ECO-INDUSTRIAL PARK. Group 4. Chibesa Pensulo, Johhny Musumbu. Amir Hafiz, Zhou Qinsheng, Derya Eryilmaz, Hanna Öberg, Yamashita Shihomi

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1 Our natural resources, fall 2009 ECO-INDUSTRIAL PARK Group 4 Chibesa Pensulo, Johhny Musumbu. Amir Hafiz, Zhou Qinsheng, Derya Eryilmaz, Hanna Öberg, Yamashita Shihomi ECO-Industrial Park Page 1

2 Table of contents Abstract 3 1 Introduction 3 2 Presentation of the industries Refinery (gasoline) Biofuel plant Soda bottle factory Solar energy cell plant Paper recycling plant (Tetra Pak) Coffee roasting and packaging (Gevalia) Tetra Pak manufacturer 6 3 The Eco-industrial park 7 4 Discussion 8 References 10 ECO-Industrial Park Page 2

3 Abstract The aim of this study is to create an eco-industrial park by matching nine different industries and their flow of material, water and energy. There is a wide variety of the factories in the eco-park. The aim of an eco-industrial plant is that industries should take after nature s own ecosystems where someone's waste product is another one s raw material in order to create sustainable industries. The different industries could be matched through energy and water use. There was a large surplus of energy that could go to surrounding areas. One conclusion was that some industries can share material but in order to make the park even more efficient some industries should cooperate in trying to find ways to adjust their processes to increase the material flows. Some final thoughts concerning industrial symbiosis and eco-parks were: we think that this is a good alternative towards sustainable development; however we do understand why there are not many eco parks in existence due to the difficulties with matching outputs and inputs. 1 Introduction More than two hundred years ago, when the industrial revolution had its beginning, the first industries in the world were developed. It started in Great Britain and has from there spread to the rest of the world and has had a profound impact of human society. Today, in almost every aspect of our daily life we rely on several industries and as the population increases so does the demand for new industries. Industrialization has not only had a large impact on human society but also on the environment. To what extent might not yet be fully understood. Industries today need to be concerned about the environment in order to release less GHGs, less toxic waste and wastewater etc. Industrial ecology is a modern approach to more sustainable industries. It focuses on sustainability between environment, economy and technology. Industrial symbiosis is a part of the industrial ecology field, which encourages completely different industries to exchange materials, energy, water and by-products. [A] The aim is that industries should take after natures own ecosystems where someone's waste product is another one s raw material. On way of doing this is through an eco-industrial park. In an eco-industrial park business co-operate with each other and the local community to reduce waste and pollution to gain a sustainable development. The aim of this study is to create our own eco-industrial park by matching nine different industries and their flow of material, water and energy. We hope to gain an understanding of how industrial symbiosis works and can contribute to sustainable development. The industries in our park are: Petroleum refinery Biofuel plant Soda bottle factory Solar energy cell plant Paper recycling plant (Tetra Pak) Coffee roasting and packaging (Gevalia) Tetra Pak manufacturer District heating plant Waste water treatment plant ECO-Industrial Park Page 3

