2. BUILDING A NEW ECONOMY:
CREATING VALUE FROM WASTE
Professor Steve Halls
Sohar University
Sultanate of the Oman
3. Context for Industrial Transformation?
• The price of oil (and gas) is increasing (and it has been
predicted to rise to US$ 100/barrel by the end of 2012 and
over US$200/barrel by 2020)
• It is now widely agreed that “Peak Oil” has been reached (or
will do so in the next 2 – 5 years)
• It is necessary for industry, governments and consumers to
realize that to ensure the provision of manufactured
products; using fossil fuels without causing inflationary
pressures on the economy - it will be necessary to develop
alternatives to fossil fuels, so that economic development
can be maintained.
• Additionally by switching to these alternatives valuable fossil
fuels can be allocated to priority areas, where no
substitution is economically viable.
3
4. The Challenge
• In Sohar and Al-Batinah as whole, industrial growth, is a vital
factor for economic improvement, raising the quality of life,
and employment generation.
• However, due to the rapid expansion of Sohar, in particular
the port area and associated FreeZone, there is very real
probability of significant increase in waste production as a
result
• How can this be managed in an environmentally friendly
manner?
Disposal or transformation?
• Can wastes be transformed to produce products and
materials that were previously made using oil or gas?
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5. What is waste?
5
Something we do not
want and we throw it
away!
But we have used
materials and energy
in producing it!
13. Integrated Resource Recovery (IR2) System
Coffee
Plantation
Organic Fertilizer
Water
Natural Pesticide
Water &
“Waste”
Mushrooms
Earthworms
Human Consumption
Chickens, Cattle, etc.
Manure
Biogas = energy
Horticulture Beans
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14. ASNAES
POWER
STATION
(1500 MW)
Uses almost 90%
of primary energy
content of coal
ELECTRICAL
ENERGY
(40%)
80,000 tons/yr of
gypsum (recovered from
the station’s sulphur dioxide
scrubber)
170,000 tons/yr of flyash
and clinker (residues from
coal burning)
HEAT
(STEAM -
60%)
DISTRICT
HEATING
SYSTEM
STATOIL REFINERY
(40% of its needs
for tank &
pipe heating)
NOVO NORDISK
- Pharmaceutical &
enzyme manufacturer
ETHANE &
METHANE
BY-PRODUCTS
FERTILIZERSLUDGE
FISH-
PONDS
GYPROC
- A company
producing wallboards
CONSTRUCTION
& ROAD BUILDING
225,000 tons/yr
=19,000 tons of oil
14,000 tons/yr
215,000 tons/yr
EXCESS
HEAT
SLUDGE
ENERGY FOR DRYING
OVENS
KALUNDBORG INDUSTRIAL ECOSYSTEM, DENMARK 14
16. Example of Steel slag wastes ‘new’ products and use
16
Slow-cooled
slag (lumpy)
Road (surface, base, filler),
railway ballast
Aggregate for concrete
Harbour construction material
Ground-improving material
(for deep seat)
Cobblestone
Cement clinker material
Quenched slag
(granulated slag)
Portland and BF cement (cement mix)
Cement clinker material
Concrete admixture
Lightweight porous concrete (ALC)
Improvement of soft ground and
sea-bottom sludge (surface and deep seat)
Fine aggregate for concrete and asphalt
Semi-quenched slag
(expanded slag)
Aggregate for lightweight
concrete
Lightweight backfill,
reclamation material
Other (heat insulation)
Calcium silicate fertilizer
Mineral wool
Other (glass, tile, roof-tile, etc.)
