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Curtin University is a trademark of Curtin University of Technology

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Sustainable Engineering Group

The !enefits of Industrial Sym!iosi The "#inana e$%erience

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&' (ngineers )ustralia Sustaina!ility %olicy

*atural vs Industrial ecosystems

+istory of (nvironmental management

Industrial ecology theory

(co,efficiency

Cleaner Production

&3 Industrial sym!iosis-synergies

Regional synergies

(co,industrial Park

($am%les of industrial sym!iosis

Practical case,study Regional synergies in the "#inana Industrial )rea ./)

This lecture .&3

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/hat are Industrial Sym!iosis2 Synergy

It is e$change of resource and energy !et#een collated com%anies

2 Ty%es of industrial synergy2 4y,%roduct synergy One com%any uses discard of the other com%any

2 Utility synergies com%anies have 5oint infrastructures and reuse #ater-energy from

each other

2 Su%%ly chain synergies local manufacturer and client

2 Service synergies organi6ing and sharing services and facilities2 4enefits

2 (conomic !enefit cost saving and higher efficiency

2 (nvironmental !enefit &ess 7#asted8 materials and energy

2 (nvironmental-(conomic Increased resource efficiency and security

2 Social (m%loyment o%%ortunities

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Reduces Source and Sink

Reducing 7Source and Sink8 enhance carrying ca%acityand reduce ecological foot%rints

The total through%ut of the human economy must !e ke%t

small enough to avoid e$ceeding t#o %hysical limits of the

ecosystemits ca%acity to regenerate itself9 and

its ca%acity to a!sor! our #astes:(Herman E. Daly, Beyond Growth (Boston: Beacon Press, 1996). ISB !"#!$!"%$!#"&)

)ctivities #hich systematically reduce the ca%acity of

nature to regenerate itself are e$cluded .PC4s9 C;Cs

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2 =efinition 7Ca%ture9 recovery and reuse of %reviously discarded resourcesfrom one industrial o%eration !y other9 traditionally se%arate9 industries

o%erating in their close %ro$imity8

2 (ngages traditionally se%arate industries in a collective a%%roach to

com%etitive advantage involving %hysical e$change of materials9 energy9

#ater and-or !y,%roducts:2 Categories

2 4y,%roduct synergies

2 /ater and energy utility synergies

2 Su%%ly chain synergies-management

Regional Synergies - Industrial Sym!iosis

.Cherto#9 >arian R: ?Industrial sym!iosis literature and ta$onomy:? )nnual revie# of energy and the

environment '@9 no: 1 .'000 313,33A:

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Inorganic 4y,Products2 ;ocus on high volume residues .!au$ite and gy%sum

2 &ink into local construction develo%ments

/ater

2>a%%ing of com%any #ater in%uts and out%uts2 /ater synergy sco%ing study and #orksho%

2 Industrial #aste#ater reuse

(nergy

2 Industry energy survey .uses and losses

2 (nergy sco%ing study and #orksho%2 /aste heat recovery .use for desalination

Planning ma% for Industrial Sym!iosis

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♦ Tools to facilitate the identication and development ofnew regional synergies

♦ Regional Synergy Toolkit

Stage 1: Assess potential for synergies in an industrial

area• With very limited industry data

Stage 2: Deliver detailed listing of possible synergies• Based on available/collected industry data

• Water, energy by!products

Stage ": #rioritise identi$ed synergies• Sustainability bene$ts % ease of implementation

Regional Synergies - Industrial Sym!iosis

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Source: Bossilkov et al (200!

