Environ. Sci. Technol.

2008, 42, 4958–4963

industrial park (EIP) or estate. It is common to require at

Model-Centered Approach to Early least three resource streams to be exchanged among at least
Planning and Design of an three firms to define something as an industrial park. Unlike
traditional estates, where there is little attempt to encourage
Eco-Industrial Park around an Oil synergies, EIPs are built around networks of associated
supplier and distribution chains that have a greater depen-
Refinery dence upon local material and energy flows (1). Descriptions
of successful cases such as the Kalundborg industrial
XIANGPING ZHANG, symbiosis in Denmark (2, 3) and the Guitang industrial park
ANDERS H. STRØMMAN, in China (4, 5) emphasize the slow, incidental evolution of
CHRISTIAN SOLLI, AND these ecosystems. Many planned industrial ecosystems,
EDGAR G. HERTWICH* including most of the 15 projects proposed by the U.S.
Industrial Ecology Program and Department of Energy and President’s Council on Sustainable Development, have failed
Process Engineering, Norwegian University of Science and to materialize, at least as industrial symbioses (6). The field
Technology, NO-7491 Trondheim, Norway of industrial ecology has hence turned its attention to social
processes and networks, organizational cultures, and policy
environments that give rise to the emergence of industrial
Received May 15, 2007. Revised manuscript received
symbiosis, as well as barriers to the development of such
March 27, 2008. Accepted April 3, 2008.
symbioses where opportunities for collaboration have been
identified. We fully acknowledge the findings of this qualita-
tive research, which emphasize the importance of including
Industrial symbiosis promises environmental and economic social, cultural, and business factors in the development of
policies and planning approaches to promote the develop-
gains through a utilization of the waste of some processes as
ment of industrial symbiosis. Our work is complementary to
a resource for other processes. Because of the costs and this research, as a better understanding of the technical
difficulties of transporting some wastes, the largest theoretical possibilities and benefits based on accepted modeling
potential for industrial symbiosis is given when facilities are approaches can provide confidence to the decision makers.
colocated in an eco-industrial park (EIP). This study proposes In this study, we attempted to improve and demonstrate
a model-centered approach with an eight-step procedure methods to use quantitative process models of different
for the early planning and design of an eco-industrial park industrial facilities, modeling the interaction among potential
consideringtechnicalandenvironmentalfactors.Chemicalprocess partners, as part of a process to identify and plan for an EIP.
simulation software was used to model the energy and In this paper, we present the design of a hypothetical EIP
material flows among the prospective members and to quantify including six main members around the existing oil and gas
the benefits of integration among different firms in terms of refinery in Mongstad, on the west coast of Norway. This
design has been developed following an eight-step procedure
energy and resources saved as compared to a reference situation.
including a process simulation of the different members to
Process simulation was based on a combination of physical identify integration options and match the different members.
models of industrial processes and empirical models. The modeling We present a carbon and hydrogen flow analysis to illustrate
allows for the development and evaluation of different the features of the hypothetical EIP.
collaboration opportunities and configurations. It also enables The interest in EIPs has coemerged with the focus on
testing chosen configurations under hypothetical situations materials reuse and material cycles modeled on nature’s
or external conditions. We present a case study around an nutrient cycles, powerfully put forward by Ayres as an
existing oil and gas refinery in Mongstad, Norway. We used the industrial metabolism (7) and by Frosch and Gallopolous (8)
approach to propose the colocation of a number of industrial as industrial ecosystems. In the English language literature,
facilities around the refinery, focused on integrating energy use the focus on the exchange of byproducts among facilities in
among the facilities. An EIP with six main members was close geographic proximity has been traced back to the
designed and simulated, matching new hypothetical members description of industrial symbiosis in Kalundborg, Denmark,
in the Financial Times in 1990 (6). The subject of many
in size to the existing operations, modeling material and
studies, the industrial symbiosis in Kalundborg is a good
energy flows in the EIP, and assessing these in terms of carbon example for the spontaneous but slow evolution of resource
and hydrogen flows. exchange among companies. Once the possibility for col-
laboration between two firms is discovered, its implementa-
Introduction tion clearly depends on detailed planning and design. Our
Industrial symbiosis offers a better utilization of available question is, however, as to whether such planning and design
material and energy resources through the integration of can be introduced earlier to discover and evaluate op-
traditionally separate industries, where one facility uses what portunities and thus accelerate the evolution of EIPs. Several
was traditionally the waste of another facility as valuable industrial symbioses have evolved or been established so
input. Because of the relatively low value density of the waste far, and these symbioses have achieved evident economic,
resources, a relative geographic proximity is often a pre- environmental, and social benefits (1, 2, 9–13). Relying on
requisite for the development of industrial symbiosis spontaneous emergence, the number of such arrangements
because the transport of these waste resources would be too for resource exchanges among facilities is quite small (14, 15).