4 2 Presentation of the industries 2.1 Petroleum refinery A petroleum refinery is a facility that produces refined petroleum products by the distillation of crude oil or by the reinstallation, cracking, or reforming of unfinished petroleum derivatives. There are hundreds of different configurations of refineries. The main products of a petroleum refinery are gasoline, diesel, asphalt base, heating oil, kerosene, liquefied petroleum gas (LPG), and feedstock for petrochemical industries that manufacture plastics, detergents, solvents and fibers such as nylon and polyester. Sitting of refineries Petroleum refineries are often located close to navigable rivers or a sea shore, to take advantage of cheap transportation of crude oil and bulk products by river or sea. Refineries also need large quantities of process steam and cooling water. It is also best to site refineries in locations where there is abundant space for use by the same company or others for the construction of industrial plants that make use of the refinery s bulk products, or that produce chemical additives that the refinery may need for blending into a product. About 10% of the energy content of the crude oil is consumed at the refinery. Refineries use more heat energy than electricity, and can supply excess heat to district heating networks. Some refineries are designed to use gases produced on-site to generate electricity, which is then used for other processes within the refinery and supplied to the electricity grid. Petroleum refinery in the eco-industrial park Capacity: 1 million tons of crude oil per year, i.e. approximately 20,000 barrels per day. (conversion factor: 1 barrel per day = 50 tons per year) Source of raw material: Norway (a net exporter of crude oil) Electricity requirements: 4.73kWh/US gallon, which converts to 1390 GWh per year Excess heat supplied to district heating plant: 79 GWh, enough to heat 5200 single-family homes Water required: 2m 3 per ton, which converts to 2 million cubic meters per year. Wastewater output: 0.3m 3 per ton, which is 300,000m 3 per year 2.2 Biofuel plant The activities of bio-ethanol production are usually divided into two main sectors that are as follows: -Agriculture sector. A simplified overview of sugarcane production encompasses different steps: 1. Soil treatment 2. Planting 3. Monitoring 4. Harvesting 5 Loading and transport to the sugarcane plant. -Industrial sector. Sugarcane-based bioethanol production flowchart can be depicted as follow: 1. Milling 2. Chemical treatment 3. Filtration 4. Fermentation 5. Distillation 6. Rectification 7. Dehydration 8. Ethanol. ECO-Industrial Park Page 4

5 Considering the entire sugarcane bioethanol production cycle, the residues generated in the process are vinasse, filter cake and boiler ashes. In the Brazilian mills such residues are well appreciated by-products that once recycled can be used as fertilizers, contributing to both significantly the need for mineral fertilizers and avoid the need for irrigating sugar crops. Moreover, it is worth noting that sugarcane processing is water demanding. As a result, liquid effluents from the bioethanol industry comprise water from sugarcane washing, water from multi-jets and barometric condensers and spillages and residual water. The sillage constitutes the most important effluent from sugarcane agro-industry. It contains high levels of potassium and organic matter once again used in fertilizing sugarcane crops or other crops as well. What is more is that, particularly in Brazil, mills are energy self-sustained and they often manage to export increasing amounts of electricity power surpluses to the public grid, thanks to the growing use of energyefficient equipment. Some useful numbers of bioethanol Plant per year 1. 2,015,267 tons of sugarcane processed ,720,601 m 3 of liquid effluent produced ,297,695 liters of bioethanol 4. 1,171,297,695 liters of sillage 5. 2,015, liters of vinasse 6. 80, tons of filter cake 7. The plant has an installed capacity of MW with surpluses of 6.67 MW offered to the public electric grid [ Silvestrin ( 2007 ) ] 2.3 Soda bottle factory The factory producing soda bottles uses petroleum gas; these are ethane and propane which are obtained from crude oil. The gases (LPG) are put in a catalyst in a reactor which transforms the gases to fluff powder polymers. This powder is then turned into pellets. The pellets are made to plastic bottles by processes which involve blowing and molding. The factory in our EIP produces 1000 bottles per day and the input of water is 990 L of water. In addition to this the factory requires kilograms of crude oil. The energy used in the factory for producing a thousand bottles is 1122 MJ. This numbers are put in an annual perspective in our eco-industrial park. The issue that is worth taking in consideration in the ecoindustrial park is the fact that not all bottles are recycled. But still a large number of the bottles are, approximately 75% of the bottles are being recycled. 2.4 Solar energy cell plant In our Eco-industrial Park, the solar energy plant is designed to supply electricity to the Tetra Pak manufacturer and Paper recycling plant. The annually electricity demand by the above mentioned two factories is 15.08GWh (7.9GWh+7.18GWh). Thus the design capacity of the plant is 17.52GWh and we need to use 100,000 solar panels to form the array. Solar panel are being made from raw material silicon and assembled into solar panel array together with aluminum and plastics. This plant will generate electricity for Tetra Pak manufacturer and Paper recycling plant while the biofuel plant will supply electricity to the Soda bottle factory and coffee factory. Annually, approximately 280 tons of raw material silicon, 35tons of aluminum and plastics and 300 tons of gasoline will be consumed during the process of production. We need to import silicon from outside of the park, however aluminum and plastics can be supplied with the plastic pellet manufacturer we added to the park whose material is form the Refinery, Paper recycling plant, Tetra Pak manufacturer, and the soda bottle factory. And the gasoline (300 tons) is from the Refinery. At the mean time, 1,520 tons of CO 2, wastewater contains 980 tons of SiCl 3 and 1,260 tons of SiCl 4 will be released, which will be sent to the wastewater treatment plant in the Eco-industrial Park. 2.5 Paper recycling plant (Tetra Pak) Paper recycling plant has the function of recycling the used Tetra Pak Carton Packages which are produced by the Tetra Pak Manufacturer in the Eco-industrial Park. The used Tetra Pack carton packages ECO-Industrial Park Page 5

