James Woodcock 17.5.2013: Case Study Examples

© International Synergies Limited

Version date 02 May 2013

Industrial Symbiosis in Action

Case Study Examples



UK NISP delivered Outcomes April 2005 – March 2012

METRICS Unit RESULTS

TO DATE

5YEARS Projection

with 20% decay

5YEARS Projection with

no decay

Landfill diversion T 9,074,493 21,863,907 45,372,465

CO2 reduction T 7,869,473 17,555,721 39,347,365

Virgin material savings T 11,679,029 33,262,089 58,395,145

Haz waste eliminated T 420,739 369,204 2,104,145

Water savings T 14,114,161 34,825,914 70,565,805

Cost savings £

£205,648,184

£411,546,215

£1,028,240,920

Additional sales £

£198,520,840

£351,614,047

£992,604,200

Other metrics

Jobs created Qty 10,000+ jobs have been directly created and

safeguarded

Jobs saved Qty

People trained in IS Qty 6,296

Private investment

£

£ 316,610,204



Case Study: Fruitful Collaboration

Terra Nitrogen: Industry produces derivatives of nitrogen and methanol.

Waste:12,500 tonnes of CO2 released to atmosphere, hot steam and ammonia.

John Baarda: Tomato producer Additional production capacity

limited due to high costs of energy

Partnership

•Elimination of CO2 emissions

•Construction of a greenhouse capable of producing 300,000 tomatoes per year

•Investment of £15M

•Creation of 65 new jobs

•Recovery of heat from steam



Case Study: Innovation in materials

Companies: • Mil-Ver Metals • Denso Manufacturing UK

Summary: • Hazardous waste generated from Denso producing air conditioning units was collected and reprocessed by Mil-Ver for use in its manufacturing process

Achievements: • Cost Saving €45,000 per year • Hazardous waste eliminated 15 tonnes per year • Carbon emissions reduced by 242 tonnes per year



Case Study: Redevelopment of a hospital

Companies: • Skanska • Armoury Demolition

Summary: • Skanska needed to address voids from low depth mines during redevelopment of a hospital Material from a high rise demolition was used to create a stone blanket prior to piling

Achievements: • 11,550 tonnes material reused •>£250,000 cost savings



Case Study: Scallop shells to forestry

Companies: • West Coast Sea Products • Forestry commission

Summary: • Over 1,800 tonnes of shells generated per year Shells incorporated in to sub-base aggregates for forestry roads Also used as top dressing of roads – decreasing punctures •Release calcium, reducing effects of acidification of waters •Decrease in disposal costs of £25,000 per annum



Case Study: Cambridgeshire Guided Busway

• Cambridgeshire County Council is in the process of building the longest guided busway in the world.

• NISP working on CGB at site clearance stage:

– Outlet found for 20,000 railway sleepers

– Sourced 3,000T of recycled aggregated for temporary roads

• Request to source 60,000m3 of drainage material

– NISP proposed tyre shred as an alternative



NISP facilitation

• Tyre recyclers introduced to Major Contractor

• 18,000T of tyre shred used

• Replaced 60,000T of aggregate

Outcomes • Significant project cost savings

• >6,000 tonne CO2 saved

• Replication for next project

Case Study: Cambridgeshire Guided Busway



Case Study: IS Transforms Individual Businesses: e.g. John Pointon & Sons Ltd

• Pre – NISP: animal renderer

inputs: carcasses

outputs: landfill

perception: dirty industry

• Initial NISP stage: animal by-products diverted from landfill to cement industry

• Second stage: improved efficiency of processes

• Third stage: move into bio-fuels utilising more by-product

• Fourth stage: move to AD and grid connection

• Fifth stage: transfer in of innovative technologies

• Current situation

inputs: carcasses, organic residues

outputs: energy, minerals

vision: clean energy company

“Long term culture change needs long term business engagement”



Case Study: Business Solution for Foundry Waste

• Links to foundries via Cast Metal Federation

• Identified ways to reuse spent foundry sand to brick manufacture

• Sustainable solution rather than landfill

• Additional Sales - £200k

• Landfill Diversion – 10,000 te

• Cost Savings - £300k

• Virgin Materials – 10,000 te

• Jobs Saved - 42

http://images.google.co.uk/imgres?imgurl=http://www.pulpandpaper-technology.com/contractor_images/over_meccanica/3_Foundry_pouring.jpg&imgrefurl=http://www.pulpandpaper-technology.com/contractors/paper_machines/over_meccanica/&usg=__OSCSiPO0l8hvy2bxzkkkxFJAs04=&h=373&w=511&sz=44&hl=en&start=1&tbnid=rqlE3fnUY_pxWM:&tbnh=96&tbnw=131&prev=/images?q=foundry&gbv=2&hl=en&sa=G



A Powerful Alliance for Subcontractors WPD and East Alliance Partners

NISP worked with WPD (then E-on) to

increase the amount of recycled

aggregates used on sites and reduce

landfill costs via their contractors.

NISP created a Workspace so data about

local recyclers could be shared between

the East Alliance Partners. One common

Compliance Checklist was created which

amalgamated the individual Partners’

forms. This was used to assess new suppliers

joining the Framework.

The results include:

•Diversion from landfill: 73260 tonnes

•CO2 reduction: 168 tonnes

•Cost savings: £76077 per year

Central Networks Alliance SUPPLIERS COMPLIANCE

CHECKLIST/QUESTIONNAIRE

Plant Operator

Local address

Registered address

What Geographic/Highway Authority areas can you supply to?

YES NO Waste Management requirements (QP ref* 3.4.1, 3.4.4, 3.6.1 and 3.7.1)

Does your recycling operation have the required environmental permit/waste management

licensing/exemptions and is the Duty of Care applied?