expensive. When collaborating facilities are located together The phenomenon of byproduct exchange and process
on the same or adjacent properties, we speak of an eco- integration needs to become far more widespread and
systematic for it to move from being a curiosity to having a
* Corresponding author phone: 47-735989649; fax: 47-73598943; substantial impact on our society’s environment. Casavant
e-mail: [email protected]. and Cote (16) proposed using chemical process simulation
4958 9 ENVIRONMENTAL SCIENCE & TECHNOLOGY / VOL. 42, NO. 13, 2008 10.1021/es071138l CCC: $40.75  2008 American Chemical Society
Published on Web 05/22/2008
technology to design industrial ecosystems to quantify
associated technical synergies. In the present paper, we
implement Casavant and Cote’s proposal.
A quantitative model of the (potential) exchange of
material and energy in an EIP carries a number of promises:
(i) Chemical process modeling software enables a consistent
and seamless coupling of models of different facilities and
can hence produce a match between input and output
streams, taking into account not only the characteristics of
existing streams but also the ability and cost to change these
streams to a required quality level. Associated databases
contain models of many existing processes, and existing
modeled configurations can be easily extended. (ii) A small
change in the production of one member may impact the
performances of the others (17) and subsequently of the entire
EIP. Models allow for the sensitivity analysis of a dynamic
network to provide a better understanding of the interde-
pendence among the EIP members. This ability can be used
to understand and limit operational risks to each member,
either through backup systems or contractual arrangements.
(iii) A quantitative evaluation of the material and energy flows
can provide an indication of costs and environmental benefits
(18, 19) in different configurations and a tradeoff among
these criteria. (iv) Various EIP assessment approaches exist,
such as life cycle assessment (LCA), exergy (20) and emergy
analyses (21–23), and environmental impact analysis of waste
and emissions (19). The proposed method provides much of
the data required by those assessments. FIGURE 1. Procedure for the planning and design of an EIP
with a model-centered approach.
As an industrial complex, an EIP could involve many
industries, such as chemical, energy, steel, cement, aquac-
Step 4. Formation of Preliminary Structure of EIP. A
ulture, etc. The common feature for these industries is their
preliminary structure of the EIP from Steps 1-3 should be
ability to carry out physical changes and chemical conversions
formed.
of the raw material to (by)products. Fortunately, process
Step 5. Modeling and Simulation of Members. This step
models for various industries have been developed and
consists of establishing the models of all members and
verified, such as a power plant (24, 25), a methanol synthesis
obtaining the performances through simulation, as well as
process (26, 27), a CO2 capture process (28), etc. Commercial listing material and energy flows and designing the potential
software (e.g., Aspen Plus, HYSYS) provides comprehensive exchange network. It also includes the evaluations of the
tools for simulating units and processes. These available economic, environmental, and social benefits and an optimal
technologies and tools can now be used to provide insight network among the members.
into the complicated synergic relationship among various Step 6. Sensitivity Analysis of Key Variables or Param-
members in an EIP. eters in Members as well as in Whole Park. The aim is to
identify as to how a small change in the production of one
Materials and Methods member impacts the performances of the others and
subsequently of the entire EIP. The iteration of Steps 5 and
Figure 1 shows the eight-step procedure for the early planning 6 by parameter adjustment was carried out to ensure that
and design of an EIP, in which the utilization of process the models of the members were adequate and provided a
models plays an important role. good fit.
