SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES Cases and Impact Edited by JAN HARMSEN JOSEPH B POWELL A JOHN WILEY & SONS, INC., PUBLICATION SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES Cases and Impact Edited by JAN HARMSEN JOSEPH B POWELL A JOHN WILEY & SONS, INC., PUBLICATION Copyright © 2010 by John Wiley & Sons, Inc All rights reserved A Joint Publication of the Center for Chemical Process Safety of the American Institute of Chemical Engineers and John Wiley & Sons, Inc Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through 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2009033993 Printed in the United States of America 10 CONTENTS Contributors ix Foreword xi Preface xiii Introduction Jan Harmsen 1.1 1.2 1.3 1.4 Reason for This Book, Scope of the Book, Use in Education, Use in Industry, Sustainability Metrics, Indicators, and Indices for the Process Industries Joseph B Powell 2.1 2.2 2.3 2.4 Overview and Scope, Hierarchy of SD Metrics, Indices, and Indicators, Practical Tools for the Process Industries, 10 Summary and Conclusions, 17 References, 19 Resource Efficiency of Chemical Manufacturing Chains: Present and Future 23 Jean-Paul Lange 3.1 3.2 3.3 3.4 Introduction, 23 Resource Efficiency, 24 Economic Impact, 32 Conclusions, 35 References, 35 v vi CONTENTS Regional Integration of Processes, Agriculture, and Society 39 Michael Narodoslawsky 4.1 The Formative Character of Raw Materials, 39 4.2 The Systemic Engineering Challenge, 44 4.3 Regional Integration of Technologies, 46 References, 57 Eco-industrial Parks in The Netherlands: The Rotterdam Harbor and Industry Complex 59 L W Baas and G Korevaar 5.1 Introduction, 59 5.2 Industrial Ecosystem Programs in Rotterdam, 60 5.3 Conclusions, 76 References, 78 By-product Synergy Networks: Driving Innovation Through Waste Reduction and Carbon Mitigation 81 Andrew Mangan and Elsa Olivetti 6.1 6.2 6.3 6.4 6.5 6.6 6.7 Introduction, 81 BPS Origins, 83 The BPS Process, 87 Barriers and Challenges, 94 Benefits and Opportunities, 97 Examples, 100 Conclusions, 106 References, 106 Fast Pyrolysis of Biomass For Energy and Chemicals: Technologies at Various Scales R H Venderbosch and W Prins 7.1 7.2 7.3 7.4 Introduction, 109 Oil Properties, 114 Fast Pyrolysis Process Technologies, 120 Mass and Energy Balance for Production of Bio-oil and Char in a 2-ton/h Wood Plant, 136 7.5 Bio-oil Fuel Applications, 139 7.6 Chemicals from Bio-oil, 144 7.7 Economics, 148 7.8 Concluding Remarks, 149 References, 150 109 vii CONTENTS Integrated Corn-Based Biorefinery: A Study in Sustainable Process Development 157 Carina Maria Alles and Robin Jenkins 8.1 Introduction, 157 8.2 Technology Development for an Integrated Corn-Based Biorefinery, 159 8.3 LCA Results: ICBR Versus Benchmarks, 165 8.4 Final Reflections, 168 References, 169 Cellulosic Biofuels: A Sustainable Option for Transportation 171 Jean-Paul Lange, Iris Lewandowski, and Paul M Ayoub 9.1 9.2 9.3 9.4 10 Introduction, 171 Case Studies, 175 Sustainability of Biomass Production, 183 Conclusions and Recommendations for R&D Activities, 194 Note Added in Proof, 196 References, 196 Integrated Urea–Melamine Process at DSM: Sustainable Product Development 199 Tjien T Tjioe and Johan T Tinge 10.1 10.2 10.3 10.4 Short Summary of Melamine Development, 199 Current Uses of Melamine, 200 Urea Production, 201 Conventional DSM Stamicarbon Gas-Phase Melamine Production Process, 202 10.5 New Integrated Urea–Melamine Process, 205 10.6 Conclusions, 207 References, 207 11 Sustainable Innovation in the Chemical Industry and Its Commercial Impacts Joseph B Powell 11.1 11.2 11.3 11.4 Overview, 209 Historical Perspective, 210 Innovations in the Age of Sustainability, 212 Sustainability Driven by Innovation and Performance, 215 References, 216 209 256 INDUSTRIAL ECOSYSTEM PRINCIPLES IN INDUSTRIAL SYMBIOSIS (indicative of the results lead by Dow Environmental Technology Center in the United States alone) 14.5.1 Synergy Between the Chemical and Water Industries and the Local Community A case study of by-product synergy among the triad of chemical industry, water industry, and the local community, is described as follows: • Secondary material name: municipal wastewater • Secondary material generator: community (with a population of around 55,000) in Terneuzen, the Netherlands • Secondary material quantity: around 