The benefits of Industrial Symbiosis

The Kwinana experience

Sustainable Engineering Group

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

This lecture (L3)

L2

Engineers Australia Sustainability policy

Natural vs Industrial ecosystems

History of Environmental management

Industrial ecology theory

Eco-efficiency

Cleaner Production

L3

Industrial symbiosis/synergies

Regional synergies

Eco-industrial Park

Examples of industrial symbiosis

Practical case-study

Regional synergies in the Kwinana Industrial Area (WA)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

What are Industrial Symbiosis?

Synergy:
It is exchange of resource and energy between collated companies

Types of industrial synergy:

By-product synergy: One company uses discard of the other company

Utility synergies: companies have joint infrastructures and reuse water/energy from
each other

Supply chain synergies: local manufacturer and client

Service synergies: organizing and sharing services and facilities

Benefits:

Economic benefit: cost saving and higher efficiency

Environmental benefit: Less wasted materials and energy

Environmental/Economic: Increased resource efficiency and security

Social: Employment opportunities

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Reduces Source and Sink

Reducing Source and Sink enhance carrying capacity
and reduce ecological footprints
The total throughput of the human economy must be kept
small enough to avoid exceeding two physical limits of the
ecosystem:
its capacity to regenerate itself, and
its capacity to absorb our wastes.
(Herman E. Daly, Beyond Growth (Boston: Beacon Press, 1996). ISBN 0-8070-4708-2)

Activities which systematically reduce the capacity of

nature to regenerate itself are excluded (PCBs, CFCs.)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Regional Synergies / Industrial Symbiosis

Definition Capture, recovery and reuse of previously discarded resources
from one industrial operation by other, traditionally separate, industries
operating in their close proximity
Engages traditionally separate industries in a collective approach to
competitive advantage involving physical exchange of materials, energy,
water and/or by-products.

Categories:

By-product synergies
Water and energy utility synergies
Supply chain synergies/management

(Chertow, Marian R. "Industrial symbiosis: literature and taxonomy." Annual review of energy and the
environment 25, no. 1 (2000): 313-337.)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Planning map for Industrial Symbiosis

Inorganic By-Products
Focus on high volume residues (bauxite and gypsum)
Link into local construction developments

Water
Mapping of company water inputs and outputs
Water synergy scoping study and workshop
Industrial wastewater reuse

Energy
Industry energy survey (uses and losses)
Energy scoping study and workshop
Waste heat recovery (use for desalination)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Regional Synergies / Industrial Symbiosis

Tools to facilitate the identification and development of

new 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 3: Prioritise identified synergies

Sustainability benefits + ease of implementation

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Other Industrial Symbiosis Examples

Source: Bossilkov et al (2005)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Inorganic By-Products Reuse

Australia Vs World
Inorganic By-Product

Reuse - Australia

Reuse - World

Iron and steelmaking slags

Accepted and used as a

cement replacement

USA & EU: 85-100%

Fly and bottom ash

Cement blending, concrete

addition, CSIRO advanced
construction material
technology (with BF slag and
silica fume)

USA & EU: 25-100% (FA)

EU: 55.6% of all coal combustion
products are utilised in
construction and underground
mining

Sand (foundry)

No data

USA: high utilisation rates, vary

between states

Lime kiln dust

No data
Some in Kwinana

USA: 100% (LKD)

Chemical gypsum

(Flue Gas
Desulphurisation and
Phosphogypsum)

Pasminco Hobart Smelter

USA: 93% (FGD), PG banned

EU: 87% (FGD), PG in 2 pilot roads,
Finland

Construction and demolition

waste & recycled concrete
aggregate

Some in NSW and VIC

Limited in WA

USA: 75% (recycled asphalt

pavement)
EU: 50-100%

Boiler slag

No data

USA: 80%, EU; 100%

Bossilkov, A. and C. Lund. 2008. Market Assessment for the Reuse of Inorganic Industrial Byproducts in the Kwinana Industrial Area. Perth, Western Australia: Centre for Sustainable
Resource Processing (CSRP).
Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

Australian Guidelines for

By-Product Reuse
No standard requirements of reuse for many applications, e.g. soil
conditioning, or for use as a road base, fill material
The process of authorisation time consuming and laborious
Continuous concerns of potential opposition to the reuse, with limited
support from government
Lack of leadership and support from government when dealing with
related community issues and concerns
Lack of security, especially where community concerns can blow out
of proportion and effectively end the reuse
By-products continue to build up in storage facilities
Harris, S. 2007. Regulatory and Policy Issues of Regional Resource Synergies in the Kwinana
Industrial Area: A Scoping Study. Perth, WA: Centre of Excellence in Cleaner Production, Curtin
University of Technology.

