Eco Industrial Parks for Waste Minimization

Wang Jing-Yuan Associate Professor, School of Civil & Environmental Engineering Director, Environmental Engineering Research Centre

1 November 2006

To maintain the integrity of life, we need to understand how nature works:

Nature works in cycles There is no waste - what is unused by one species becomes nutrients for the next

No Waste

The suns energy drives the process Green celled plants using photosynthesis create net concentration and structure
(Marian Chertow)

In contrast, our industrial system functions primarily in a linear fashion:

Take Make Waste

Take natural capital, structured valuable material, and process it into unusable waste

Only 6% of material flow ends up in products

(Marian Chertow)

This industrial system, operating on an ever larger scale, is embedded in and affecting natures cycle:

(Marian Chertow)

Industrial Ecology (IE)

(Brad Allenby)

3 Levels of Operation of IE

Source: Marian Chertow, Industrial Symbiosis: Literature and Taxonomy Taxonomy, Annual Reviews of Energy Environment 2000

Industrial Symbiosis/EIP
By-products / Wastes Resources

Factory A

Factory B

Resources

By-products / Wastes

EXCHANGE OF RESOURCES

Advantages of EIP
Recycling of by-products; the by-product of one company becomes an important resource for another company Reduced consumption of resources, e.g. water, coal, oil, gypsum, fertilizer Reduced environmental strain, e.g. reduced CO2 and SO2 emissions Improved utilization of energy resources; e.g. waste gases are used in the energy production Minimization of waste materials to be treated and disposed of in these industrial estates Greatly reduce operational costs

Examples of Established Eco Industrial Parks around the World

Kalundborg, Denmark (Layout)

Heat Kemeria Steam Water Lake Tisso Water Water Fertilizer Sludge Statoil Refinery Gas Cooling Water Waste Water Greenhouses Heat District Heating Gas Gypsum Heat Gyproc Fish farming Cement; Roads

Asnaes Power Station Steam Novo Nordisk

Fly ash
Source: Christensen, 1999

Eco Industrial Park Initiatives in Asia Pacific Region

China Philippines

Dalian, Tianjin, Suzhou, Yantai, Guigang, Nanhai Laguna International Industrial Park, Light Industry & Science Park, Carmelray Industrial Park, LIMA, Laguna Technopark, Philippine National Oil Company Petrochem Industrial Park; Clean City Center project (USAID) Lingkungan (LIK), Tangerang; Semarang; Industri Sona Maris Naroda; Tirupur Textile sector; Tamil Nadu tanneries; Calcutta foundries; Tamil Nadu Paper / Sugar; Bagelore Water project; Ankleshwari, Nandeseri, Thane-Belapur LHT Resources Linkage 12 ecotowns (e.g. Kitakyushu, Itabashi), Fujisawa, Toyota City Tainan Technology & Industrial Park, Changhua Coastal Industrial Park; Corporate Synergy System (CSS II) projects Amata (envi mgt), Hanoi Sai Dong II (feasibility study) Industrial Estate Authority of Thailand plans (Map Ta Phut, Northern Region, Amata Nakorn, Eastern Sea Board, Bang Poo); Samut Prakarn Province CPIE project (ADB funded); Bangkok (Panapanaan) Ministry of Economic and Industrial Development plans

Indonesia India

Malaysia Japan Taiwan Vietnam Thailand

Sri Lanka

Source: Anthony S.F. Chui, EcoEco-Industrial Network in Asia Asia, International Conference on Cleaner Products 2001

Kitakyushu Ecotown, Japan

Energy generated by combustion of some wastes is supplied to the facilities of the Complex. Plastic PET bottle recycling project by Nishi-Nippon PET-Bottle Recycle Office equipment recycling project by Recycle Tech Co., Ltd. Automobile recycling project by West Japan Auto Recycling Co. where not only automobiles were disassembled but oil and gas were also treated. Home appliance such as TVs, refrigerators, and washing machines are disassembled and their parts recycled for remanufacturing. Fluorescent tube recycling project Medical waste recycling project
Source: Anthony S.F. Chui, EcoEco-Industrial Network in Asia Asia, International Conference on Cleaner Products 2001

Establishing the Tuas/Jurong Industrial Estate as a Model Eco Industrial Park (EIP) through Integrated Waste Minimization

Introduction
Tuas/Jurong Industrial Estate is home to most important industries in Singapore Huge amount of liquid and solid waste generated, e.g. 100,000 tonnes of oil sludge and 26,000 tonnes of lubricating oil Most of the waste is sent for disposal or incineration; huge amount of money spent on disposal and treatment of these waste Environmental problems such as land and water pollution emerge due to these waste treatment methods

Objective
To evaluate the feasibility of developing an EIP in the Greater Tuas/Jurong Industrial Estate To develop all the industrial estates into a comprehensive EIP

EIP Master Plan

1st step of EIP development Identify EIP potentials Master plan of EIP in Jurong conceived more integrated links JTC-NEA-NTU waste minimization study-phase 2

Develop EIP

2012
Systematic management system of EIP developed EIP maturing and taking shape

JTC-NEA-NTU waste minimization study-phase 1

EIP network monitoring system implemented

The Proposed Schedule

Questionnaire
The survey questionnaire was prepared to collect the data/information on the inputs and outputs of energy, water and material of a generic industrial facility. It was designed as an initial screening of industrial facilities. The questionnaire consisted 2 main parts, i.e. OUTPUT and INPUT OUTPUT:
Part A: Materials (Quantity produced, treatment processes, specification, etc.) Part B: Water (Amt. of wastewater generated, types of treatment, etc.)