Stabilization of subgrade and subbase courses,
filler course
Calcium silicate fertilizer
Harbour construction material
(lightweight backfill)
Civil ensineering material (lightweight backfill)
Other (ceramic material)
23. اإلتجاه ‘Kwinana Industrial Complex’
23
10 km
Note: Hope Valley area
will be home to
Latitude 32 the largest
eco-industrial/IR2 park
in the Southern
hemisphere
7 km
From Sohar
26. Kwinana Industrial Complex, WesternAustralia
26
• Established since early 1950’s, home to heavy process
industries and their suppliers of products and services
• Currently 10 km coastal strip
• Adjacent to Cockburn Sound
Deep water port facilities
Sensitive marine environment
• Surrounded by Cockburn, Kwinana and Rockingham
communities
• Southern end of the Perth Metro Area
~ 1.5 million inhabitants
Drought affected
28. 28
Kwinana Industrial Integration in 2010
INDUSTRIES THAT SERVICE MANY
INDUSTRIES*
CBI CONSTRUCTORS: FABRICATION, CONSTRUCTION
FREMANTLE PORTAUTHORITY: PORT FACILITIES
TRANSFIELD SMP:FABRICATION, CONSTRUCTION
WATER CORPORATION: WATER SUPPLY, SEWAGE
TREATMENT
KWINANA POWER STATION & EDISON MISSION:ELECTRICITY
SULPHURIC
ACID
WESFARMERS
CSBP
FERTILIZERS
AMMONIA
AMMONIUM NITRATE
SODIUM CYANIDE
CHLOR-ALKALI
CHLORINE &
CAUSTIC SODA
BP REFINERY
OIL PRODUCTS WASTE
GASES
BOC GASES
OXYGEN NITROGEN
HYDROGEN
WMC NICKEL
REFINERY
NICKEL
AIR LIQUIDE
OXYGEN NITROGEN
ARGON
CARBON DIOXIDE
TIWEST
PIGMENT
PLANT
TITANIUM DIOXIDE
NU-FARM/
COOGEE CHEM.
CHLOR-ALKALI
CHLORINE &
CAUSTIC SODA
CAUSTIC
SODA
CAUSTIC
SODA
AMMONIUM SULPHATE
SULPHUR
HYDROGEN
NITROGEN
HYDROGEN
LPG
COOGEE
CHEMICALS
INORGANIC CHEMICALS
TANK TERMINALLING
ARGON
CARBON DIOXIDE
NITROGEN
CARBON
DIOXIDE
LIME
LUBE OIL
OXYGEN
OXYGEN
FLOCCULANT
AVENTIS CROP
SCIENCES
AGRICULTURAL
CHEMICALS
GASOLINE
COMPONENTS
CHEMICALS
GENERAL
SUMMIT
FERTILIZERS
FERTILIZERS
NITROGEN
OXYGEN
EDISON
MISSION
ENERGY
ELECTRICITY
CAUSTIC
SODA
OXYGENNITROGEN
NITROGEN
AMMONIUM CHLORIDE
COPPER
SULPHATE
GRANULATED PRODUCTS
HYDROCHLORIC
ACID
ALCOA WORLD
ALUMINA
ALUMINA
COCKBURN
CEMENT
CEMENT & LIME
AUST. FUSED
MATERIALS
FUSED ALUMINA
FUSED ZIRCON
ALUMINA
LIME
SHINAGAWA
THERMAL
CERAMICS
REFRACTORIES
FUSED
ALUMINA
SILICA
FUME
WESFARMERS
LPG
PROPANE BUTANE
CIBA
SPECIALTY
CHEMICALS
FLOCCULANT
MILLENNIUM
PERFORMANCE
CHEMICALS
HIGH PURITY ZIRCON
POWDERS
SODIUM
SILICATE
SODIUM SILICATE
SULPHUR
SODIUM
SILICATE
STEAM
FUEL
GAS
AMMONIA
SULPHURIC
ACID
CHLORINE
KERO-
SENESCARBON
DIOXIDE
CARBON
DIOXIDE
CARBON
DIOXIDE
MOLTEN
SULPHUR
AMMONIA
SULPHUR
NITROGEN
HYDROCHLORIC ACID
SULPHURIC ACID
CO-OPERATIVE
BULK
HANDLING
GRAIN STORAGE
SHIP LOADING
NATURAL
GAS
HYDROCHLORIC ACID
NITROGEN
STEAM
SODIUM
ALUMINATE
SULPHURIC
ACID
CAUSTIC
SODA
HYDROCHLORIC
ACID
NITROGEN
ALUMINA
CAUSTIC
SODA
SODIUM
HYPOCHLORITE
NUFARM
LIMITED
PESTICIDES
CAUSTIC SODA
PESTICIDES
AMMONIA
ONE STEEL
MARKET MILLS
PATIO TUBING
OXYGEN
DIESEL
OILS
CHLORINE
LIME
DIESEL
OILS
TYCO WATER
STEEL PIPES
CEMENT
DIESEL OILS
LUBE OILS
PROPANE
OXYGEN
NITROGEN
HYDROGEN
CARBON DIOXIDE
LPG
SULPHURIC
ACID
HYDROGEN
SULPHUR
KWINANA
POWER
STATION
ELECTRICITY
TRANSFIELD
SMP
