plant
That exact same year, this industrial ecosystem, described in theory by F&G, was found in Kalundborg Denmark.
Sludge
(treated)
Steam
Fish farming
Water
Heat
Pharmaceutical
Fly ash
Cement; roads
Sludge
(treated)
Farms
Recovered nickel and vanadium
Yeast slurry

6. 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
Frl Randers – K”burg researcher at Roskilde
Ground water ……………… 2.0 mill. m3/year
Surface water ……………… 1,0 mill. m3/year (265 million gallons)
FROM SYMBIOSIS.DK :
Yearly CO2 emission reduced by tons.
3 million m3 of water saved through recycling and reuse.
tons of straw converted to 5,4 million litres of ethanol.
tons of yeast replaces 70% of soy protein in traditional feed mix for more than pigs update – now used for gasification in Pyroneer plant
Recycling of tons of gypsum from desulphurization of flue gas (SO2) replaces import of natural gypsum (CaSO4).
More than 95% of the water input at the power plant is part of the symbiotic network, whereas 98% of the water input for the refinery is symbiotic in character, as is approximately 20% for the Novo facility.

7. 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)

8. Jurong Island, Singapore
EU, Vienna, Austria
Since I announced the symposia in 2003, a great deal of uptake around the world.
The ZeroWIN-project will examine and develop new and innovative approaches and effective strategies for the prevention of waste in industries based on industrial symbiosis. Industrial Symbiosis is concerned with regional collab
oration of companies from traditionally separated sectors which exchange by-products, energy, water and materials in such way, that the waste from one industry becomes raw material for another.
Goal:
To find new and innovative approaches and effective strategies for the prevention of waste in industries based on industrial symbiosis
The development of innovative technologies, waste-prevention methodologies, strategies and system tools (e.g. eco-design, local industrial clusters, and resource exchange) exportable into other European and worldwide contexts shall represent the main focus of this action.
The goal is to develop a structured and innovative production model for resource-use optimisation and waste prevention, also taking residues as secondary raw materials, and test it in real cases of sustainable industrial networks.
Results should translate the vision of a sustainable development into elements of a sustainable entrepreneurship, focusing at enhancing business opportunities according to a "towards zero waste" approach.
Expected Results:
a decrease of at least 30% of greenhouse gases emissions,
at least 70% of overall re-use and recycling of waste,
a reduction of at least 75% of fresh water utilisation.
Monfort
Boy’s Town, Suva, Fiji UK

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

10. Tianjin Economic-Technological Development Area (TEDA) - 2006

11. Summary of all symbiotic exchanges identified in TEDA
Resource 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%)
3.5
Material
16 (20%)
46 (56%)
62 (76%)
28.2
Subtotal
33 (41%)
48 (59%)
81 (100%)

12. Nanjangud Industrial Area, Karnataka
20km
India
Two researchers – one from Yale and one from ROI
45 facilities – 900,000 tons of potential discards

13. 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

14. Industrial food web in Nanjangud Industrial Area
Mysore, India 14

15. Final disposition of all materials generated by NIA facilities in Mysore, India
End with 99.5%

16. EIP master plan for South Korea Korea Industrial Complex Corporation
2015 ~ 2019
5 EIP pilot projects
(US$ 17 million)
2010 ~ 2014
2005 ~ 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)

18. Electrical, Electronics
Overview of Ulsan National Industrial Parks
Ulsan Mipo industrial complex
Category
Ulsan Mipo
Onsan
Total
Food 8 -
Textile 5
Wood / Papers 14 3 17
Petrochemicals
135 63
198
Non ferrous 29 9 38
Steel
132 66
Machinery 13 21 34
Electrical, Electronics 84 7 91
Transport Equipments
223 70
293
Others 27
Services 93
122
763
275
1,038
Onsan industrial complex
Source : KICOX (As on Apr. 2011)

19. Overall Objectives for Ulsan National Industrial Parks
Pollution reduction
Cascading Zero-Emission via Resource recycle
Environmental
Cost Reduction and Enhanced competitiveness
New business
Industrial
Harmony with Community
Eco-Polis Ulsan
Sustainable Society
Social
Ulsan Mipo-Onsan EIP Transition Project
Objectives
Environmental Quality Improvement
Enhancement of Industry Competitiveness
Zero Emission via Resource Circulation

20. Implementation: Top-down IS network
Carbon dioxide and steam network (2010)
CO2 Supply
Air emission
CO2 generation
CO2 generation
CO2 reuse
BOILER
Cogeneration Plant & BOLIER
PROCESS
PROCESS
STEAM Supply
STEAM supply
Outside steam
Outside sale
Economic benefit : 6.6 million US$/yr (Steam selling and B-C replacement)
Environmental benefit: Reduction of 63,643 tons CO2/yr, ton /yr air pollutants

21. http://www. clustercollaboration. eu/documents/270945/0/KICOX_ENGLISH

22. Thank you and
Next!

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

24. 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 24

25. 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

26. Kalundborg Symbiosis Institute spread over ~ 7 km
Good Planning?
RSG 90 -
Remediation of tons oil and metal year.
The Symbiosis Activities
Kalundborg Symbiosis Institute