Sustainable Development in the Process Industries E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 454

Veröffentlichungsjahr: 2011

Beschreibung

The complete, hands-on guide to sustainable development

Today's process industries must develop natural resources within an eco-friendly framework that balances current demand with future need. Realizing this goal necessitates global vigilance of three key areas—people, planet, and prosperity—known as the Triple Bottom Line or, simply, the Triple P.

Sustainable Development in the Process Industries details how worldwide implementation of sustainable processes in present-day industries can positively influence the Triple P going forward by lowering poverty, reducing pollution, and conserving resources. This in-depth guide includes:

• Real-world case studies and examples

• Individual chapters written by industry experts

• Application in industries such as petroleum and fuel, food, recycling, mineral processing, and water processing

• Focus on the micro (molecules, unit operations, processes) to the macro (industrial sites, value chains, regions, the world)

Providing lessons with practical application rather than pure theory, Sustainable Development in the Process Industries offers sound solutions to social, ecological, and economic challenges imperative to assuring our planet's well-being for generations.

Leseprobe

Contents

Cover

Half Title page

Title page

Copyright page

Contributors

Foreword

Preface

Acknowledgments

References

Chapter 1: Introduction

1.1 Reason for This Book

1.2 Scope of The Book

1.3 Use in Education

1.4 Use in Industry

Chapter 2: Sustainability Metrics, Indicators, and Indices for The Process Industries

2.1 Overview and Scope

2.2 Hierarchy of SD Metrics, Indices, and Indicators

2.3 Practical Tools for The Process Industries

2.4 Summary and Conclusions

References

Chapter 3: Resource Efficiency of Chemical Manufacturing Chains: Present and Future

3.1 Introduction

3.2 Resource Efficiency

3.3 Economic Impact

3.4 Conclusions

References

Chapter 4: Regional Integration of Processes, Agriculture, and Society

4.1 The Formative Character of Raw Materials

4.2 The Systemic Engineering Challenge

4.3 Regional Integration of Technologies

References

Chapter 5: Eco-Industrial Parks in The Netherlands: The Rotterdam Harbor and Industry Complex

5.1 Introduction

5.2 Industrial Ecosystem Programs in Rotterdam

5.3 Conclusions

References

Chapter 6: By-Product Synergy Networks: Driving Innovation through Waste Reduction and Carbon Mitigation

6.1 Introduction

6.2 BPS Origins

6.3 The BPS Process

6.4 Barriers and Challenges

6.5 Benefits and Opportunities

6.6 Examples

6.7 Conclusions

References

Chapter 7: Fast Pyrolysis of Biomass for Energy and Chemicals: Technologies at Various Scales

7.1 Introduction

7.2 Oil Properties

7.3 Fast Pyrolysis Process Technologies

7.4 Mass and Energy Balance for Production of Bio-Oil and Char in A 2-Ton/H Wood Plant

7.5 Bio-Oil Fuel Applications

7.6 Chemicals From Bio-Oil

7.7 Economics

7.8 Concluding Remarks

References

Chapter 8: Integrated Corn-Based Biorefinery: A Study in Sustainable Process Development

8.1 Introduction

8.2 Technology Development for An Integrated Corn-Based Biorefinery

8.3 LCA Results: ICBR Versus Benchmarks

8.4 Final Reflections

References

Chapter 9: Cellulosic Biofuels: A Sustainable Option for Transportation

9.1 Introduction

9.2 Case Studies

9.3 Sustainability of Biomass Production

9.4 Conclusions and Recommendations for R&D Activities

Note Added in Proof

References

Chapter 10: Integrated Urea-Melamine Process at DSM: Sustainable Product Development

10.1 Short Summary of Melamine Development

10.2 Current Uses of Melamine

10.3 Urea Production

10.4 Conventional DSM Stamicarbon Gas-Phase Melamine Production Process

10.5 New Integrated Urea–Melamine Process

10.6 Conclusions

References

Chapter 11: Sustainable Innovation in the Chemical Industry and its Commercial Impacts