FABRICATION
CONSTRUCTION
NITROGEN
OXYGEN LPG
STEEL
PRODUCT
HYDROCHLORIC ACID
CAUSTIC SODA
AMMONIA
SULPHURIC ACID
HYDROGEN
WAXES
CARBON
DIOXIDE
CONDENSATE
LUBE OIL
NITROGEN
NITROGEN
AMMONIUM SULPHATE
GRANULATED PRODUCTS
SULPHUR
COPPER SULPHATE
FERROUS SULPHATE
SULPHURIC ACID
SULPHURIC
ACID
STEAM
WAXES
CARBON DIOXIDE
DEMINERALISED WATER
CAUSTIC SODA
CAUSTIC SODA
29. Outcome
• More jobs – now and future
• More economic resilience
• More amenities
• New products
• Reduced operating costs
• Less waste and pollution
• Happier local communities
• A cleaner and better life for all!
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30. Needs
• More general and specific education to meet demand
• On-going R&D to take novel waste streams and transform
into value-added products
• Environmental monitoring
• Innovative permitting (i.e. Bubble approach – whole
industrial estate)
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31. Latitude 32 - an IR2-based Industrial complex
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• Discrete setting where companies locate for maximum
resource recovery efficiency
A community of businesses that cooperate with each other
and with the local community to efficiently share waste
resources (information, materials, energy, water,
infrastructure and natural habitat), leading to economic
gains, gains in environmental quality and equitable
enhancement of human resources for the business and the
local community
Embedded in regional waste exchange networks, or eco-
industrial networks
32. Latitude 32 - an IR2-based Industrial complex
32
• Resource Exchange
Networks
Eco-Efficiency at each facility
Resource Recovery and
Reuse, enhanced through
Industrial clustering
Supportive infrastructure
Eco-services provider
• Park Design and
Management
Integration into Natural
Ecosystems
Green Facilities Design
Environmental Management
System for park management
33. The Opportunity
• Globally there is an urgent need to develop and deploy
technologies, which allows waste to be transformed into
valuable products - e.g. fertilizers; construction materials;
industrial chemicals and materials etc... Where possible
the generation of energy and protect the environment and
create employment opportunities at the same time.
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34. Anew industrial model - Products from Wastes
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New Business and
Products from Wastes
Nutrient
Recovery &
Augmentation
New Materials
Composite
Materials
(Organic and
inorganic)
Biofuels &
Lubricants
Water Reuse and
Recovery
Bioplastics
Biofilms &
Biomembranes
Building
Materials
35. IR2 – Purpose &Aim
• Integrated Resource Recovery (IR2) produces
efficient transformation of wastes and can be used
to generate energy - these wastes will become
essential requirements for industries in the future
given the imperative of sustainable development.
• The aim of IR2 is to develop an industrial system,
which prevents pollution and enhances employment
opportunities, income and industry sustainability
from wastes.