6 are collected in the special containers that are brought in the Eco Industrial Park and then sent to the recycling plant. During the recycling process, 7.18 GWh of energy from solar power plant and 1, m 3 of water from Wastewater Treatment Plant are being used per year in the paper recycling plant. Annually, 2, tons of carton packages are being recycled in the eco industrial park. [B] The cartons are put into big re-pulping containers with a certain amount of water and mixed until it becomes slurry and the paper fibers break down through hydrolysis. Water for hydrolysis is taken from Tetra Pak manufacturer which leaves over water after the production phase. And later, it is being in the screening process which separates reusable materials after recycling and the waste material from each other. But the accepted materials are not used again for the carton package production phase because of some health precautions of Tetra Pak Company and the assumption has been made that they are sent to toilet Paper Manufacturer Company outside of the Eco Industrial Park. Other part of the separated material is waste and they are incinerated or land filled for biodegradation. If the waste materials are landfilled or biodegraded then it will take approximately 28 days for biodegradation of paper board and the polyethylene which are used to produce the package. [C] But it depends on the aerobic or anaerobic biodegradation and besides, if it is an anaerobic (without oxygen) biodegradation there will be a release of methane to the atmosphere. If the waste materials are incinerated then there is a release of 46 MJ of energy per 1 kg of package. [D] Thus, this energy can be used for heating inside the recycling plant. Besides, according to the carbon footprint of Tetra Pak Company, there is a release of 1,08 kilograms of CO 2 package to the atmosphere. [5] After recycling process it has been assumed that m 3 of wastewater is remained and there is a certain amount of paper and aluminum + plastic remains which is 1, tons and tons per year consequently. 2.6 Coffee roasting and packaging (Gevalia) In this coffee factory raw coffee beans are being roasted, grained and then packaged before being sent to retailers. Annually the factory produces tons of coffee. The roasting is done in ovens driven by natural gas or gasoline. The yearly amount of gasoline needed is 720 tons. The beans are then quickly cooled down and next sent to packaging. The waste products during the process per year are combustible disposal, 576 tons, vegetable based disposal, 324 tons as well as negligible amounts of metal, wood and corrugated cardboard. Some electric energy are being used for the machines. [E] 2.7 Tetra Pak manufacturer To produce packing materials, Tetra Pak uses paperboard with 75%, plastic (polyethylene) with 20% and aluminum with 5%. 117 billion packages are produced in Swedish market and totally 102.6GW of energy is used for one year. We assume our Tetra Pak manufacturer in the Eco-industrial Park produces 10% of the Tetra Pak used in Swedish market. Our main material is paper, coming from forest: we don t use recycled paper or recycled plastic for our packages since our package must be durable and light. For the package, 3510 tons of raw materials are used per year. In other words, we input 2,632.5ton of paper, 702ton of plastic and 175.5ton of aluminum. As resources of energy, we largely rely on electricity with 77% (7.9 GWh/y), which is followed by natural gas with 14% ( GWh/y), LPG with 7% ( GWh/y) and district heating with 2% ( GWh/y). The yearly water consumption is 1,744.5m3; water is not used as an input into the converting process but mainly for cooling and cleaning purposes. As we cannot get the proper number of water and energy output, we assumed as 40% of input water (697.8m 3 ) is wasted; as 70% of input energy (7.18GWh) is wasted in this manufacturer. Through the process of producing packages, 3.85ton of solid waste we have per year and 2,457 ton of packages are wasted from after domestic consumption. Total amount of those wastes is 2, tons. As recycling is the dominant waste handling option, we send them to the paper recycling plant. ECO-Industrial Park Page 6