11.1 Overview

11.2 Historical Perspective

11.3 Innovations in The Age of Sustainability

11.4 Sustainability Driven By Innovation and Performance

References

Chapter 12: Implementation of Sustainable Strategies in small and Medium-Sized Enterprises Based on the Concept of Cleaner Production

12.1 Overview

12.2 Active Strategies for Sustainable Management

12.3 Eloxieranstalt A. Heuberger GmbH: Sustainable Management in An Anodizing Plant

12.4 Analysis of the Results

12.5 Implementation of Sustainable Strategies

Appendix: A Successful Regional Cleaner Production Project

References

Chapter 13: Sustainable Concepts in Metals Recycling and Mineral Processing

13.1 Overview

13.2 Bioleaching Process Design and Development

13.3 Bioleaching Reactor Design: Applicability of The Core Particle Model

13.4 Industrial Applications

13.5 Conclusions

References

Chapter 14: Industrial Ecosystem Principles in Industrial Symbiosis: By-Product Synergy

14.1 Introduction

14.2 Relationship Between Industrial Symbiosis and Sustainable Development

14.3 Challenges, Barriers, and Countermeasures in Exploration, Evaluation, and Implementation of Industrial Symbiosis

14.4 What By-Product Synergy Is and Is Not

14.5 Work Process and Successful Cases of Industrial Symbiosis

14.6 Conclusions and Recommendations

References

Index

SUSTAINABLE DEVELOPMENT IN THE PROCESS INDUSTRIES

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.

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Library of Congress Cataloging-in-Publication Data:

Sustainable development in the process industries: cases and impact / edited by Jan Harmsen, Joseph B. Powell.p. cm.Includes index.ISBN 978-0-470-18779-1 (cloth)1. Industrial ecology. 2. Sustainable development. I. Harmsen, Jan, 1950– II. Powell, Joseph B., 1956–TS161. S87 2010670-dc22

2009033993

CONTRIBUTORS

Carina Maria Alles, DuPont Engineering and Research Technology, Wilmington, Delaware

Paul M. Ayoub, Shell Technology Centre, Amsterdam, The Netherlands

L. W. Baas, Erasmus Centre for Sustainability and Management, Erasmus University, Rotterdam, The Netherlands; Linköping University, Linköping, Sweden

Nitosh Kumar Brahma, Indian Institute of Technology, Kharagpur, W. Bengal, India; IGE-Badu-Kolkata, India

Johannes Fresner, STENUM GmbH, Graz, Austria

Jan Harmsen, State University Groningen, Groningen, The Netherlands

Robin Jenkins, DuPont Engineering and Research Technology, Wilmington, Delaware

G. Korevaar, Delft University of Technology, Delft, The Netherlands; Institute of Environmental Sciences, Leiden University, Leiden, The Netherlands

Jean-Paul Lange, Shell Technology Centre, Amsterdam, The Netherlands

Iris Lewandowski, Shell Technology Centre, Amsterdam, The Netherlands

Andrew Mangan, U.S. Business Council for Sustainable Development, Austin, Texas

Michael Narodoslawsky, Institute for Process Technology, Graz University of Technology, Graz, Austria

Elsa Olivetti, Massachusetts Institute of Technology, Cambridge, Massachusetts

W. Prins, Biomass Technology Group, Enschede, The Netherlands; Ghent University, Ghent, Belgium

Joseph B. Powell, Shell Global Solutions, Houston, Texas

Jan Sage, STENUM GmbH, Graz, Austria

Johan T. Tinge, DSM Research, Technology and Analysis Geleen, SRU Industrial Chemicals, Geleen, The Netherlands

Tjien T. Tjioe, DSM Research, Technology and Analysis Geleen, SRU Industrial Chemicals, Geleen, The Netherlands

R. H. Venderbosch, Biomass Technology Group, Enschede, The Netherlands

Qingzhong Wu, Environmental Technology Center, The Dow Chemical Company, Plaquemine, Louisiana

FOREWORD

The book offers an important industry perspective on how companies develop and design innovative solutions to complex environmental and societal challenges. It goes well beyond theory, offering case studies with quantifiable results that illustrate how companies can save money while improving the environment and helping local communities. It shows how small, medium-sized, and large companies are using resources more efficiently, sometimes by teaming up with other industries, to achieve results that balance the triple bottom line of people, planet, and prosperity.