Step 1. Analysis of Goals and Opportunities. Why should Step 7. The Proposition of Alternative Strategies and
the EIP be established? What are the expectations related to Scenarios Improve Structure Obtained in Step 4 with
economic, environmental, and social issues? To answer these Respect to Selected Performance Attributes. Because of the
questions, collaboration between governments, industries, complexity of social and market factors, actor-oriented
and academic organizations is required. The associated methods and participative processes can be used for
regulations and laws, as well as commercial changes and evaluating exchange opportunities and EIP configurations.
market conditions, should be taken into account. Addition- Steps 3-7 were repeated until the final EIP structure satisfies
ally, the boundary and site of the planned EIP should be the goal proposed in Step 1.
determined. Step 8. Conclusion of Early Planning and Design of EIP.
Step 2. Analysis of Current Existing Activities on Site An early version of this procedure was used in an iterative
Considering Technical, Social, and Market Dimensions. The fashion to develop a proposal for an EIP at Mongstad, Norway.
comprehensive analysis of the current status should consider It is not possible or desirable to explain as to how we went
resource availability, product market status, geographical through the procedure or to display the technical details
characteristics, environmental regulations, governmental concerning decisions about the selection, dimensioning, or
planning, transportation, information, security services, design on which the individual members are based. Rather,
products, utilities, etc. we have chosen to present, in the following section, the
Step 3. Identification of New Potential Activities. On the resulting design proposal of the EIP. We provide a rationale
basis of results from Steps 1 and 2, certain new activities for the selection of the design and show an analysis of the
could be selected to achieve the goals in Step 1. In this work, mass and energy flows. Various other designs that differ in
ad-hoc, brainstorming approaches were utilized. The ad- technical details have emerged from the present design
aptation of more systematic process selection procedures as method, and a change of boundary conditions will probably
developed in chemical engineering remains to be explored. lead to a different design recommendation. The purpose of

VOL. 42, NO. 13, 2008 / ENVIRONMENTAL SCIENCE & TECHNOLOGY 9 4959
the present paper, however, is not to present the best possible specialists was a problem. Another option under investigation
specific design but rather to illustrate the capabilities and was greenhouses; however, unfavorable sunlight conditions
potential outcomes of the approach, as well as to provide would cause a substantial additional electricity demand for
insight into potential solutions. lighting as compared to other Norwegian locations. Processes
With the Mongstad EIP as a case study, based on the connected to the aquaculture value chain, however, including
procedure in Figure 1, Goals and Opportunities at Existing fish farms, fodder pellet production, and processing of fish
Site demonstrates Steps 1-3. Step 4 is embodied in Elements and fish wastes, seem promising (30). Wood pellet production
and Structure of EIP. Modeling of Mongstad EIP describes is also an option, using excess low-pressure steam.
the modeling and analysis of the members; a detailed Elements and Structure of EIP. Six main members are
description in the Supporting Information illustrates Steps included in this EIP (Figure 1 in the Supporting Information):
5-7. The Results and Discussion provides the results analysis (i) refinery plant; (ii) coal gasification; (iii) combined heat
of this study, including Step 8. and power plant; (iv) production of synthetic transportation
fuels; (v) carbon capture and utilization; and (vi) aquaculture.
Mongstad Case Study In the following sections, we present a rationale for the new
Goals and Opportunities at Existing Site. The potential EIP activities.