7 3 The Eco-industrial park PAPER RECYCLING PLANT Energy (9) DISTRICT HEATING PLANT Used Carton Used carton, al and plastic TETRA PAK MANUFACTURER Organic and Combustible Disposal (5) Energy (8) Alimunium and Plastic (1) Energy (8) SOLAR PLANT Waste Water (2) Energy (9) SODA BOTTLE FACTORY Energy (7) Energy (7) COFFEE ROASTING AND PACKAGING Treated Water is supplied to all the industries in the ecoindustrial park that require process water (2) WASTE WATER TREATMENT PLANT Gasoline (4) Heat & gasoline (6) BIOFUEL PLANT Waste Water (2) PETROLEUM REFINERY Sludge (3) Waste Water (2) FARM growing Sugarcanes Supplementary water input (2) Borehole ECO-Industrial Park Page 7

8 1. The Soda bottle factory needs 8775 tons of plastic and Aluminum in their process, since the Paper recycling plant has plastic and Al as a byproduct it can be used in the Soda bottle factory. However the output is not enough and therefore some Al and plastic needs to be taken from somewhere else. 2. The wastewater from all the industries goes to the wastewater treatment plant. It is then redistributed to all the industries. Is it sufficient to supply all the water required by all the industries except the petroleum refinery, which will require extra input from groundwater. 3. Farms around the eco-park can grow sugar cane which would provide the bio fuel plant with raw material and then give back sludge for fertilizing. The produced fuel can then be used for the coffee-, soda bottle- and coffee factories vehicle s when distributing groceries to retailers. 4. Gasoline needed by the solar plant (30 tons) and the coffee factory (72 tons) has to be obtained from the refinery. 5. The coffee factory can then give their organic and combustible disposal to the district heating plant. 6. The Refinery can supply excess heat (79 GWh) which is enough to heat 5200 houses. 7. The Soda bottle factory consumes 93.6*10-6 GWh electricity annually, the coffee factory consumes 83.5*10-6 GWh electricity annually (estimated number), and all of them can be satisfied by the Biofuel plant which has 7,220*10-6 GWh electricity output annually. The Refinery needs 1390GWh electricity annually which is a large amount and cannot possibly to be satisfied by neither the solar power plant nor the Bio fuel plant, thus it has to rely on the grid. 8. The solar panel plant is taking 300 tons gasoline from the Refinery. It generates 17.52GWh electricity to meet the need of Tetra Pak Manufacturer (7.9002GWh/y) and Tetra Pak Recycling Plant (7.18GWh/y). 9. Tetra Pak Manufacturer is totally taking GWh of energy (7.9002GWh) from District Heating Plant (0.2052GWh), Refinery (0.7082GWh) and Bio fuel Plant (1.4364GWh) m 3 of water is taken from Waste Water Treatment Plant. Through the production process, tons of cartons and tons of plastic and aluminum are produced annually and they are sent directly to the Tetra Pak Recycling Plant. 10. Tetra Pak Recycling Plant consumes 1, m 3 of water from Water Treatment Plant per year. After recycling process m3 of waste water is left over which is sent directly to water treatment plant. 1, tones of cartons and tons of aluminum and plastic are produced and aluminum and plastic are sent to meet the need of the soda bottle factory and the solar panel production. 4 Discussion While designing our eco-park we found that most of our industries could share some outputs and inputs and all the industries could be a part of the park. However this might not work in real life as some of the outputs where too small. Another weakness in our park is that one of the factories did not have an output. This works against the whole idea. Some of our factories are self-depending. For instance the tetra pack factory uses raw materials for the packages, not the recycled ones because they found that there is not an obvious environmental case for using recycled one. As some of the factories are not so similar they cannot provide each other with sufficient amounts of outputs. When building an eco industrial park one should include industries that can contribute with outputs for at least one industry to make it sufficient. Water is a major in- and output for almost all over our industries. The input is larger than the output and water needs to be taken from somewhere else. This is in our opinion not in harmony with the concept of eco industrial park. Furthermore, the wastewater treatment plant is grossly underutilized. Another large ECO-Industrial Park Page 8