This richly detailed study should be of great interest to industry leaders, policymakers, scholars, and students of sustainable development.

ANDREW MANGAN

Executive Director

U.S. Business Council for Sustainable Development

PREFACE

This book presents examples and approaches to the application of sustain-ability in the process industries. Before describing some ways in which the book can be used in courses and in industry, let’s look at the evolution of the concept of sustainable development and how industry has played its role in this evolution.

The term sustainable development was redefined and became globally known through the publication of Our Common Future, commonly called the “Brundtland report” (WCED 1987), which states:

Sustainable development is not a fixed state of harmony, but a process of change in which the exploitation of resources, the direction of investments, the orientation of technological development and institutional change are made consistent with future as well as present needs. Sustainable development is development that meets the needs of the present generation without compromising the ability of future generations to meet their own needs.

It is clear from this description that sustainable development contains social, cultural, environmental, and economic aspects and takes worldwide and long-term perspectives into account.

After publication of the definition in 1987, the concept of sustainable development was debated broadly and deeply by those in a variety of scientific and academic fields (de Beer and Swanepoel 2000). It survived this discussion and became broadly accepted by many governments. The financial and business world also adopted the concept, but defined it further by introducing three essential dimensions of sustainable development: the social, ecological, and economic dimensions (Serageldin 1993; Hart 1997; WBCSD 1997). Elkington (1997), in turn, transformed the concept into the triple bottom line of people, planet, and profits. Soon after, a number of companies began to use it (Shell 2000).

According to the triple-bottom-line concept, in corporate activities equal weight should be given to:

People: the social consequences of its actionsPlanet: the ecological consequences of its actionsProfits: the economic profitability of companies (being the source of “prosperity”)

The main point is that the “bottom line” of an organization is not only an economic-financial one—an organization is responsible for its social and ecological environment as well. From this “triple P” perspective, an organization that considers a strategy of sustainability must find a balance between economic goals and goals with regard to the social and ecological environment.

The adoption of triple-bottom-line concepts in industry helped to forward its popularity by governments. In the United Nations World Conference on Sustainable Development in Johannesburg, South Africa in 2002, the “triple P” description was adopted and modified, with profit changed to prosperity. To quote:

We, the representatives of the peoples of the world, assembled at the World Summit on Sustainable Development in Johannesburg, South Africa, from 2 to 4 September 2002, reaffirm our commitment to sustainable development. We commit ourselves to act together, united by a common determination to save our planet, promote human development and achieve universal prosperity and peace (UN 2002).

—Johannesburg Declaration on Sustainable Development

Thus, industry helped make the concept of sustainable development more applicable and, perhaps even more important, easier to remember, by introducing the terms triple P and triple bottom line. Moving beyond definitions to actual implementation can be a challenge for any organization given the expanded array of considerations required by the triple-bottom-line concept and the frequent lack of quantitative metrics available for use in decision making. Although some attention is paid to an overview of the current status of metrics and methodologies in beginning chapters, the examples and case studies that follow help us to focus on the more specific set of drivers that affect decision making in applications across the process industries and related disciplines. Topics include the design of industrial parks and synergistic industrial networks, mining, chemicals, water treatment, and new domains, such as biofuels, which are driven by a desire for more sustainable industries.

The book can be used in courses on sustainable development, regional planning and development, industrial ecology, industrial metabolism, process design, and innovation. It can, for example, be used in exercises to apply a specific analysis or assessment method to a selected case study. It can also be used to analyze and compare the approaches used to implement and apply sustainability principles. Finally, it can be used in process design by giving it as an exercise to improve a specific case process.

