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KALUNDBORG
DANMARK 5,5 mioindbyggere
COPENHAGEN
1. Fact sheet for Kalundborg
1. 49.743 inhabitants, 603,7 km2 2. Industry and port leverage levelling a medium sized European city3. Leading on biomass conversion/biorefinery (Inbicon.dk; Pyroneer.dk)4. Leading on industrial collaboration since 1972 (www.symbiosis.dk)5. Leading on Smart City Initiatives6. Denmark’s largest CO2 emitter (ETS) 10% in 2011
Al Gore in Copenhagen 17 December 2009:
"Currently pollution has zero value, we must put a price on our pollution
i.e. put a price on carbon!"
Photo: Luc Hardy©
4
…waste, water and energy
Municipalities, cities and industry can and should make a difference bothwithin and exterior to the ETS:
Too much energy and too many resources are wasted.
We need to adopt the waste hierarchy fully and spur the inherent successthat is entailed within a proper use of the many resources that we do not utilitise at its utmost today, that be either waste, power, heat, water or otherresidues.
Failure to comply with resource efficiency, integratedplanning and an optimate use of residues will either leadto a sustained or even increased investment in extracapacity and expansion of utility facilities (wwt; combustion; CHP, even roads for transportation) basedon ’old’ technologies that will tie our hands even further, rather than solving the climate and resource challengeswith future oriented solutions
RENOVATE THE PAST OR INVEST IN THE FUTURE
-But excessive resource consumption has a value,
We must include this value in our valorisation of theoverall production costs
The cheapest cost-cutting is not to lay people off but to avert consuming resources that are expendable therebyincreasing competitiveness and net profits.
Introducing industrial symbiosis is also a means to a viablereduction of uptakes of virgin materials thereby improvingour resource foot-print
7
“Industrial Symbiosis… should be standard procedure by 2020”
Environment Commissioner Potocnic
Green Week 27 May 2011, Photo Patrick Mascart
4 R’s
EnergyWasteWater
Industrial Symbiosis conceived in Kalundborg
Kalundborg Industrial Symbiosis conceived in Kalundborg - a Pioneer at a glance since 1972 driven by profitA resource and environmental collaboration network consisting of 32 major bi- or trilateral commercial agreements (projects) composed initially by 8 founding partners
Three categories of projects:Exchange of energy: 9 ProjectsRecycling of waste products: 11 ProjectsRecycling of water: 12 Projects
Some of the annual results of the Symbiosis in Kalundborg are: 272.000 tons CO2 emissions down since 1982 3 mio m3 water saved through reuse and recycling 150.000 tons NovoGro replaces traditional fertilizers 150.000 tons yeast slurry replaced 1989-2011 traditional soy protein
in feed - now feedstock for biogas 150.000 tons gypsom replaces imported nature gypsum (CaSO4)
reduced to 110.000 tons (reduced in line with decarbonisation) 4 mio m3 ground water substituted by surface water
-> changes in regulatory framework (incl. higher carbon tax) couldincrease figures adding the nexus between water and energy
http://www.symbiosis.dk/en/video
ISK 1972 – 2012 40
Cronology of Kalundborg Industrial Symbiosis– a growth model
LakeTissø
Statoil
Waste watertreatment plant
KalundborgUtilties
Novo Nordisk
NovozymesDONG Energy
ASV
Major vatsfor reuse
Tissø water
Treated Tissø water
Steam
Sea water
Dionat
Drainage water
Technical water
Waste water
Waste water
Cooling water
Potable water
Intern Bio-treatment
Gyproc
RGS 90
KalundborgFjord
Water Projects - Mapping of water flows between Symbiosis industries
Additional water (Spædevand) district heating
4462
24
1710
622
886
512
1464
408178
1672
247
59
40
7
59
2705
Gyproc
413 ? 272
12
1349
?
?
Water from inluent
?
All figures are from 2010, (1000 m3)Influent water from Statoils own pump station
2,6
The Symbiosis Institute1996
RGS 90LakeTissø
Novozymes
Novo Nordisk
Farms
Fish farm
DONG EnergyAsnæs
Power Station
The Municipalityof Kalundborg
Gyproc
Fertilizer industry
Re-usebasin
Cementindustry
StatoilRefinery
10 Surface water 1987
12Yeastslurry
1989-2011
4Biomass/NovoGro1976
13 Sulphur 1990Fertilizer 2001
5 Fly ash1979
16 Gypsum 1993
9 Steam 1982
15 Gas 1992
11 Coolingwater 1987
7Heat1981
6 Heat1980/89
8 Steam 1982
2Gas
1972
19 Sludge
17 Waste water 1995
1 Surface water 1961
3 Surface
water1973
14 Tech.water 1991
18 Drain water 1995
1998Waste water
treatment
20Fly
Ash1999
Kara/Noveren
21 Deionized water 2002
Purifica-tion
of water22Water200425 Sea water 2007
Recovery of nickeland vanadium
Pig farms
24Alko-holicResidue2006
26 Steam 2009
30 Bioethanol
Inbicon
Farms
27 Straw 2009
23 Waste gypsum
29 Condensate2009
Pyroneer32 Gasifier 2011
31Lignin
2010
32C5/C6 sugars2010
KALUNDBORG INDUSTRIAL SYMBIOSIS SYSTEM 2012
China's top legislature passed a law to promote circular economy on Friday at the closingof the fourth session of the Standing Committee of the 11th National People's Congress(NPC).The draft law was ratified after its third reading, and President Hu Jintao signed it into law. It will come into force on January 1, 2009. The aim of the law is to boost sustainabledevelopment through energy saving and reduction of pollutant discharges.Government departments will map out a system for recycling and improve energy-savingand waster utilization standards. China Daily 2008
Danish Climate Commission 28 September 2010: The answer is ”through wind and biomass”
BUT WHERE IS THE GROWTH TO FINANCE
THIS?