Other Industrial Sym!iosis ($am%les

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Inorganic By-Product Reuse - Australia Reuse - World

Iron and steelmaking slags Accepted and used as a

cement replacement

USA & EU !"-#$$%

ly and bottom as' (ement blending) concreteaddition) (SIR* ad+ancedconstruction materialtec'nology ,it' B slag andsilica .ume/

USA & EU 0"-#$$% ,A/EU ""12% o. all coal combustionproducts are utilised inconstruction and undergroundmining

Sand ,.oundry/ 3o data USA 'ig' utilisation rates) +ary

beteen states

4ime kiln dust 3o dataSome in 5inana

USA #$$% ,456/

('emical gypsum• ,lue Gas

6esulp'urisation andP'osp'ogypsum/

Pasminco 7obart Smelter USA 89% ,G6/) PG bannedEU !:% ,G6/) PG in 0 pilot roads)inland

(onstruction and demolitionaste & recycled concreteaggregate

Some in 3SW and ;I(4imited in WA USA :"% ,recycled asp'altpa+ement/EU "$-#$$%

Boiler slag 3o data USA !$%) EU< #$$%

Inorganic 4y,Products Reuse

)ustralia Bs /orld

4ossilkov9 ): and C: &und: '00: >arket )ssessment for the Reuse of Inorganic Industrial 4y,

%roducts in the "#inana Industrial )rea: Perth9 /estern )ustralia Centre for Sustaina!le

Resource Processing .CSRP:

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)ustralian Duidelines for

4y,Product Reuse

2 *o standard reEuirements of reuse for many a%%lications9 e:g: soilconditioning9 or for use as a road !ase9 fill material

2 The %rocess of authorisation time consuming and la!orious

2 Continuous concerns of %otential o%%osition to the reuse9 #ith limited

su%%ort from government

2 &ack of leadershi% and su%%ort from government #hen dealing #ith

related community issues and concerns

2 &ack of security9 es%ecially #here community concerns can !lo# out

of %ro%ortion and effectively end the reuse

2 4y,%roducts continue to !uild u% in storage facilities

+arris9 S: '00A: Regulatory and Policy Issues of Regional Resource Synergies in the "#inana

Industrial )rea ) Sco%ing Study: Perth9 /) Centre of ($cellence in Cleaner Production9 Curtin

University of Technology:

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2 In US) and (U regulatory frame#orks and standardsalready e$ist and are #idely used:

2 These could %otentially !e ado%ted relatively easily and

Euickly in )ustralian 5urisdictions:

2 Some guidelines and reuses e$ist in )ustralia9 es%ecially

for slag and fly ash F driven !y industry associations:

International Regulatory ;rame#orks and

Standards

Ban 4eers =:9 4ossilkov ):9 &und C: '00G: Progressing the Reuse of Inorganic 4y,Products

The Case of "#inana9 /estern )ustralia: Resources9 Conservation and Recycling9 Bol: @3

.A9 %%: 3H@,3A:

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Identifying =rivers 4arriers to synergy

develo%ment♦ Regulation

": #ir$ water %uality re%uirements& reporting schemes B: 'omplicated$ approval procedures

♦ conomics

": )ncreased revenue

B: *ow costs for resources and waste disposal

♦ 'ommunity ": )mprovement of %uality of life

B: 'ommunity opposition and pu+lic concerns to waste reuse

♦ Technology

": Replacement,decommissioning of old e%uipment

B: *ack of suita+le technology to transport,convert +y-product♦ Risk and *ia+ilities

": Reduction of lia+ilities associated with waste storage

B: "ependencies$ lack of supply securities

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/hatJs *eeded to =evelo% Inorganic

4y,Product Synergies on Significant Scale•

Clearly defined mar'et drer, re*+latory +ll .e:g: use ofsecondary-recycled material e$%licitly articulated in %olicies9

%rocedures and tenders

• (sta!lishment of -ramewor's and standards for industrial !y,

%roduct re,use9 such as those e$isting overseas

• ;ull s+stanalty and l-ecycle analyses of industrial !y,

%roduct-recycled materials in %ro%osed a%%lications9 com%ared to

virgin-e$isting materials F to illuminate discussions #ith community

and remove misconce%tions

• /eadersh and s+ort from government #hen dealing #ith related

community issues and concerns

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;actors for Successful Synergy Pro5ects

