Taking Action on Materials : Global Examples of By-Product Synergy

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)

3. Industrial ecology is concerned with managing the physical resources of our modern technological society

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” 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 Statoil Refinery A-S Bioteknisk Jordrens Liquid Fertilizer Sulfur Sludge Steam Municipality of Kalundborg District heating Water Coolingwater Boilerwater Steam Gas Energy E2 PowerStation LakeTissø Water Scrubber Sludge Wall-board Plant Sludge (treated) Steam Fishfarming Water Heat Pharmaceutical Cement;roads Fly ash 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

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 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

12. Nanjangud Industrial Area, Karnataka 20km India Nanjangud 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

15. Final disposition of all materials generated by NIA facilitiesin Mysore, India

16. EIP master plan for South Korea Korea Industrial Complex Corporation Phase 3 Phase 2 Phase 1 Diffuse EIP concept to 8 industrial parks (US$ 68 million) 5 EIP pilot projects (US$ 17 million) 2 to 3 new EIP (US$ 6.8 million) 2010 ~ 2014 2015 ~ 2019 2005 ~ 2009

18. Overview of Ulsan National Industrial Parks Ulsan Mipo industrial complex Onsan industrial complex Source : KICOX (As on Apr. 2011)

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

20. 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 Carbon dioxide and steam network (2010) Carbon dioxide and steam network (2010) Implementation: Top-down IS network CO2 Supply Airemission CO2 generation CO2 generation CO2 reuse BOILER Cogeneration Plant & BOLIER PROCESS PROCESS STEAMSupply STEAM supply Outside steam Outside sale

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

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 Kalundborg Symbiosis Institute