The book should also be useful in industry: by implementing approaches described in the case-study processes, or by using the sustainable development metrics and methods described. The cases come from small, medium-sized, and large enterprises. The reader may notice interesting differences in the methods used, depending on the size of the company or industrial branch. Cross-fertilization may happen in this way.

ACKNOWLEDGMENTS

We thank the authors of and contributors to the chapters. Given the breadth of the subject of sustainability, the variety of perspectives and insights presented by our fellow authors has made the preparation of this book an enriching exercise. We trust that you will find it similarly insightful.

G. JAN HARMSENJOSEPH B. POWELL

REFERENCES

de Beer, F., and H. Swanepoel. 2000. Introduction to Development Studies. Oxford, UK: Oxford University Press.

Elkington, J. 1997. Cannibals with Forks. Oxford, UK: Capstone.

Hart, S. 1997. Beyond greening: strategies for a sustainable world. Harvard Bus. Rev., Jan.–Feb., pp. 66–76.

Serageldin, A. 1993. Making development sustainable. Finance Dev., 30(4):6–10.

Shell. 2000. People, Planet & Profit, The Shell Report 2000.

UN (United Nations) Department of Economic and Social Affairs, Division of Sustainable Development). 2002. Johannesburg Declaration on Sustainable Development, Sept. 2–4, 2002. Accessed Jan.2009 at http://www.un.org/esa/sustdev/documents/WSSD_POI_PD/English/POI_PD.htm.

WBCSD (World Business Counsil for Sustainable Development). 1997. Exploring Sustainable Development: Global Scenarios, 2000–2050, London, UK.

WCED (World Commission on Environment and Development). 1987. Our Common Future. Oxford, UK: Oxford University Press.

Chapter 1

INTRODUCTION

JAN HARMSEN

State University Groningen, Groningen, The Netherlands

1.1 REASON FOR THIS BOOK

The editors of this book have long industrial experience in process development and novel commercial-scale process implementations. In the past decade we became convinced that sustainable development (SD) is a good driver for innovation, as it makes good business sense to provide for the needs of people in an ecological, economical, and socially acceptable way. Our company, Shell, was adopted sustainable development as one of its business principles, as have many other companies. Formation of the World Business Council for Sustainable Development, with its large number of contributing companies worldwide, is a good indicator of this new direction in global businesses.

However, we felt the lack of reported industrial cases necessary to convince and inspire our colleagues, academics, and students that, indeed, sustainable development has entered the process industry. We assumed that industrial cases existed not only in our company but were also present in other companies. Evidence for this was obtained from the overwhelming response to a proposed session of the American Institute of Chemical Engineers in the spring of 2006 in Orlando, Florida, on “Sustainability in Practice,” which ultimately swelled into a four-session topical conference. So when we asked our peers in the process industry to provide written cases from their companies to serve as chapters in this book, they responded quickly. All of them had to write the cases at least partially in their spare time, but they were sufficiently motivated to do so. Obtaining permission to publish the case descriptions presented another hurdle, but that hurdle was also overcome. So what you find in this book are true industrial cases of novel processes or systems that contribute to sustainable development based on the “triple bottom line” or “triple P” dimensions of “people, planet, and profits.”1

1.2 SCOPE OF THE BOOK

To make the book as useful as possible, we obtained cases from a variety of:

Industries: oil and gas, bulk chemical, specialty chemical, material and mineral processingGlobal regions: Asia, Europe, and the United StatesSystems: industrial ecopark, regional development, domestic-industrial ecology, individual corporate operating sites

To the example cases we added methods and metrics that can be used by industry to assess processes as to sustainability. All examples are real industrial cases. Some of the processes are in the pilot-plant stage, but most have already been implemented at a commercial-scale capacity.