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36. IR2 - Principle and Outcome
• The ‘waste’, which provides jobs and income through
producing a valuable product, in effect, becomes a
‘resource’.
• The major focus of this approach is to maximise the
utilisation of waste steams and produce valuable by
products.
• This is a systems (i.e. holistic) approach with a high degree
of reliability and flexibility, which presents sustainability
options for industries to adapt to their needs depending on
circumstances.
• IR2 leads to robust, resilient, healthy ecosystems whilst
meeting the needs of people and supports our environment.
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37. Turning Waste into Business Opportunities
37
• Critical Assets on sustainable IR2 agenda
– Access to Land (e.g. Sohar Freezone)
– Good R&D and education (e.g. Sohar University)
– Incubator and Enterprise creation (e.g. Sohar
University)
– Business opportunities through
• Eco-Efficiency: smarter operations
• Industrial Ecology: better collaboration
• Innovation: leaner and cleaner products and services
• IR2: resource efficiency, material substitution, zero
waste
38. Benefits of IR2
• Removes an environmental hazard
• No cost for waste disposal
• Creates employment opportunities
• Can be started as small-scale and enlarged using modular low cost
technologies
• Low infrastructure requirements (needs access to non-potable water,
electricity, land, labour and easy transport access)
• Low to medium skill requirement, workers can be easily trained
• Management skills - same as other businesses but need to focus on
marketing/selling in early stages
• High level innovation opportunities to ‘generate’ new products or
materials in novel ways
• Cost-competitive with conventional industrial processes
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39. IR2 - Industries to benefit
• A number of industries (where wastes are produced) are
potential beneficiaries.
Aquaculture
Chemical
Horticulture and Viticulture
Livestock systems
Meat and food processing industries
Metal industries
Mining
Municipal Governments
Oil & Gas
Pasture and Crop Industries
Ports
Wastewater and sewage treatment plants
Etc…
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40. Barriers/Limitations
• Poorly defined and limited number of markets (at present)
• Consumer lack of awareness
• Regulator ‘unfamiliarity’ of technologies
• Competition from conventional products – no price point
differential (at present)
• Competition for land
• Little experience in work force
• Lack of education and training providers – formal and
informal
• Technical issues – durability and breakdown
• Cheap energy (watch this space closely!)
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41. IR2 Strategy
41
• Objectives
Develop integrated technology systems to treat waste streams
suitable for adoption at enterprise based business levels and
regional scale operator levels.
Mesh industrial production technologies with technologies
developed for processing waste streams
• Outcomes
Sustainable growth and increase in regional economies
Increase in company profits adding to GDP and creating new
jobs and enterprises
Easily adopted by SMEs and large enterprises
Reduced environmental impact
42. Recommendations
To overcome the previously mentioned challenges
stakeholders need to play different roles in the
industrialization process of IR2 systems.
Governments
Companies
Retail and business consumers
NGOs and public authorities option of IR2 -based
products will be hard to accomplish.
Universities – Education, R&D, Incubation and
Enterprise creation
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43. Recommendations
The most effective measures to induce a significant impact
of IR2-based production on all industries are:
Stimulate and fund needs-based research and technology
development by Universities in conjunction with industry
Create new markets for businesses to support IR2-based products
and encourage competition
Set up public-private partnerships to initiate private sector
investments and reduce the delay between product development
and commercialization
Identify potential growth and impact areas for key industries and
provide them with incentives to achieve specified targets, such as
CO2 equivalents reduction
Inform the public that IR2-based products are a realistic supplement
to fossil-based products but that they cannot mitigate the rising
demand for fossil fuels
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44. Summary
● There is a unique opportunity to bring about significant
financial and job impacts to the Omani economy, target
industries and enterprises of all sizes, creating jobs,
generating profit whilst sustainably recycling precious
resources and protecting the environment.
● Thus, by adopting a proactive, collaborative approach to
R&D, education, innovation, enterprise and employment
the creation of a new industry that has enormous
potential not only in Oman but also Gulf States can be
achieved!
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