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© International Synergies Limited
Version date 02 May 2013
Industrial Symbiosis in Action
Case Study Examples
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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”
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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.
© International Synergies Limited
Version date 02 May 2013
• 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
© International Synergies Limited
Version date 02 May 2013
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.”
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
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
© International Synergies Limited
Version date 02 May 2013
Splitting the sludge
© International Synergies Limited
Version date 02 May 2013
Cellular concrete
© International Synergies Limited
Version date 02 May 2013
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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