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Resource ($change *et#orks

2 Cleaner Production at each

facility

2 Resource Recovery and

Reuse9 enhanced through

2Industrial clustering

2Su%%ortive infrastructure

2(co,services %rovider

Park =esign and >anagement2 Integration into *atural

(cosystems

2 Dreen ;acilities =esign

2 (nvironmental>anagement System for

%ark management

(co Industrial Park

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2 Ty%e 1 through #aste e$changes2 Ty%e ' #ithin a facility9 firm9 or

organi6ation2 Ty%e 3 among firms collocated in a

defined eco,industrial %ark2 Ty%e K among local firms that are not

collocated2 Ty%e @ among firms organi6ed

7virtually8 across a !roader region:

(0hertow, aran 2. 3Ind+stral symoss: lterat+re and ta4onomy.3

5nn+al reew o- ener*y and the enronment &, no. 1 (&!!!): 717"

77$.)

(co Industrial Park

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2 )n eco,industrial %ark creates niches for !usiness develo%ment2 =ecom%oser firms %racticing recovery9 recycling and reuse .LscavengerJ

niche

2 Remanufacturing %lants

2 (nvironmental monitoring and

information systems

2 Trans%ortation services

2 (nvironmental management

4usiness *iches

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• Port "em!la in *e# South /ales

• Dladstone in Mueensland

• /hyalla in South )ustralia

• Port Pirie in South )ustralia

• &averton in Bictoria

• Deelong in Bictoria

• "#inana in /)

Potential for Synergies in )ustralia

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Industrial (cology4est Practice "#inana Industrial )rea

• +eaviest industrial area in /)

• K0 km south of Perth9

• Coastal stri% of a!out km long .' km #ide

• Resource %rocessing alumina9 nickel9 oil refineries9 +Ismelt9 etc:

• Utility %o#er9 #ater treatment9 co,gen %lants9 etc:

• >anufacturing cement9 chemical9 fertiliser %lants9 etc:

• 4est %ractice e$am%le of regional synergy im%lementation

• KA diverse and matured e$isting synergies

• /orld leading industry colla!oration

• ($isting synergies result in significant !enefits

• (conomic9 environmental9 and social

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Industrial Integration in 1GG0

27 interactions between 13 industries

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Sourced from CECP, Curtin

($am%les of 4y,Products Synergies1: Reuse of slag from smelting

Road construction9 fill material

Sand !lasting

Insulation .air granulation of slag slag #ool

Deo%olymers

': Reuse of fly ash from coal,fired !oilers

Road construction

Deo%olymers

Soil conditioner 3: Reuse of gy%sum from scru!!ing systems

Plaster !oard manufacturing

Cement %roduction

Soil conditioner

K: Reuse of lime kiln dust from cement %lant

=esul%hurisation .scru!!ingSoil conditioner

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/ater synergies in "#inana1: )lternative su%%lies for %rocess #ater

2 .Treated effluents

2 Cooling to#er !lo#do#n

2 4oiler !lo#do#n

2 /ashing #ater

2 oint #ater reclamation-recycling %lant

': oint %roduction of demineralised #ater

3: oint treatment of oily #aste#ater

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/ater synergy develo%ment

Approac'

2 >a%%ing of com%any #ater in%uts and out%uts

2 /ater synergy sco%ing study #orksho%

4essons learnt

2 Currently lo# #ater %rices9 !ut increasing

2 Changing !usiness drivers for #ater conservation

2 Promising #ater synergies e$ist

8ne"on"one comany and collecte -or wnana

2 )%%ly direct reuse or lo# cost technologies2 Sustaina!ility through diversity of #ater su%%ly