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

International Regulatory Frameworks and

Standards
In USA and EU regulatory frameworks and standards
already exist and are widely used.
These could potentially be adopted relatively easily and
quickly in Australian jurisdictions.
Some guidelines and reuses exist in Australia, especially
for slag and fly ash driven by industry associations.

Van Beers D., Bossilkov A., Lund C. 2009. Progressing the Reuse of Inorganic By-Products:
The Case of Kwinana, Western Australia. Resources, Conservation and Recycling, Vol. 53
(7), pp. 365-378.

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Identifying Drivers & Barriers to synergy

development
Regulation

D: Air, water quality requirements; reporting schemes

B: Complicated, approval procedures
Economics
D: Increased revenue
B: Low costs for resources and waste disposal
Community
D: Improvement of quality of life
B: Community opposition and public concerns to waste reuse
Technology
D: Replacement/decommissioning of old equipment
B: Lack of suitable technology to transport/convert by-product
Risk and Liabilities
D: Reduction of liabilities associated with waste storage
B: Dependencies, lack of supply securities
Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

Whats Needed to Develop Inorganic

By-Product Synergies on Significant Scale?
Clearly defined market driver, regulatory pull (e.g. use of
secondary/recycled material explicitly articulated in policies,
procedures and tenders)
Establishment of frameworks and standards for industrial byproduct re-use, such as those existing overseas
Full sustainability and lifecycle analyses of industrial byproduct/recycled materials in proposed applications, compared to
virgin/existing materials to illuminate discussions with community
and remove misconceptions
Leadership and support from government when dealing with related
community issues and concerns
Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

Factors for Successful Synergy Projects

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Eco Industrial Park

Resource Exchange Networks
Cleaner Production at each
facility
Resource Recovery and
Reuse, enhanced through
Industrial clustering
Supportive infrastructure
Eco-services provider

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Park Design and Management

Integration into Natural
Ecosystems
Green Facilities Design
Environmental
Management System for
park management

Eco Industrial Park

Type 1: through waste exchanges

Type 2: within a facility, firm, or
organization
Type 3: among firms collocated in a
defined eco-industrial park
Type 4: among local firms that are not
collocated
Type 5: among firms organized
virtually across a broader region.

(Chertow, Marian R. "Industrial symbiosis: literature and taxonomy."

Annual review of energy and the environment 25, no. 1 (2000): 313337.)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Business Niches

An eco-industrial park creates niches for business development

Decomposer firms practicing recovery, recycling and reuse (scavenger

niche)

Remanufacturing plants

Environmental monitoring and

information systems

Transportation services

Environmental management

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Potential for Synergies in Australia

Port Kembla in New South Wales

Gladstone in Queensland
Whyalla in South Australia
Port Pirie in South Australia
Laverton in Victoria
Geelong in Victoria
Kwinana in WA

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Industrial Ecology
Best Practice: Kwinana Industrial Area

Heaviest industrial area in WA

40 km south of Perth,
Coastal strip of about 8 km long (2 km wide)
Resource processing: alumina, nickel, oil refineries, HIsmelt, etc.
Utility:
Manufacturing:

power, water treatment, co-gen plants, etc.

cement, chemical, fertiliser plants, etc.

Best practice example of regional synergy implementation

47 diverse and matured existing synergies
World leading industry collaboration

Existing synergies result in significant benefits

Economic, environmental, and social

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Industrial Integration in 1990