3,000,000 m3/yr • Secondary material end user: Dow’s integrated R&D and production site at Terneuzen • Results of by-product synergy • From 2007 onward, the municipal wastewater treatment plant effluent that was previously discharged into the sea (Western Scheldt) is now reclaimed and reused by a chemical plant • Dow’s integrated R&D and production site at Terneuzen won the European Responsible Care Award in 2007 for innovative industrial reuse of municipal wastewater This is an example of how a by-product synergy that is driven by system factors gradually evolves and is ultimately turned into reality by innovative strategic planning, investigation, research, and a public–private partnership Figure 14.4 illustrates the key players involved and their respective roles in this industrial symbiosis The characteristics of the symbiosis are detailed below Evolution In the mid-1990s, Dow Benelux enlarged its production capacity at the Terneuzen site significantly This production expansion required corresponding expansion of the site’s water facilities Given the fact that the region of Zeeuws-Vlaanderen in the Netherlands, where the Dow Terneuzen site is located, is structurally short of fresh water, Dow’s higher water demand made it necessary to review the water supply in the entire region Therefore, Dow and Evides, Terneuzen’s local water purifier, joined their efforts to sustainably control the regional water balance Improving water efficiency by reducing reliance on the increasingly scarce fresh water has been a long-standing priority for the Dow site Working closely with Dow, Evides Industriewater conducted several studies to evaluate various water sources besides water conservation (water reuse and recycling) practices at the site In 2000, these studies resulted in the construction of water treatment facilities producing various types of water from six different water sources The WORK PROCESS AND SUCCESSFUL CASES OF INDUSTRIAL SYMBIOSIS 257 Community of the city Terneuzen (Generation of municipal wastewater) Municipal wastewater Zeeuws-Vlaanderen Water Board (Treatment of the municipal wastewater in the water board’s biological wastewater treatment plant) Clean secondary effluent Evides Industriewater, subsidiary of Evides NV (Treatment of the secondary effluent in its DECO plant to produce demineralized water, and deliver it to Dow Benelux) Demineralized water Dow Benelux site at Terneuzen (Use of the demineralized water as boiler feed water for steam generation) Figure 14.4 Key players and their respective roles in industrial symbiosis of municipal wastewater reuse by the chemical industry water sources for the production of demineralized water included seawater, effluent from the municipal wastewater treatment plant, river water from the river Maas (Biesbosch water), and sweet surface water from Belgium From 2007 onward the seawater source was abandoned and the Evides’ Integrated Membrane System plant was refurbished to support the treatment of a new source, which is the effluent from the municipal wastewater treatment plant Collaboration Among Multiple Organizations The current successful symbiosis status could not be achieved without close cooperation among Dow Benelux, Evides Industriewater, the Zeeuws-Vlaanderen water board, the community of the city of Terneuzen, and the research organizations that conducted the various water treatment studies The sustained success still calls for close cooperation among all parties involved Innovation The current status of the successful reuse of municipal wastewater for high-value industrial applications on such a large scale required innovative thinking and strategic planning These innovations demonstrate how to change or improve the following system factors in order for the symbiosis to occur: 258 INDUSTRIAL ECOSYSTEM PRINCIPLES IN INDUSTRIAL SYMBIOSIS • The regional infrastructure had to be adapted, requiring investment for channel crossing and km of pipeline from the municipal wastewater treatment plant to the Evides pumping station • The diurnal fluctuation of the flow, which is typical of municipal wastewater, had to be dampened (equalized) • The existing reverse osmosis (RO) and pretreatment facility needed to be modified to accommodate the source water change from seawater to biologically treated municipal wastewater Thanks to the powerful people factor