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(nergy synergies in "#inana

#1 Use o. alternati+e .uels at cement plant

2 /ood chi%s from concentrator2 Tyres

2 /aste oils

2 >unici%al solid #aste

01 ,Coint/ cogeneration .acilities

2 Use fuel gases su%%lemented #ith gas

91 Energy reco+ery .rom .lue gases) steam2 (lectricity and steam %roduction

2 .Pre,heating of #orking liEuids

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(nergy synergy develo%ment

Approac'2 Industry energy survey .uses and losses

2 (nergy synergy sco%ing study #orksho%

4essons learnt

2 Changing !usiness drivers for energy conservation

2 ;ocus on energy recovery from flue gases

H*hest ener*y contents (;) and temerat+res

2 Proven sim%le technologies seem most attractive

2 Significant energy losses over larger distances

2 ;easi!ility de%ends on energy needs of user

P t ti l f " i I i

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Potential for "#inana Inorganic

4y,Product Synergies

4ossilkov9 ): and C: &und: '00: >arket )ssessment for the Reuse of Inorganic Industrial 4y,

%roducts in the "#inana Industrial )rea: Perth9 /estern )ustralia Centre for Sustaina!le

Resource Processing .CSRP:

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Recycling Industrial 4y,Products

&ifecycle 4enefits

Figure: Use of energy by each life cycle stage in the system.

Olsson9 S:9 (: "arrman9 and : P: Dustafsson: '00H: (nvironmental Systems )nalysis of the Use

of 4ottom )sh from Incineration of >unici%al /aste for Road Construction: Resources9

Conservation and Recycling K 'H,K0

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)rtificial #etland treatment at CS4PChemical Plant

– On 4P Refinery land

– Some of 4P effluent going into

#etland cells as #ell

' Cogeneration facilities

– 4P Refinery .11H >/

– Ti#est Pigment Plant .K0 >/

($am%les of Utility Synergies

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Sourced from CECP,

Curtin

Icon Synergy Pro5ect , "/RP

TO OC()*

S(PI) =(PR(SSIO* OC()* OUT&(T &)*=&I*(

W**6>A3 P*I3=

WWP=

I36US=RIES

5WRP

SC+(>( /)T(R

4OR( /)T(R

'K >&-d A >&-d

1A >&-d

H >&-d

110 >&-d

TO COC"4UR*

SOU*=

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4enefits and Success ;actors

• )llustrative +enets2 *ess .waste/ and emissions to environment (all

synergies!

2 Reduced operational costs (gypsum!

2 )ncrease company income (lime kiln dust!

2 )ncreased water eciency (1R3!

2 )ncreased energy eciency (cogen facilities!2 ater and energy security (1R3 4 cogen!

• 5avoura+le features in 1winana2 1winana )ndustries 'ouncil

2 "iversity of industries

2 6on-competitive

2 'lose pro7imity of industries

Technology

BusinessCase

Licenceto Operate

successfulsynergyprojects

&an Ber'el, 2(()

Corder, G., an Beers, !., Lay, ". and an Ber#el, $.: Benefits and %uccess Factors of regional $esource %ynergies in Gladstone and&'inana, Green (rocessing Conference, pp )*+-, e'castle, %/, 0ustralia, -112.

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Curtin Research into Regional Synergies

2 "#inana Case,Study .CSRP funding2 Provide %ractical su%%ort to "#inana industries #ith

identification and evaluation of synergy o%%ortunities

2 (na!ling Tools and Technologies .CSRP funding2 =evelo% customised and smarter tools to facilitate the

identification and evaluation of regional synergies

2 (na!ling >echanisms .)RC funding

2 ;acilitating structures2 O%erational and contractual arrangements

2 (valuation methods

& & t f " i

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&essons &earnt from "#inana♦ 7isting synergies provide range of sustaina+ility +enets

8ore synergy opportunities e7ist

♦ Business case of synergies

6eed to understand +roader sustaina+ility +enets

♦ Regulatory +arriers

3revent or delay implementation synergies

♦ )ndustry champions

'rucial for synergy development

♦ )ndustry involvement

"evelopment of synergies is not core +usiness

♦ 1winana )ndustries 'ouncil has key role

3latform for industry colla+oration

Documents

ESD201 IE L3 S1 2016