27 interactions between 13 industries

Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

Industrial Integration in 2000

NIT ROGEN
LUBE OIL
CONDENSAT E
DIESEL OILS
LUBE OILS
SULPHURIC ACID

PROPANE
OXYGEN
NIT ROGEN
HYDROGEN
CARBON DIOXIDE

HYDROCHLORIC ACID
AMMONIA
DIESEL
OILS
NIT ROGEN

NIT ROGEN

LPG

OXYGEN

ARGON
CARBON DIOXIDE

ST EAM

DEMINERALISED WATER
CARBON DIOXIDE

TYCO WATER

CEMENT

NIT ROGEN

CEMENT & LIME

HYDROGEN

BP REFINERY

OXYGEN
CARBON
DIOXIDE

OXYGEN NIT ROGEN

ARGON
CARBON DIOXIDE

ST EEL PIPES

CIBA
SPECIALTY
CHEMICALS

LUBE OIL

AIR LIQUIDE

COCKBURN
CEMENT

OIL PRODUCTS WAST E

GASES

CARBON
DIOXIDE

NIT ROGEN
NIT ROGEN

LIME
LPG
FLOCCULANT

WESFARMERS
LPG

ALCOA WORLD
ALUMINA

PROPANE BUTANE

ALUMINA

SODIUM
SILICATE
SODIUM
ALUMINAT E
ST EAM

FUSED ALUMINA
FUSED ZIRCON

MILLENNIUM
PERFORMANCE
CHEMICALS
HIGH PURIT Y ZIRCON
POWDERS

SULPHURIC
ACID

CAUST IC
SODA

SULPHUR
CHLORINE
SULPHURIC
ACID

SULPHURIC
ACID
SULPHURIC
ACID

FUSED SILICA
ALUMINA FUME

SHINAGAWA
THERMAL
CERAMICS

AMMONIUM
HYDROGEN
SULPHAT E

CAUSTIC
SODA
CHLORINE

REFRACT ORIES

OXYGEN NIT ROGEN

HYDROGEN

ELECT RICITY

NIT ROGEN
OXYGEN LPG

TRANSFIELD
SMP
ST EEL
PRODUCT

ONE STEEL
MARKET MILLS
WAXES
PATIO T UBING

FUEL
GAS
CARBON
DIOXIDE

SULPHURIC
ACID

CO-OPERATIVE
BUL K
HANDLING
GRAIN ST ORAGE
SHIP LOADING

HYDROCHLORIC ACID
CAUST IC SODA

NU-FARM/
COOGEE CHEM.
CHLOR-ALKALI
CHLORINE &
CAUST IC SODA

AMMONIA

SODIUM
SILICAT E
ST EAM

EDISON
MISSION
ENERGY

COPPER
SULPHAT E
CAUST IC
SODA

ELECT RICIT Y

SULPHUR
SULPHURIC ACID
AMMONIUM SULPHAT E
SULPHUR

C OOGEE
CHEMICALS
INORGANIC CHEMICALS
T ANK T ERMINALLING

AVENTIS CROP
SCIENCES
GASOLINE
COMPONENT S

AGRICULT URAL
CHEMICALS

AMMONIUM CHLORIDE

SUMMIT
FERTILIZERS
FERT ILIZERS

GRANULAT ED PRODUCT S

SODIUM SILICAT E

COPPER SULPHAT E
SULPHUR

INDUSTRIES THAT SERVICE MANY

INDUSTRIES*
CBI CONSTRUCTORS: FABRICATION, CONST RUCT ION
FREMANTLE PORT AUTHORITY: PORT FACILIT IES
TRANSFIELD SMP: FABRICATION, CONST RUCT ION
WATER CORPORATION:
WATER SUPPLY, SEWAGE
T REATMENT
KWINANA POWER STATION & EDISON MISSION:ELECTRICIT Y

FERROUS SULPHAT E
GRANULAT ED PRODUCT S
SULPHURIC ACID
PESTICIDES
CAUSTIC SODA
CHEMICALS
GENERAL
LIME
HYDROCHLORIC ACID

106 interactions between 28 industries

Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

NATURAL
GAS

OXYGEN

NICKEL

AMMONIA

HYDROCHLORIC
ACID CAUST IC
SODA

AMMONIA

WMC NICKEL
REFINERY

KWINANA
POWER
STATION

NIT ROGEN
OXYGEN

FABRICAT ION
CONST RUCTION

CAUST IC SODA

SODIUM
HYPOCHLORIT E
HYDROCHLORIC
ACID

FERT ILIZERS
AMMONIA
AMMONIUM NIT RAT E
SODIUM CYANIDE
CHLOR-ALKALI
CHLORINE &
CAUST IC SODA

T IT ANIUM DIOXIDE

NIT ROGEN

AUST. FUSED
MATERIALS

PEST ICIDES

HYDROGEN

TIWEST
PIGMENT
PLANT

ALUMINA
ALUMINA

MOLT EN
SULPHUR

WESFARMERS
CSBP

CAUST IC
SODA

CAUST IC SODA

NUFARM
LIMITED

DIESEL
OILS
WAXES

NIT ROGEN OXYGEN

LIME

FLOCCULANT

HYDROGEN

KEROSENES

CARBON
DIOXIDE

CARBON
DIOXIDE

BOC GASES

NIT ROGEN

SULPHUR

Examples of By-Products Synergies

1. Reuse of slag from smelting
Road construction, fill material
Sand blasting
Insulation (air granulation of slag slag wool)
Geopolymers
2. Reuse of fly ash from coal-fired boilers
Road construction
Geopolymers
Soil conditioner
3. Reuse of gypsum from scrubbing systems
Plaster board manufacturing
Cement production
Soil conditioner
4. Reuse of lime kiln dust from cement plant
Desulphurisation (scrubbing)
Soil conditioner