Water scarcity – friend or foe?
Globally water is a scarce ressource, also in Kalundborg. Projections foresee increased costs. Currently the consumptionof ground water in Western Zealand is estimated to exceed theavailable capacity by more than 35% ref. Nature Agency. Water scarcitycould jeopardize future industrial growth but it could also spurresource efficiency and growth
Can we afford all this?
WE NEED A GAME
CHANGER – WE NEED
INDUSTRIAL SYMBIOSIS!
IS 2.0
There is a clear nexus between water and energyand we need to save both resources:
• Water needs energy in all the steps along the water value chain: pumping water for supply and sanitation; delivery of irrigation water, for food- and bio energy production, etc.
• The energy requirements to produce water is significant 586 kWhelectricity to treat 1 mio liters of water. As water is becoming more scarce it is foreseen that water will be transported over longer distances (ref. WssTP 2011)
• Clash between EU Directives: Conservative estimates predictelectricity increases of 60-100% over 15 years in order to meet new EU Directive requirements, which conflicts with energy- and CO2 reduction targets. Alone in the UK energy consumption in the watersector has doubled since 1990 as a result of the Urban Waste WaterTreatment Directive and Drinking Water Directive due to the requiredadditional treatment. Further increases are likely to result in ”pollution displacement” from water bodies to the atmosphere (ref. WssTP2011)
-
Water and Energy nexus are also low-hanging fruits:
A Heat recovery where heat from cooling using a heat exchanger canoffer significant energy savings with a return on investments for industries down to a few months. Heat generated at industrial sites e.g. from cooling can also be exchanged and used off-site such as districtheating as in Kalundborg
B Anaerobic biogas (CH4) production from industrial waste water is wellsuited for industries discharging highly concentrated waste waters(1,500 mg COD/l) (5MW gasifier) e.g. Novozymes 5MW
C Kalundborg is partner in PPP Flagship project ”E4WAter” where thepartner Dow Chemical’s site in NL re-uses daily 10 mio liters ofmunicipal household waste water as feed water for several plants. Thewater is treated and used as feed water for cooling towers therebyreducing waste water reduction by 38%, energy use by 60% and CO2 emissions saved 5,000 tons/year Source: WssTP Water and Energy, September 2011, p. 38
D Return on investments – pay back time is often rather short howevermany industries tend to overlook the potential synergies embedded in the coherent interdependent water-energy nexus. Seen from a sector perspective water improvements have up to fivetimes longer pay back time than energy due to the cost of kWh saved is higher than costs on each m3 water saved. However if the nexus is taken into account there are major saving potentials in bothsectors to be made by introducing water reductions and recycling
Energy needs water for energy production (power and renewables)
• In industries optimisation of the water cycle tends to imply energyreduction when reusing water with low or high temperatures.
• Expected increases in energy prices impact water supply systems and will foster industries shifting towards energy efficiency and energyrecovery, and IS is a helping hand
• It all requires for a shift in the way of thinking across society and industry. We need innovations and changing of our mindsets to deviatefrom ”business as usual” by: • Integrating water and energy systems in our planning• Assess environmental footprints together with economical
performances (”ESCOs on water” business plans)• Systematically detect energy efficiency measures including
leackage reduction• Exploit untapped energy potential in water systems included
embedded energy through resource recovery• Recover other substances and materials in waste water such as
polymeers for down-stream biorefineries
Source: Regeringen, ”Vores Energi”, nov. 2011
2010 DK 22% wind power consumption2020 DK 52% wind power by adding 2100 MW incl. scrapped capacity
df• df
Source: EnergiNet.dk
Knowing how wind intermittancy affects us today– and how about tomorrow?
-
Smart City Kalundborg alsorevolves around shiftingindustry power loads within the IS
Manufacturing processes canassist load shifting in a Symbiotic Energy System bringing down e.g. wastewater treatment costs and avert additional CapEx
Shifting energy loads withinIndustrial processes, which arenot 24/7 are potential for DER e.g.
• 9 mio m3 water• 3 mio m3 is recycled• 7 MW ozon facility never 24/7
- align spikes in power grid by use of (bio)gas or CH4
EIP Water – site – Kalundborg Symbiosis - Pivotal is cost cutting through resourceefficiency sustained manufacturing in EU – 5 key challenges with the nexus:
A. Legal barriers as empediments to increased reduction of quantity
1. Water Services by official utilities require partnerships (financial models)• Water leackages detected• Water saving remedies and advisory services
2. Industries as ’local utilities’ supplying:• water (treated above minimum threshold for recycling for diverse purposes); • heated water/steam/ww (district heating, production steam replacing fossil)• energy for power and heat (wwt->CH4)
3. Energy efficiency to the benefit of whom? • Capacity in metric volumes reduced• Empediment to growth of new and existing industries• Changes in modalities/methods of WWT due to RES where CH4 is requested
an alternative to active sludge apply algae to lower COD – new biosolutions• Increase focus on scarce resources vs virgin materials (e.g. phosphorus)
4. Energy and water management: Smart Grid deployment within utilities• Water pumping e.g. 250 pumping stations and smart pumps• Waste water treatment incl. ozonuous – time of delay for grid balancing
5. Industries strive to lower water consumption/reuse even further
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Environment Commissioner Potocnic & Climate Commissioner HedegaardPhoto Patrick Mascart
Green Week 24-27 May 2011, Kalundborg Industrial Symbiosis