in this project, all the system constraints were overcome Scientific research verified the technical and economical feasibility of the municipal wastewater source to the RO process The existing usable infrastructure is now used for water conveyance from the municipal wastewater treatment plant to Evides’ DECO plant (about km) The diurnal fluctuation of the water flow has been overcome by installing an equalization tank The result is a win–win–win symbiosis • Reuse of around 2.5 million m3/yr of treated municipal wastewater from the city of Terneuzen (therefore, a corresponding 2.5-million m3/yr reduction in the freshwater intake from the region when the seawater-to-RO process was abandoned) • Energy saving at the DECO water demineralization facility; 65% reduction in energy use compared to the previous operation, when seawater was used to feed the RO desalination system • Reduction in the consumption of chemicals (and corresponding environmental burdens associated with making these chemicals from a life-cycle perspective) used for membrane fouling control • Reduction of municipal wastewater discharge and associated environmental emissions to the receiving water body • Support for the continued growth and development of both the Dow Benelux Terneuzen site and the Terneuzen community Following is an excerpt from the CEFIC news release on the European Responsible Care Award for this project (CEFIC 2007): “This innovative water project demonstrated a commitment to the local community and to the environment and showed the industry going above and beyond what is required,” the judges commented They also noted that it overcomes the huge prejudice of reusing treated sewage water Overall, the project is innovative because this is the first time that municipal wastewater is being reused on such a large scale in the industry And what’s more, both the concept and the technology have the potential to be applied by other companies to similar situations at other locations Dow Benelux is strongly committed to solving problems around scarcity of fresh water The focus is on the availability WORK PROCESS AND SUCCESSFUL CASES OF INDUSTRIAL SYMBIOSIS 259 of fresh drinking water for people in urban areas In the near future more people will live in cities than in rural areas This requires effective management of water supplies and water chains for which the award-winning concept can be a solution 14.5.2 Synergy Within the Chemical Industry By-product synergy for an off-spec formaldehyde product case study is described as follows: • Secondary material name: off-spec formaldehyde • Reason for being off-spec: high water content, high paraformaldehyde content • Secondary material quantity: 330,000 lb (150 metric tons), one time • Secondary material generator: Dow Chemical • Secondary material end user: proprietary • Application of the secondary material: raw material in the end user’s chemical manufacturing process The uniqueness of this synergy included: (1) a very short distance between the Dow site and the end user (system factor), (2) economics that are avorable for both parties (system factor), and (3) the fact that people working on this secondary material from both companies have a very strong background in environmental engineering and science, strong commitment to resource conservation and environmental protection, and very good persuasive communication skills to bring key stakeholders in their respective companies to the same level of passion and commitment (the people factor) 14.5.3 Synergy Between the Chemical Industry and Its Upstream or Downstream Industries The case study for crude cellulose ether polymer (Methocel, a Dow trademark) is summarized as follows: • Secondary material name: crude cellulose ether polymer (Methocel) • Reason for generating this crude cellulose ether: deviation in particle size, etc • Secondary material quantity: in excess of 500,000 lb (227 metric tons) per year • Secondary material generator: Dow Chemical • Secondary material end user: proprietary 260 INDUSTRIAL ECOSYSTEM PRINCIPLES IN INDUSTRIAL SYMBIOSIS • Application of the secondary material: unique applications for moisture retention and substance binding outside the chemical industry It took nearly four years from the beginning of evaluation on all potential applications of this secondary material until real synergies occurred