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Sourced from CECP, Curtin

Water synergies in Kwinana

1. Alternative supplies for process water
(Treated) effluents
Cooling tower blowdown
Boiler blowdown
Washing water
Joint water reclamation/recycling plant
2. Joint production of demineralised water
3. Joint treatment of oily wastewater

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Water synergy development

Approach
Mapping of company water inputs and outputs
Water synergy scoping study + workshop

Lessons learnt
Currently low water prices, but increasing
Changing business drivers for water conservation
Promising water synergies exist
One-on-one company and collective for Kwinana
Apply direct reuse or low cost technologies
Sustainability through diversity of water supply

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Energy synergies in Kwinana

1. Use of alternative fuels at cement plant

Wood chips from concentrator

Tyres

Waste oils

Municipal solid waste

2. (Joint) cogeneration facilities

Use fuel gases supplemented with gas

3. Energy recovery from flue gases, steam

Electricity and steam production

(Pre-)heating of working liquids

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Energy synergy development

Approach
Industry energy survey (uses and losses)
Energy synergy scoping study + workshop

Lessons learnt
Changing business drivers for energy conservation
Focus on energy recovery from flue gases
Highest energy contents (TJ) and temperatures
Proven simple technologies seem most attractive
Significant energy losses over larger distances
Feasibility depends on energy needs of user

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Potential for Kwinana Inorganic

By-Product Synergies

Bossilkov, A. and C. Lund. 2008. Market Assessment for the Reuse of Inorganic Industrial Byproducts in the Kwinana Industrial Area. Perth, Western Australia: Centre for Sustainable
Resource Processing (CSRP).

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Recycling Industrial By-Products

Lifecycle Benefits

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

Olsson, S., E. Karrman, and J. P. Gustafsson. 2006. Environmental Systems Analysis of the Use
of Bottom Ash from Incineration of Municipal Waste for Road Construction. Resources,
Conservation and Recycling 48: 26-40

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Examples of Utility Synergies

Artificial wetland treatment at CSBP
Chemical Plant
On BP Refinery land
Some of BP effluent going into
wetland cells as well

2 Cogeneration facilities
BP Refinery (116 MW)
Tiwest Pigment Plant (40 MW)

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Icon Synergy Project - KWRP

SCHEME WATER

INDUSTRIES
Sourced from CECP,
Curtin

WOODMAN POINT
WWPT

110 ML/d

BORE WATER

17 ML/d

6 ML/d

KWRP

TO

24 ML/d

COCKBURN
SOUND

7 ML/d

TO OCEAN
SEPIA DEPRESSION OCEAN OUTLET LANDLINE

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Benefits and Success Factors

Illustrative benefits
Less waste and emissions to environment (all
synergies)
Reduced operational costs (gypsum)
Increase company income (lime kiln dust)
Technology
Increased water efficiency (KWRP)
Increased energy efficiency (cogen facilities)
successful
synergy
Water and energy security (KWRP + cogen)
projects

Favourable features in Kwinana

Business
Case

Licence
to Operate

Kwinana Industries Council

Diversity of industries
Van Berkel, 2006
Non-competitive
Close
industries
Corder, G.,
van Beers,proximity
D., Lay, J. and van of
Berkel,
R.: Benefits and Success Factors of regional Resource Synergies in Gladstone and
Kwinana, Green Processing Conference, pp 83-92, Newcastle, NSW, Australia, 2006.
Curtin University is a trademark of Curtin University of Technology
CRICOS Provider Code 00301J

Curtin Research into Regional Synergies

Kwinana Case-Study (CSRP funding)
Provide practical support to Kwinana industries with
identification and evaluation of synergy opportunities

Enabling Tools and Technologies (CSRP funding)

Develop customised and smarter tools to facilitate the
identification and evaluation of regional synergies

Enabling Mechanisms (ARC funding)

Facilitating structures
Operational and contractual arrangements
Evaluation methods

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J

Lessons Learnt from Kwinana

Existing synergies provide range of sustainability benefits

More synergy opportunities exist

Business case of synergies

Need to understand broader sustainability benefits

Regulatory barriers

Prevent or delay implementation synergies

Industry champions

Crucial for synergy development

Industry involvement

Development of synergies is not core business

Kwinana Industries Council has key role

Platform for industry collaboration

Curtin University is a trademark of Curtin University of Technology

CRICOS Provider Code 00301J