presented is located in Mongstad in western Norway, ca. 60 Combined Heat and Power Plan with Carbon Dioxide
km north of Bergen. The existing anchor tenant is an oil Capture and Storage (CCS). The rationale for building a
refinery, and the complex includes a gas processing facility, natural gas (NG)-CHP lies in that it would allow for the
a port, and significant underground storage tanks. The retirement of existing boilers at the facility and meet the
refinery’s operator, Statoil, also operates the oil refinery in power needs of the region, including the electrification of
Kalundborg and is hence very familiar with the concept of off-shore oil platforms, which is required to reduce CO2 and
industrial symbiosis. In the refinery, the principal products NOx emissions. The energy demands of the refinery are 330
are petrol, diesel oil, jet fuel, and other light petroleum t/h (metric tonnes per hour) of HP steam for distillation and
products. The heaviest oil components are used in part to 70 to ∼90 MW of heat for preheating the crude. As the
produce petroleum coke, an important raw material for anode feedstock of CHP, NG is a more valuable and scarce resource
production in the aluminum industry. The refinery processes and obtains a higher price. Given its lower carbon content
fairly light crude petroleum from the North Sea and produces of 0.2 kg CO2/kW h thermal (vs 0.33 kg CO2/kW h thermal
transportation fuels for European and U.S. markets. It thus for coal), it is probably wise to save it for applications where
has the flexibility to adjust the composition of the fuel to the CCS is unlikely. There exist various technologies for a CHP
requirements of the markets. Environmental policy and with CCS (31–34), and a precombustion solution would offer
the depletion of North Sea oil fields will clearly influence the more heat surplus for the refinery and flexibility with respect
future refining and fuel supply business. The Mongstad to the utilization of the hydrogen produced in the process.
refinery will have to process heavier crude from further afield. The gas turbine technology, however, has not yet been verified
Heavier feed and tighter specifications on sulfur and for hydrogen, given the high temperature of the combustion
aromatics imply an increasing hydrogen demand. (32). Statoil and the Norwegian government have already
Statoil has for a long time intended to build a gas-fired agreed on building a gas-fired CHP with postcombustion
combined heat and power plant (CHP), comprised of gas technology. Thus, we chose to model the planned facility.
turbines to produce electricity for onsite and offsite usage An amine-based CCS system will be installed, but given the
and a heat-recovery steam generator to produce the high- large demand for HP steam by the refinery, not much steam
pressure (HP) steam required by the refinery. At the present is available to run an additional steam turbine. An infra-
time, there are no onshore, fossil fuel-fired power plants in structure for handling the CO2 will be put in place, making
Norway, and the construction of such a plant has been a it interesting to colocate other facilities that utilize CCS.
political hot topic for the past 10 years. The oil companies Coal Gasification and Transportation Fuel Production.
are under pressure to electrify offshore oil platforms, and Coal is an inexpensive and abundant fossil fuel but is also
such an action would aggravate the electricity shortage on dirty and inconvenient. Given a growing global fuel demand
the Norwegian West coast. Statoil has argued that a power and an increasing shortage of oil, there is a rising interest in
plant in Mongstad would supply the electricity for the offshore producing transportation fuels from coal (35, 36). Coal
electrification and that the retirement of inefficient offshore gasification could produce syngas with varying H2/CO ratios
gas turbines would more than offset the additional CO2 with different technologies, but the relative environmental
emissions from a gas-fired CHP. Statoil received a permit for merit and economic viability of coal-based transportation
the construction of the CHP in the fall of 2006; however, CO2 fuels produced with CCS remains to be determined. In the
emissions must be controlled from 2014 onward through a overall project, we investigated the production of a number
postcombustion CO2 capture facility. Part of the CO2 may be of different fuels, including hydrogen and biofuels. Since the
utilized for an enhanced oil recovery in the Halten or Draugen distribution and on-board storage of hydrogen still faces
field, and the rest will be injected into a saline aquifer. numerous technical and commercial hurdles, we also
The largest and potentially most valuable waste stream investigated other energy carriers, such as methanol and
from both the refinery and the future power plant is low- DME, since they are regarded as possible replacements for
temperature heat. Today, 330 MW of cooling water at 27 °C petrol and offer an interesting illustration of our approach.
runs into the fjord, and further heating of the fjord will not The synfuel production train consists of coal gasification,
be permitted by environmental authorities. Potential ad- CO2 capture, and fuel synthesis. The coal gasification also
ditional tenants, however, are difficult to identify as a result opens the possibility of producing hydrogen for the needs
of the region having low unemployment and high labor costs, of the refinery or to utilize the syngas as a supplementary
being remote from potential markets, and the Norwegian fuel in the gas turbine to improve or maintain the capacity
economy being mature enough so that there are few of the CHP in case of a shortage of natural gas.
companies looking for sites to locate new industrial produc- Aquaculture. Land-based systems for aquaculture offer a
tion (29). The special geographical situation and previous good possibility for utilizing low-temperature waste heat.
investigations exclude a large number of activities. For Elevated temperatures and the controlled conditions allow
example, petrochemical and pharmaceutical options have for a faster maturation of species such as lobster, turbot, and
already been investigated, and it was found that the large cod. The use of waste heat leads to a substantial reduction
distance to the respective markets and the lack of qualified in both energy use and costs for such facilities, thus rendering

4960 9 ENVIRONMENTAL SCIENCE & TECHNOLOGY / VOL. 42, NO. 13, 2008
FIGURE 2. Structure of the planned EIP displaying the main material and energy flows.