In this case, both the system and people factors played important roles In terms of the system factor, there are no nearby end users because of the local climate and industry setup in the vicinity of the generator The synergy is achieved between the generator and the current consumers, who are located far away However, both the economic value and environmental benefits justify the synergy In terms of the people factor, this synergy cannot be achieved without teamwork supported by various functions within Dow Chemical who enjoy working together not only for the results but also for the journey itself; the customers stood firmly and work very closely with Dow in the course of evaluation and never give up during trials both in the lab and on the field scale Methocel (www.dow.com) has very diversified properties and functions, and this has opened the door for many potential applications The key is to find which application by which end user can generate the most value to both the generator and the end user, both economically and environmentally Methocel is a cellulose derivative (Figure 14.5) with a high molecular mass that bears both hydrophilic and hydrophobic functional groups Methocel cel- CH2 H H HO O H H O H O H O CH2 O H H O H O H2C H HO CH2 HO CH3 CH2 H CH3 HO H OH O H H O CH2 O H n-2 O CH3 (a) H HO O H H O CH2 HO H CH3 CH2 H H O CH2CHCH2 OH H CH2 O H H HO H O H O O HO CH2 H OH H O CH2 O CH2CHCH2 H OH HO H O CH3 n-2 (b) Figure 14.5 Structures of Methocel polymers: (a) methylcellulose (Methocel A products); (b) hypromellose (Methocel E, F, J, K, and 4-Series products) CONCLUSIONS AND RECOMMENDATIONS 261 lulose ether products are available in two basic types: methylcellulose and hypromellose, both of which have the polymeric backbone of cellulose, a natural carbohydrate that contains a basic repeating structure of anhydroglucose units Methocel belongs to the general group called water-soluble polymers, which are used primarily to disperse, suspend (thicken and gel), or stabilize particulate matter Methocel has the following general properties and functions (not inclusive): • • • • • • • • • • No ionic charge Water retention Thermal gelation Enzyme resistance pH stability Binding Dispersing, suspending, stabilizing capability Film formation Lubrication and friction reduction Rheology modification and control 14.5.4 Synergy Among Various Geographic Regions (Across Country Borders) Under certain circumstances, synergy can be achieved between two remotely located partners in two different countries if: • There are no competent partners close by • The material is of high commercial value and/or manufacture of the materials requires a large environmental footprint (considering nonrenewable resources from and environmental emissions to the Earth) • LCA evaluations justify long-distance transportation, so that environmental benefits associated with prime product and raw material substitution far exceed the environmental burdens associated with material transportation • All relevant regulations are in full compliance 14.6 CONCLUSIONS AND RECOMMENDATIONS From industrial symbiosis (by-product synergy) idea generation to its successful implementation, the following are important enablers in turning the symbiosis or synergy from theory to reality 262 INDUSTRIAL ECOSYSTEM PRINCIPLES IN INDUSTRIAL SYMBIOSIS • Motivation: motivation of all parties involved to the same level of passion for and commitment to sustainability • Validation: validation of ideas or beliefs through down-to-earth investigation and research, including investigation of synergy feasibility considering all the system factors required, and validation of environmental benefit claims • Collaboration: collaboration among generators, end users, and all other parties involved who will benefit from the synergy • Innovation: innovation for breakthroughs, including novel applications of the material, new processing technology to enable the material’s applications in the current market, or a combination of new processing technology and novel applications • Communication: timely, transparent, and effective communication of all information that is required for the success of the symbiosis or synergy • Professionalism: a win–win attitude and professionalism during collaboration The challenge facing the industrial symbiosis practice in general is lack