9 input for industries is energy and since we have a heating plant, refinery, solar plant and a biofuel plant, which are all producing large amount of energy, we have a large surplus of energy that can be sent to the other industries as well as to the local community. Some industries can share material but in order to make our park even more efficient some industries should cooperate in trying to find ways to adjust their processes to increase the material flows. The efficiency of our park would decrease if the climate or any other factor would make it impossible to grow sugar beans on the farm because then the biofuel plant would have to take their raw material from somewhere else. We do not consider that our eco-park is the best solution since there are not enough material outputs from each industry to sustain other industries. During this process we have gained an understanding in eco parks and industrial symbiosis. We think that this is a good alternative towards sustainable development; however we do understand why there are not many eco parks in existence due to the difficulties with matching outputs and inputs. ECO-Industrial Park Page 9

10 References [A] Marian R. Chertow, Industrial symbiosis: Literature and taxonomy. Energy environment 25: [2.1 Refinery] 1 Preem Annual Report Oil Industry Conversions: accessed Gasoline and Oil: accessed [2.2 Biofuel plant] 4 SILVESTRIN, C. R. Dependência Elétrica de São Paulo: Desafios & Oportunidades. São Paulo: 5 Cogen-SP, Secretarias de Desenvolvimento e de Saneamento e Energia do Estado de São Paulo, March 2007 [2.3 Soda bottle factory] 6 ebottles: accessed ENSO Bottles, LLC Environmental Impact : accessed Earth Bottle Institute: accessed [2.4 Solar energy cell plant] 9 Environmental Life Cycle Assessment of Advanced Silicon Solar Cell Technologies, E. A. Alsema, M. J. de Wild-Scholten: accessed Data of solar cell, Ningbo Solar Electric Power Co., Ltd: accessed Environmental Impact, Solar Panel Articles: accessed Monocrystalline silicon production process, semiconductor engineering accessed Sunshine intensity, NASA: accessed Consecutive rainy days, NASA: accessed [2.5 Paper recycling plant] 15 Tetra Pak (2007), Environmental and Social Report. [B ]There is an assumption has been made with these figures. [C] Boni M. Rosaria and Musmeci Loredana,(1998), Organic fraction of municipal solid waste (OFMSW): extent of biodegradation. Waste Manag. Res.,16; 103 Table 2, page 105 [D] Dean, Carrie; Sickert, Lars and Gustaffson, Kerstin (2003), Sustainable Packaging: Replacing Polyethylene with Biopolymers for Tetra Pak non-aseptic cartons in Sweden, LUMES Thesis, Lund University, Sweden, p.16 [2.6 Coffee roasting and packaging] [E] Pia Klarström, Kraft foods Europe. All the figures were given through . pklarstroem@krafteurope.com [2.7 Tetra Pak manufacturer] 16 Tetra Pak Environmental Social Report 2008 : f accessed Tetra Pak Environmental Performance : accessed ECO-Industrial Park Page 10