it potentially interesting. It is not yet clear as to whether such as synfuel production than in a power plant. Ratios typically
systems are commercially viable, and there are ecological range from pure CO for the production of acetic acid to 2:1
concerns regarding the use of fish as feed in aquaculture and for methanol, and 1.8-2 to 1 for a typical Fischer-Tropsch
high-energy requirements connected to the fishing for feed syngas in the Sasol process (38). In the present study, we
(37). Intensive work is ongoing to produce other types of have considered a Shell entrained gasifier where the feedstock
feed, including fishing lower on the food chain and adding is Surat coal (39), and methanol and DME were selected as
plant-based materials to the fodder. Another attractive the case products. The related parameters and flowsheet
option is placing young lobsters from an aquaculture-based descriptions were taken from literature (26, 27, 39). The
nursery into waters that used to have natural lobster detailed simulations were shown in the Supporting Informa-
populations and harvesting them there once they are mature. tion.
This should work fairly well since the Norwegian lobster is Modeling for the integrated CHP with the CO2 capture
a stationary and territorial species, and in this case, the lobster system included a sensitivity analysis to investigate as to
would only be kept in culture in its first life stage (37). We how the CO2 capture influenced the net heat and electricity
also investigated a number of other options for utilizing the efficiencies in the CHP system, as well as evaluating the
heat (30), mostly low-pressure (LP) steam in drying and benefit of the supplemental firing of coal syngas to produce
processing, but these results are not included here. more heat.
Modeling of Mongstad EIP. Models for the individual
members were developed based on a chemical engineering
Results and Discussion
approach. The model and its components are described in We established a preliminary structure of Mongstad EIP with
more detail in the Supporting Information, which also an eight-step method shown in Figure 1. The utilized models
provides a description of the park members. allowed us to dimension the facilities, calculate the energy
Two CO2 absorption facilities, one for the flue gas from and mass balance, understand the exchange relationships
the CHP and one for the syngas from the coal gasification, among the members, analyze the flow of carbon and
both with a similar design, use diethanolamine as the solvent. hydrogen, and evaluate the park in terms of important
Strict simulation shows that the heat required for capturing parameters, such as CO2 emission.
CO2 is 2.9 and 4 to ∼5 MJ per kg of CO2 in gas with a CO2 Material and Energy Flow Analysis. A quantitative
content of 18 and 4%, respectively, which served as a guide description of energy flow and material exchange is presented
for selecting a suitable technology for capturing CO2 indus- in Figure 2. The feedstock of the EIP is 1000-1200 t/h of
trially. The detailed results are shown in the Supporting crude oil for the refinery, 41.7 t/h of natural gas for the CHP,
Information (SI2 and SI4). 92 t/h of coal for gasification, 2470 t/h of air for combustion
For coal gasification, it is important to have a suitable and gasification, and 49 t/h of steam for coal gasification.
H2/CO ratio in the syngas for petrochemical industries such The refinery delivers 15.4 t/h of refinery gas to the CHP.

VOL. 42, NO. 13, 2008 / ENVIRONMENTAL SCIENCE & TECHNOLOGY 9 4961
FIGURE 3. Schematic representation of the element balance and flow of (a) carbon and (b) hydrogen in the park.