of diversity in the secondary material reuse–recycle–recovery industry network at the local scale (such as in North America) However, the biggest challenge is the current cultural environment and its associated price structure, developed around the production and consumption of products Other barriers preventing successful by-product synergy identification and implementation include level of education, experience and expertise of industrial symbiosis practitioners, and the legal system and regulations Industrial symbiosis researchers and practitioners need to realize that there are two indispensable factors governing successful symbiosis or synergy: the system factor, which determines the synergy feasibility, and the people factor, which transforms the synergy from potential to reality The ultimate industrial ecosystem may take a long time to evolve, but it is and should be our humanity’s journey toward sustainable development Acknowledgments This contribution would not have been possible without the strong commitment to sustainable development by The Dow Chemical Company The author acknowledges the support of the company, particularly of Dow’s Environmental Technology Center, in writing and sharing our experiences and conclusions regarding the widespread practice of industrial symbiosis Appreciation is due to all the reviewers, both those from Dow and external reviewers, for comments and suggestions for improvement of this chapter It is to be noted that the views and opinions expressed herein not necessarily endorse, state, or reflect those of The Dow Chemical Company REFERENCES 263 REFERENCES CEFIC (European Chemical Industry Council) 2007 European Responsible Care Award, Budapest, Hungary, Oct 6, 2007 Accessed at http://www.cefic.org/Files/ NewsReleases/071002-C%20Award%20Press%20Release.pdf Duchin, F., and R Lifset 2008 Industrial ecology: transforming the use of energy, materials, water and wastes 6th Gordon Conference in Industrial Ecology, Colby– Sawyer College, New London, NH, Aug 17–22 Accessed Nov 1, 2008 at http:// www.grc.org/programs.aspx?year=2008&program=industeco ISIE (International Society for Industrial Ecology) 2008 A History of Industrial Ecology Accessed Nov 1, 2008 at http://www.is4ie.org/history.html Korhonen, J 2001 Four ecosystem principles for an industrial ecosystem J Cleaner Prod., 9:253–259 Korhonen, J 2007 Environmental planning vs systems analysis: four prescriptive principles vs four descriptive indicators J Environ Manag., 82:51–59 Korhonen, J., and J.-P Snäkin 2005 Analysing the evolution of industrial ecosystems: concepts and application Ecol Econ., 52:169–186 Robèrt, K H., B Schmidt-Bleek, J Aloisi de Larderel, G Basile, J L Jansen, R Kuehr, P Price Thomas, M Suzuki, P Hawken, and M Wackernagel 2002 Strategic sustainable development: selection, design and synergies of applied tools J Cleaner Prod., 10(3):197 Wu, Q 2008 By-product synergy: Dow Chemical’s successful experience Presented at the American Chemical Society 235th National Meeting, New Orleans, LA, Apr Wu, Q., K C Lee, Z Bell, and A Mangan 2005 “Sustainable development through by-product synergy Proceedings of the 2005 ACEEE Summer Study on Energy Efficiency in Industry, pp 4–170 INDEX Adhesive, 200 Adipic acid, 27 Agriculture, 45, 47, 109, 122, 160, 172, 192 AIChE, 1, 6, 9, 10 Algae, 75, 240, 245 Aluminium, 221 American Institute of Chemical Engineers, see AIChE Ammonia, 26, 146, 199, 201 synthesis, 210 Animal feed, 169 Anodizing, 222 Antibiotics, 147 Aquaculture, 45 Arabinose, 180 ATP, 240 Auto shredder residue, 86 Bacterium, 181 genetic engineering, 239 Baekeland, Leo, 211 Bakelite, 211 Benchmarking, 17, 164, 222, 233 Biodiesel, 49, 109, 194 Biodiversity, 188, 211 Biofuel, 49, 54, 109, 157, 159, 171–198 cellulosic, 171, 195 feasibility, 194 greenhouse gas emissions, 186 lignocellulosic, 192 second generation, 110 Biogas, 47 Biogenic resource, 40 Bioleaching, 237–246 reactor, 241 Biolime, 146 Biological nanotubes, 238 Biomass, 41, 74, 84, 109, 123, 149, 171, 174, 178, 182 lignocellulosic, 163, 164, 187 production costs, 192 thermal decomposition, 111 Biomass Technology Group, see BTG Bio-oil, 139, 142 chemicals, 144 gasification, 143 health and safety, 120 hydrotreating, 143 Bioplastics, 213 Biopolymer, 214 Biorefinery, 48, 110, 157, 159, 168, 182 Bio-remediation, 245 Biosludge, 64 Boustead model, 