1.3 USE IN EDUCATION

The book can be used in many different academic educational programs and courses and in many different ways. Perhaps the first use is to motivate students to work on sustainable development, because it is a real business driver, as shown in the industrial cases. In undergraduate courses, the book can be used to provide students with real examples of industrial sustainable systems and processes. Chapters 12 and 14 illustrate the concept of industrial ecology with the closing of material cycles. A very simple and clear case on domestic wastewater used as feed for boiler feedwater production is described in Chapter 14. A further example, on by-product synergy, is provided in Chapter 6. Also, the translation of the high-level “triple P” dimensions into qualitative and quantitative methods and metrics to assess real processes and their life cycles are illustrated in the cases. In graduate-level courses, the book can be used as test cases and scenarios for the evaluation of theories and frameworks for sustainable development.

The benefit of incorporating all three dimensions of sustainable development (ecology, economy, and society) in solutions is highlighted by the examples provided in Chapters 3 to 6. For industrial ecology courses, Chapters 4 to 6 and 14 will be useful. The cases presented can be used to illustrate the practical use of the corresponding principles.

Courses on renewable energy can benefit from Chapters 7 to 9. Courses on process design can benefit from any of the industrial cases. In particular, the closing of material cycles is illustrated in Chapter 12, a case study from an anodizing company.

Courses on life-cycle assessment can use Chapter 8, based on an integrated biorefinery, and Chapter 14, a case on industrial symbiosis in wastewater management, where an end-of-cycle wastewater stream is upgraded to a feedstock for chemical processes. Cases throughout the book can be used to analyze the various emission types and emission reductions obtained by the synergy between a local society’s waste and the use of that waste by a company, compared to the choice of a conventional solution.

1.4 USE IN INDUSTRY

The book can be used by anyone in industry to convince others in a company that working on innovative processes and systems that contribute to sustainable development makes good business sense and to demonstrate that many other companies are already doing it. An excellent treatment of value added is presented in Chapter 6 using such an innovative process. The book can also be used to apply sustainable development metrics to rank existing and novel process alternatives for sustainability, and to give direction and guidance to process innovation, and small and medium-sized enterprise companies can use the very practical strategy provided to implement sustainable development in their companies. In addition, the book can be used to obtain specific ideas and insights on how to modify processes to direct them toward more sustainable deployment of technology within an industry.

1 The origins of “triple P” (or “3P”), encompassing “people, planet, and profits,” and “triple bottom line,” denoted as “TBL” or “3BL,” are described in the preface and are attributed to John Elkington in publications such as Cannibals with Forks: The Triple Bottom Line of 21st Century Business (Oxford, UK: Capstone, 1997).

Chapter 2

SUSTAINABILITY METRICS, INDICATORS, AND INDICES FOR THE PROCESS INDUSTRIES

JOSEPH B. POWELL

Shell Global Solutions, Houston, Texas

2.1 OVERVIEW AND SCOPE

This book is devoted to sustainability in practice, or how one translates the often vague and high-level concepts of sustainability into action. It has been said that a person can manage only that which can be measured and defined.1 How then do we define and measure sustainability? In the following review we look at broad definitions and indicators of sustainability, followed by a focus on a more specific subset of metrics and tools relevant to the process industries.

The emergence of sustainability science and engineering as a meta-discipline is described in a recent academic-center review (Mihelcic et al. 2003); a more in-depth review of sustainability metrics for the chemical and process industries may be found in the book Transforming Sustainability Strategy into Action (Beloff et al. 2005). Batterham (2006) presents a hierarchical perspective of sustainability for the practicing chemical engineer: from global objectives, through enterprise and corporate strategies, to individual work tasks. Practices and approaches recommended for use by the process industries are also available from chemical engineering institute working groups (AIChE 2000; ICheme 2002; Schuster 2007). A number of recent reviews of sustainability metrics, indicators, and frameworks with assessment of state-of-the-art implementation strategies have appeared from leaders in environmental agencies, nonprofit institutes, and universities. In this chapter we provide an overview of the current state of the art and best practices, with updates as to recent trends and assessments. An extensive reference list is provided for use in the implementation of sustainability frameworks and the use of metrics.