The outputs from the EIP are 1121 t/h of refinery products 1000 t/h of crude oil through the refinery is much larger than
(including C3/C4, naphtha, gasoline, etc.), 31.6 t/h of the other flows, which are on the order of tens of tonnes per
methanol, 22.7 t/h of DME, 270.7 t/h of CO2 (99.1%) (which hour. The carbon for the nonrefinery portion of the park is
could be used for enhanced oil recovery (41)), 4.9 t/h of H2 derived from three sources: natural gas, coal, and refinery
produced inside the park to be used by the refinery itself or gas; the proportion of feed stock could be adjusted depending
for the market, approximately 960 t/h of warm water (partly on the demand for the products as well as on the price and
used in aquaculture), and 1925 t/h of purge gas (N2, O2, etc.). availability of the resources. In this case, 77.79% of the total
The energy balance for the EIP is tabulated in the Supporting carbon is converted to CO2, and 11.32 and 11.31% of carbon
Information. Air compression consumes 48% of the total are stored in methanol and DME, respectively. If the amount
produced electricity, air separation 7.6%, and the refinery of syngas required by the power plant is reduced, more
11.5%, so that only 21.9% could be sent to grid. For the heat methanol and DME can be synthesized, and more carbon
cogenerated in the park, 52.3% of HP steam came from the can be stored in these products. Because of the tradeoff
CHP and 11.53% from the heat recovery of hot coal syngas. between the heat consumption and the CO2 recovery
Some of the HP steam is used directly in the processes, but efficiency as well as CO2 purity, 6.4% of carbon is discharged
∼28.5% of the total heat is used to produce LP steam by a from this system to the environment.
steam turbine and then is sent to the CO2 capture process. Limiting CO2 emissions is one of the critical considerations
Evidently, the steam produced in the coal gasification process for this park. In the refinery plant, the old boilers would be
is not enough for capturing CO2 in the coal syngas, so an shut down, and the refinery gas would be utilized in the
additional 64 t/h of LP steam is provided by the CHP. CO2 CHP. This would lead to a reduction in the CO2 emissions
capture carries a substantial efficiency penalty. In this facility, of at least 0.36 million t/year. According to this carbon flow
the total heat efficiency was reduced by 22.9% (LHV). Similar diagram, 2.41 million t of CO2 would be captured annually
results are reported in the literature (34). in this EIP.
A significant amount of energy will eventually be converted Hydrogen Flow Analysis. Figure 3b shows the hydrogen
to waste heat. Because of the use of process heat in the new flow through the park. The hydrogen proportions in four
facilities, the amount of waste heat increases as compared hydrogen-containing feedstocks were 34.5 wt % in coal (39),
to the situation today. Since the facility is not allowed to 33.87 wt % in natural gas, 12.85 wt % in refinery gas, and 18.8
discharge more heat into the fjord, a cooling tower is required. wt % in steam used for coal gasification and water gas shift.
Utilization of part of the waste heat (395 t/h of water, ∼11.6 Of the total amount of hydrogen in the coal syngas, 23.6 wt
MW) in aquaculture has been investigated (37), and it is % is used for supplementary firing, and the remaining 77.66%
considered that additional waste heat from new activities is used for producing substitute fuels. An amount of 55.48%
may be recovered with this method in the future. Although of the total hydrogen is utilized in the CHP, 23.8% for fuels,
the coal gasification tends to be cleaner than direct combus- and 16.87% as H2 product. H2 from the park is sent to the
tion, inevitable ash and byproduct sulfur are produced in Mongstad refinery to satisfy the tighter fuel specifications.
the process. Using biomass as a replacement would be a The hydrogen production can be expanded if H2 is planned
possible future choice. as a transportation fuel. The hydrogen balance inside the
Carbon Flow Analysis. One of the advantages of the refinery plant, as well as the hydrogen flow of the utility
method proposed in this work is that it allows for an analysis systems (steam, cooling water, etc.), has not been considered.
of material flows of the most important elements through In conclusion, the proposed method made it possible to
the overall system. In this case, we focused on hydrogen and predict the quantitative energy and material flows of the
carbon, two vital elements that are contained both in the members, their collaborations, and the scenario of the EIP
raw materials and in the products. as opposed to carrying out real-life tests. Such information
Figure 3a shows the carbon flow in the planned EIP. The could be used in financial evaluation and public planning,
balance of the refinery is not included: the carbon flow of thus supporting the development of an EIP. One challenge

4962 9 ENVIRONMENTAL SCIENCE & TECHNOLOGY / VOL. 42, NO. 13, 2008
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