14 BPS, 94, 99, 103, 104, 106, 250 See also By-product synergy barriers, 94 economic challenges, 96 network, 91, 97 BTG, 109, 122, 129, 131, 132, 140, 150 Business Council for Sustainable Development for the Gulf of Mexico, 85 Sustainable Development in the Process Industries: Cases and Impact, Edited by Jan Harmsen and Joseph B Powell Copyright © 2010 John Wiley & Sons, Inc 265 266 Business Council for Sustainable Development of Latin America, 85 Business Resource Efficiency and Waste (BREW), 99 By-product, 81, 106, 120, 205 By-product synergy, 3, 23, 81–106, 249–262 Dow, 252 keys, 97 legal barriers, 252 people factor, 252 principles, 252 system factor, 252 value, 254 California Low Carbon Fuel Standard, 167 Calvert social index, Caprolactam, 27 Carbon capture, 186 Carbon cycle, 53 Carbon emissions, 98 Cascading, 87 Catalyst, 178, 179 poison, 195 Cellulase, 181 Celluloid, 211 Cellulose, 112, 145, 173, 179, 182 Cellulose ether polymer (Methocel), 259 Cement, 84 CemStar process, 86 Center for Sustainable Technology Practices, 12 Center for Waste Reduction Technologies, 11 Chaparral Steel, 85 Char, 111, 126, 127 Charcoal, 110 Chemical industry, 209 Chemicals, 169, 172 Chemviron, 147 Chicago Manufacturing Center, 104 Chicago Waste to Profit Network, 104 Choren, 174, 176 City development index, Cleaner production, 219–235 CleanTech, 16 Climate change, 44, 82, 95, 157, 171 CMLCA, 14 CO2, 17, 65, 66, 67, 70, 71, 72, 84, 86, 98, 99, 102, 105, 148, 159, 161, 163, 168, 171, 172, 186, 187, 202, 210, 211, 238 Coal, 41, 60, 84, 161, 166 Cobalt, 238 Cogeneration, 84, 94, 161, 168 Cold storage, 66 INDEX Combined heat and power, 52 Combustion, 163 Compliance, 222, 231 Compressed air system, 63, 69 Concrete, 104 Contextualization, regional, 44 Cook Composites and Polymers, 103 Copper, 238 Corn, 47, 54, 157, 159, 168 stover, 160, 163, 164, 168, 184 yield, 164 Counter-tops, 200 Cradle-to-gate, 158, 165 fossil energy, 163 Creative destruction, 209 Crops, 47 perennial vs annual, 185 Crude oil, 60, 74 De-centralization, 56 Deltalinqs, 61 Density, 51, 56 biomass, 193 of biogenic raw materials, 42 separation, 86 Designing Industrial Ecosystems Tool, 91 Detergents, 215 Diesel, 142 Dinitrotoluene, 27 Disposal cost, 98 Dow, 100, 249, 252, 254 Dow Jones sustainability index, Dry mills, 163 Drying, 174 DSM, 200, 204 Dupont, 157, 158, 159 Dynamotive, 127 Eco-efficiency, 229, 230 EcoFlow, 92 Eco-industrial park, 58–78, 82 Ecoinvent, 14 Ecological footprint, 7, 56 Ecological impact, 48, 53, 54 Ecological symbiosis, 74 Economy of scale, 51, 64 Ecoprofit, 222 Club, 235 Graz, 231 Ecosystems, 41, 43 Efficiency, 25, 27, 64, 163, 166, 167, 179, 210, 211, 221 energy, 100 Einstein, 219 267 INDEX EIO-LCA, 14 Electricity, 47, 54, 66, 69, 99, 161, 172, 223 renewable, 172 Electron transport membrane, 240 Elephant ivory, 211 Eloxieranstalt A Heuberger, 221 Emissions, 86, 219, 229 Energy, 30, 33, 40, 74, 81, 157, 196, 205, 220, 224 balance, 46, 90, 136, 137, 139, 164, 165, 221 credit, 166 demand, 172 duty, 174 efficiency, 17 savings, 70, 250 yield from biomass, 187 Energy and mobility, 210 Energy density, 42, 110, 172, 178 Energy Independence and Security Act, 167 Ensyn Technologies, 128 Environmental adjusted domestic product, Environmental cost, 91 Environmental Excellence Business Network, 102 Environmental impacts, 158 Environmental management system, 61, 221, 230 Environmental performance index, Environmental science, 212 Environmental sustainability index, Environmental vulnerability index, Enzyme, 160, 166, 179 cost, 182 submerged liquid culture, 182 Enzyme kinetics, 238 EPA, 82, 85, 89, 91, 95, 98, 100, 103, 212 Epichlorohydrin, 27 Escherichia coli, 240 Ethanol, 34, 51, 109, 160, 174, 179, 180, 195 case study, 52 cellulosic, 159, 164 titer, 166 Ethylene, 73 Eucalyptus, 184 European Environmental Agency, Eutrophication, 215 FaST (Facility Synergy Tool), 91 Fast pyrolysis, 109, 110, 120 Fatty acids, 173 Feedstock, 111, 158, 194 lignocellulosic, 160 renewable, 183 Fermentation, 110, 160, 166, 179, 180 Fertilizer, 40, 56, 84, 102, 146, 164, 166, 169, 182, 185, 186, 195, 210 Fischer-Tropsch synthesis, 175–176 Fish farm, 84 Flame retardant, 201, 211 Flaring, 64 Flue gas, 66, 93 Food, 47, 74, 147, 159, 185, 190, 195, 210 Forest, 42, 47, 49, 160, 168, 184, 189, 192, 210 Formaldehyde, 145, 200 Formic acid, 179 Fossil fuel, 30, 48, 52, 111, 139, 