INPUT:
Part A: Materials (Quantity required, sources, description of material, etc.) Part B: Water (Sources and purposes of water, amt. daily requirement, etc.) Part C: Fuels and Alternatives (Total amt. of electricity used in previous year, highest peak demand value, etc.)

Industries of Concern
The priorities of industries and clusters are shown below: 1 Petroleum 2 Petrochemicals 3 Chemicals 4 Pharmaceuticals 5 Biochemical 6 Shipyard 7 Power Plants 8 Food & Beverage 9 Semiconductor and other E-wastes 10 Constructions 11 Plastics 12 Other Recyclable Municipal Solid Wastes Industries 1 through 7 were considered as EIP Cluster 1 that would be surveyed first, followed by EIP Cluster 2 (Food and Beverage), EIP Cluster 3 (Semiconductor), and EIP Cluster 4 (industries 10, 11, and 12)

Survey
Survey Results
100 80 60 40 20 0 No of Qs given out No of Qs returned Total IPIs conducted 27 87

21

SSIC Codes of the Participants

Waste Minimization experience of the interviewed 21 Industrial Facilities

Database Structure
SSIC Code Description of Item Manufacture of Petroleum and 2510 Petroleum Products I /O? Quantity Facility (mnth) Code Current Additional Information practice Technology/ strategy needed to market Potential Industries which could use this Partnership Type Name of Facility

Waste polyvinyl alcohol

8 -10 tons A

Paper bags (torn contaminated)

600 pcs

biodegradable, 2 kinds wet(30%) dry granular slabs (70%) higher potential for reuse, water soluble - trace methanol and solvents like methyl acetate may be present (due to batch process consistency may not be sent for maintained) incineration Batching out different consistencies (feasible as per owner) may be contaminated with PVA - sent to recycler at a cost sent to recycler Resource Recovery Facility Waste wood can be used as mulch, compost. Rest can be made into compressed wood if cannot be restructured sent to recycler Resource Recovery Facility traces of methyl acetate,methanol and acetic acid but total impurities less than 200 Water Pinch Technology use less contaminated streams ppm sent to SUT for lower grade jobs

Paper , Adhesives, Textiles as high strength glue IV

II

Wooden Pallets

Random

Wastewater

8610 cu.m A

Compost Industries, furniture industries IV internally reused for jobs demanding lower grade water, IV

Partnership Categories
Type I - Partnerships appeared possible in the long term (1) Type II - Partnerships seemed unlikely (13) Type III - Partnerships probable in the short term (one time exchange or contract period linkage due to production pattern) (1) Type IV - Open channels that had an immense potential to be reused; however companies which could use this byproduct have not yet been involved in the project (42)

Type I Probable Partnership

Methanol Firm J to Firm D

Type II Unlikely Partner Byproducts

1. 2. 3. 4. 5. 6. 7. 8. 9. Paper bags (torn /contaminated) Spent T catalyst (a form of metal chelate) Chemical esters Purified isophthalic acid (PIA) waste from washing Organic waste stream Sludge cake Dye spray Glass frit Paint sludge

Type III Short Term/Contract Partnership Metal Scrap Between Firm B and Firm V

Type IV Open Channels

Waste polyvinyl alcohol Wooden pallets/ crates Spent alumina catalyst Bio sludge Oil and fat from ester production Waste drums/ steel /aluminum chips Chemical sludge cake Polypropylene bag waste Tar Dichloromethane Ethanol Waste oil Dust/Sand Copper slag Magnesium oxide Defective contact lenses Poly vinyl acetate Clorox Saline

Partnership Details
Each partnership was detailed as follows: Material Description 1. Information of the material from generators 2. Requirements of the material by acceptors 3. Evaluation of partnership potential 4. Analysis of the partnership based on the Pre-partnership situation of the buyer/seller Postpartnership situation of the buyer/seller and transportation (in terms of annual cost savings, total energy/carbon reduction from transportation, value and amount of material reused)

Experience learned
Participation rate Survey and interview Collaboration with waste collection and treatment facilities (contractor/broker) Necessary development of infrastructure (with government support) to enhance waste exchange Creative innovations for reusing materials

Future Plan (Phase II)

Facilitation: Continue facilitating connections among potential partners identified and new partners to be identified (include testing, matching, and exchange of waste materials) Promotion: Promote EIP awareness via newsletters, newspaper, and other media Centralized MRF: Establish a centralized material recovery facility (MRF) to promote recovery and reuse of waste materials Web site: Establish an interactive website that can be used by the potential waste generators and acceptors (info sharing) More estates: Involve all other industrial estates in Singapore

Thank You