NOTE: You must demonstrate that you meet the statutory and regulatory requirements, including use of registered waste

carriers and Waste Transfer Notes (WTNs). Please consult the Guidance Notes for further details.

Do you hold a Waste Carriers Licence?

Have you had any EA prosecutions in the last 3 years?

Acceptance of incoming waste (QP ref 3.4.1 to 3.4.4 and App C)

Do you have site/location specific Acceptance Criteria procedures for the incoming waste?

Do your Acceptance Criteria include a description of the types of waste accepted and a

description of the method of acceptance?

NOTE: List of Waste Regulations/European Waste Code for consistency with the WTNs must be used. You must

demonstrate that only inert waste is accepted for production of aggregates to the Quality Protocol. Inspection at receipt

and at tipping must be carried out.

Please list what EWC codes the site/ location can accept?

Are material input records kept?

NOTE: A record of each load received and accepted must be kept

Do you have a procedure for non-compliant waste?

NOTE: You must demonstrate how you are dealing with non-conforming incoming waste. Please consult the Guidance

Notes for further details.



• Tarmac Building Products was

looking for alternative materials as

fill material in lightweight building

blocks

• Witherley Services was managing a

large stockpile of blast furnace slag

and looking for routes to market

The results include:

• 17,300 tonnes of material was

diverted from landfill

• 1777 tonnes of carbon dioxide

savings & Cost savings for Tarmac

versus expensive raw materials

Firm Foundations for Success Witherley Services and Tarmac Building Products



2011: Birmingham Big City Plan

• Tyseley Environmental

Enterprise Zone – Framework

for Action (May, 2011)

• Birmingham’s Priorities for

Tyseley:

“Support businesses and

organisations to capitalise on

low carbon opportunities and

maximise industrial symbiosis.”



Identifying Investment Opportunities for Tyseley Environmental Enterprise Zone (TEEZ)

Positio

n B

irmin

gham

as lead

er in reso

urce

recovery tech

no

logies

Today Synergies

Tomorrow Inward

Investment

Future Innovation

• Potential resource and energy synergies • Transport infrastructure for resource efficiency

• Opportunities for green growth and inward investment • Businesses to benefit from technology transfer • ‘Catalyst’ developments (key opportunity sites)

• Innovation potential for new business creation • Opportunities for green growth and inward investment • Transport infrastructure for resource efficiency

Specific Investment Opportunities based on Local Resources

Industrial plastics

ASR/ash for metal recovery

Site 3 - RDF/ERF - Drying facility

Site 1 - Acids recovery - Pre- MRF - Plastics washing - Gasification

Site 3 - WEEE repair & metals recovery - Technology incubator - Fuel cell recovery

Site 2 - Pyrolysis - Gasification

Needs site with industrial buildings - AD with urban farming

MSW

Non-recyclable

Clean plastics

RD

F

Acids

WEEE

Non-recyclable plastics

ASR

Paper sludge

Food waste

Bottom ash for metal recovery

Medical waste

Reco

vered m

etals

plastic

s

Char

Rep

aired eq

uip

men

t

Recovered acids Bin bags

Fuel cells

Plastics manufacturer - Closed loop bin bags for B’ham - Plastics innovation

ERF



Future Vision: Integrated Resource Recovery System with Innovation Centres

Positio

n B

irmin

gham

as lead

er in reso

urce

recovery tech

no

logies

Today Synergies

Tomorrow Inward

Investment

Future Innovation

• Recover Palladium from road sweepings • Small-scale local combined-heat-and-power (CHP)

opportunities anchored by existing incinerator

• Innovate means to recycle lithium-ion and nickel metal hydride batteries in a cost-effective way

• Establish WEEE reprocessor to recover plastics, precious metals and rare earth elements from WEEE

• Capture precious metals from incinerator bottom ash • Use anaerobic digestion to anchor urban farming

integrated system



Success in Europe - Romania

• Romania Synergy Major international wood processor 20 Wood producers Sawdust / Wood chips / Boards from trunk trimming

• Total resources – 446,100 tonnes Virgin forest saved – 2,558 Hectares Deforestation major issue in region – leading to increased flooding



Success in Europe - Hungary

• Hungarian Synergy New road construction between two neighbouring towns Previously had to travel through a large detour 2 ½ KM of road built using waste aggregate, bricks and foundry sand Low grade road, fifth of cost of main roads, improving poorer communities

• Total resources – 6,000 tonnes



Sludge reutilization

Tianjin SembCorp Sewage Treatment Co. , Ltd. operates a sewage treatment plant in Tianjin Harbor Industrial Park.

The HanGu landfill site doesn't receive sludge according to the new policy in TBNA.

A safe and economical method for sludge treatment is in great need.

Yuchuan is a professional sludge treatment company, whose core technology is extracting protein from sludge for the manufacturing of protein products. The two companies met in the 9th QWW and came up with a potential synergy. Yuchuan receives 15 tons of sludge from SembCorp per month.

The Solution

The Challenge

The Results Businesses Assisted: 2 Additional Sales: 70,000Yuan Cost Savings: 464,000 Yuan Landfill Diverted: 180 t/year Virgin Materials: 180 t/year

China Project Results



Splitting the sludge



Cellular concrete



James Woodcock International Coordinator

International Synergies Limited

t: +44 (0) 121 433 2660 dl: +44 (0) 121 433 2681

e: [email protected] www.international-synergies.com

@peter_laybourn

@IntlSynergies @NISPnetwork

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James Woodcock 17.5.2013: Case Study Examples

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Transcript of James Woodcock 17.5.2013: Case Study Examples