157, 172 FTSE4Good, Fuel, 74 Fuel vs food, 189 Full-cost accounting, 96 Funding government, 94 hybrid, 93 Furan, 179 Furfural, 145, 179 Gabi4, 14 Galileo Gas turbines, 142 Gasification, 30, 110, 174, 175, 176 entrained flow, 112 Gasoline, 172 Gemi, Genuine savings index, Glass, 211 Global warming, 74, 162, 215 Global warming potential, 13, 163, 250 Glucans, 112 Glucose, 179, 238 Glycol, 102 Gold, 238 Graz, 39, 48, 221, 231, 232, 235 Green chemistry, 13, 215 Green Chemistry Award, 209 Green engineering, 15 Green procurement, 225 Green twinning, 82 Greenhouse, 71 Greenhouse gas, 82, 157, 159, 167, 186, 213 GREET, 14 Gulf Coast By-Product Synergy Initiative, 100 Gutta-percha, 211 Happy Shrimp Farm, 74 Harvest, 160, 185, 195 Hazardous waste, 95, 99 Health, 210 268 Heat, 47, 84, 120, 122, 126, 131, 149, 168, 175, 177, 181, 202, 206, 233 process, 166 Heat integration, 149 Heat recovery, 205, 207 Heat transfer, 121 Heating system, 72 Hemicellulose, 112, 173, 179 Hexose, 181 Housing, 210 Human development index, Hydrogen chloride, 102 Hydrolysis, 174, 179, 180 ICHEME, 6, 10 IFS, see Institute for Sustainability IISD, 8, Impact assessment, 161 Incineration, alternatives to, 103 Index of sustainable economic welfare, Indicators, Industrial boiler, 139 Industrial ecological cluster instrument, 72 Industrial ecology, 3, 12, 59, 62, 66, 67, 73, 83, 88, 249, 250 Industrial ecosystem, 59, 249, 250, 262 sustainability of, 250 Industrial park, 73, 93, 169 Industrial symbiosis, 60, 82, 94, 249–262 INES Project, 60, 65, 69, 77 Infrastructure, 73, 82, 94 Innovation network, 104 Inorganic waste, 24 Institute for Sustainability, sustainability index, Institution of Chemical Engineers, see ICHEME Integrated corn-based biorefinery, 159 Intergovernmental Panel on Climate Change, 163 International Institute for Sustainable Development, Iogen, 175, 180, 181, 195 Isocyanates, 215 Jobs, 98, 99, 190 Kalundborg Industrial Symbiosis project, 60 Kalundborg, Denmark, 60, 77, 83 Laminate flooring, 200 Land use, 73, 191, 210 Landfill, 82, 84, 87, 94, 95, 98, 99, 105 Land-use change, 186, 188 INDEX Levulinic acid, 179 Life cycle, 87 cost, 96 product, 250 Life cycle analysis, 32, 53 Life cycle approach, 56 Life cycle assessment, 3, 11, 12, 158, 160, 254 Life cycle inventory, 11, 12, 163 Lignin, 112, 145, 160, 173, 179 Lignocellulose, 173 Liquefaction, 110 Liquid smoke, 121 Liquid surfactant membrane, 242 Living planet index, Local Government Association (LGA), 99 Logistics, 39, 41, 46, 73, 82 Malthus, 210 Management system, 9, 220, 231 Manufacturing chains, 23 Material balance, 44, 90, 92, 221, 229 Materials budgeting, 90 Melamine, 199–208 Metal, 238 Metal recovery, 238 Metallic ores, 237 Methane, 13, 26, 49, 161 Methocel, 102, see Cellulose ether polymer Methylmethacrylate, 27 Metrics, 2, 3, 5–19, 6, 91, 92, 96, 98, 99, 105, 106, 162 Microbial engineering, 237 Mid-America Regional Council, 102 Mineral resources, 40 Miscanthus, 184, 187 Mitsubishi Chemical Corporation, 93 Mizushima Regional Cooperation Complex, 93 Monod model, 238 N2O, 161, 168, 215 Nanoparticles, 238 National Corn Growers Association, 164 National database, 100 National Industrial Symbiosis Program, 87, 98 National Renewable Energy Laboratory, 169 Natural ecosystems, 60 Natural farming, 49 Natural gas, 41, 51, 64, 74, 161, 166, 223, 224 Network, 56, 235 NGO, 68, 162 Nickel, 238 Nitrogen, 116 Normalization, 13 NREL, 123, 175, 180 269 INDEX Nutrients, 55 Nylon, 24, 210, 211, 215 vacuum, 129 Pyrolysis oil, 114, 139 Ore, 244 Organic acids, 116 Organizational barriers, 94 Out of sight, out of mind, 252 Ozone, 215 Quality management, 220 Packaging, 24, 32, 222 Paint additives, 88 Palm oil, 132, 150, 184 Paperboard, 32 Penicillin, 84, 212 Pentose, 181 People, planet and profits, 2, Per capita energy demand, 41 Pesticides, 40, 185 Petroleum, 161 Phenolics, 147 Phenols, 145 Pheromones, 147 Phosgene, 27, 215 Pinch-analysis, 46 Pine, 118 Pipeline, 66, 71 Plastic bags, 32 Plasticizer, 201 Pollution, 67 Pollution prevention, 254 Polycarbonate, 24, 27, 215 Polyester, 24, 102, 103, 104, 210 Polyether, 102 Polymer, 34, 211 Polyolefins, 24 Polystyrene, 24 Polyurethane, 24 Poplar, 184 Population, 41, 210 Preference Index, 13 Pre-treatment, 181 Process intensification, 63 Product chain, 63 management, 60 Product development, 199 Product life cycle, 63 Project champion, 88, 89 Protein, 173, 237, 238 PVC, 24 Pyrolysis, 30, 66, 109–150, 174, 177 ablative, 122 fast, 148 flash, 111 fluid bed, 124 Rapeseed, 187 Rapid thermal processing, 125 Raw materials, 39, 54, 74, 82, 86, 88, 220 REACH, 9, 216 Reactor circulating fluid bed, 128 entrained flow, 122 jet sparged, 242 rotating cone, 129, 149 vortex, 123 Recycle, 23, 29, 99, 105, 207, 215, 250–252 Red Arrow Products, 147 Refinery, 60, 74, 84, 93, 109 Regional development, 65; 39–57 Regulation, 94, 97, 252 Regulatory mechanisms, 93, 94 Regulatory, economic, and logistics tool, 91 Renewable, 29, 49, 53 energy, 171 feedstock, 29, 33, 213 fuel, 11 resources, 40, 122, 159, 229, 250 Renewable Transport Fuel Obligation Order, 167 Reputation, 98 Resins, 24, 200, 212 Resource Conservation and Recovery Act, 95 Resource Conservation Challenge, 95 Resource depletion, 162 Resource efficiency, 23 Resource scarcity, 93, 94 Responsible Care, 9, 216, 256 Reuse, 94, 97, 103, 252 Reverse osmosis, 258 Rotterdam Harbor and Industry Complex, 59, 77 Saccarification, 166 Schumpeter, 209 Sea vegetables, 75 Shareholder value, Shelf life, 42 Shell, 1, 72, 174, 176, 177 Silver, 238 Simapro, 14 Slag, 86 Small-medium enterprises, 219–235 Social dimension, 6, 10, 39, 42, 47, 67, 81, 98, 183, 189, 190, 252 270 Social network, 97 Socio-technological process, 59 Sodium hydroxide, 102 Soil, 43, 65, 146, 157, 168, 172, 183, 187, 188 remediation, 245 tillage, 186 Solar energy, 40, 165 Solvent, 88, 102, 117, 118, 120, 174, 181, 195, 212 Spine, 14 SPOLD, 14 Stakeholder, 7, 13, 68, 82, 89, 95, 162, 226, 259 Stamicarbon urea stripping process, 202 Starch, 160, 190 Steam, 66, 71, 84, 133, 148, 164, 202, 206, 207 explosion, 180 Steel, 85, 93, 116, 210 STENUM, 219 Styrene-butadiene rubber, 210 Sugar, 160, 179, 185, 190 Sugar cane, 183, 190, 193 Sulfur, 116 Sulfuric acid, 102, 210 Sustainability, 12, 158, 175, 195, 209, 216, 219, 237 index, Sustainable development, 1, 6, 60, 83, 100, 200, 230, 250 design principles, 200 Sustainable growth, 158 Sustainable process index, 53 Switchgrass, 184 Synthesis gas, 175 Synthetic fibers, 211 System diversity, 250 Systems and Technologies for Advanced Recycling (STAR), 85 T ferrooxidans, 240 Tallow, 49 Tariff, 54 TCAce, 14 TEAM, 14 Technology networks, 47 Technosphere, 59, 63 Terneuzen, 256 Tool for reduction and assessment of chemical and other environmental impacts, see TRACI Total cost analysis, 11 Toxic emissions, 13 TRACI, 13 Transport, 53, 56, 95, 110, 160, 186, 193, 195 Transportation, 42, 97, 98, 163, 171, 172 Transportation fuel, 144 Triple bottom line, 2, 216 INDEX U.S Business Council for Sustainable Development, see U.S BCSD U.S Department of Energy, industries of the future, 100 U.S Environmental Protection Agency, see EPA Umberto, 14 United Nations Conference on Environment and Development in Rio de Janeiro, 85 Uranium, 238 Urea, 200 U.S BCSD, 83, 87, 92, 94, 100, 103, 104 Gulf of Mexico, 99 model, 89 U.S President’s Council on Sustainable Development, 93 Utilities consumption, 205 Utility, 70, 74, 82 Utility sharing, 65 Value chain, 158 Vegetable oil, 109, 183, 190 Vinylchloride, 27 Waste, 25, 44, 51, 59, 65, 81, 87, 92, 93, 96, 103, 168, 219, 229, 253 hazardous, 222 minimization, 166, 254 process, 102 Waste exchange, 82 Waste heat, 64, 71, 72, 74, 148 Waste reduction, 102 Waste treatment, 73, 74 Waste water, 64, 84, 94, 102, 219, 222, 226 municipal, 256 treatment, 88 Water, 81, 99, 163, 167, 168, 181, 182, 188, 205, 224, 257 Well being index, Well-to-wheels, 158, 164, 167 Wet mill, 164 Whale oil, 211 Wheat, 51, 54, 187 straw, 163, 184 Willow, 184 Wood, 42, 90, 110, 111, 112, 125, 134, 136, 139, 145, 178, 184, 191, 200, 201 pellets, 49 World Business Council for Sustainable Development, Xylans, 112 Xylose, 180 .. .SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES Cases and Impact Edited by JAN HARMSEN JOSEPH B POWELL A JOHN WILEY & SONS, INC., PUBLICATION SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES. .. between competing interests Discussion of the way forward in sustainability indices and indicators, despite inherent complexity, is provided in the International Institute for Sustainable Development? ??s... Amsterdam, The Netherlands 3.1 INTRODUCTION Since the Earth Summit in Rio de Janeiro in 1992, the concept of sustainable development has been adopted widely in the energy and chemical industries (Eissen