1. DANMARK 5,5 mio
indbyggere
KALUNDBORG
COPENHAGEN
1

2. 1. Fact sheet for Kalundborg
1. 49.743 inhabitants, 603,7 km2
2. Industry and port leverage levelling a medium sized European city
3. Leading on biomass conversion/biorefinery (Inbicon.dk; Pyroneer.dk)
4. Leading on industrial collaboration since 1972 (www.symbiosis.dk)
5. Leading on Smart City Initiatives
6. Denmark’s largest CO2 emitter (ETS) 10% in 2011

3. Al Gore in Copenhagen 17 December 2009:
"Currently pollution has
zero value, we must put
a price on our pollution
i.e. put a price on carbon!"
Photo: Luc Hardy©

4. …waste, water and energy
Municipalities, cities and industry can and should make a difference both
within and exterior to the ETS:
Too much energy and too many resources are wasted.
We need to adopt the waste hierarchy fully and spur the inherent success
that is entailed within a proper use of the many resources that we do not
utilitise at its utmost today, that be either waste, power, heat, water or other
residues.
4

5. RENOVATE THE PAST OR INVEST IN THE FUTURE
Failure to comply with resource efficiency, integrated
planning and an optimate use of residues will either lead
to a sustained or even increased investment in extra
capacity and expansion of utility facilities (wwt;
combustion; CHP, even roads for transportation) based
on ’old’ technologies that will tie our hands even further,
rather than solving the climate and resource challenges
with future oriented solutions

6. -
But excessive resource consumption has a value,
We must include this value in our valorisation of the
overall production costs
The cheapest cost-cutting is not to lay people off but to
avert consuming resources that are expendable thereby
increasing competitiveness and net profits.
Introducing industrial symbiosis is also a means to a viable
reduction of uptakes of virgin materials thereby improving
our resource foot-print

7. “Industrial Symbiosis… should be standard procedure by 2020”
Environment Commissioner Potocnic
Green Week 27 May 2011, Photo Patrick Mascart
7

8. Industrial Symbiosis conceived in Kalundborg
4 R’s
Energy
Waste
Water

10. Kalundborg Industrial Symbiosis conceived in Kalundborg
- a Pioneer at a glance since 1972 driven by profit
A resource and environmental collaboration network consisting of 32
major bi- or trilateral commercial agreements (projects) composed
initially by 8 founding partners
Three categories of projects:
Exchange of energy: 9 Projects
Recycling of waste products: 11 Projects
Recycling of water: 12 Projects
Some of the annual results of the Symbiosis in Kalundborg are:
 272.000 tons CO2 emissions down since 1982
 3 mio m3 water saved through reuse and recycling
 150.000 tons NovoGro replaces traditional fertilizers
 150.000 tons yeast slurry replaced 1989-2011 traditional soy protein
in feed - now feedstock for biogas
 150.000 tons gypsom replaces imported nature gypsum (CaSO4)
reduced to 110.000 tons (reduced in line with decarbonisation)
 4 mio m3 ground water substituted by surface water
-> changes in regulatory framework (incl. higher carbon tax) could
increase figures adding the nexus between water and energy

11. http://www.symbiosis.dk/en/video

12. ISK 1972 – 2012 40
Cronology of Kalundborg Industrial Symbiosis
– a growth model

17. Water Projects - Mapping of water flows between Symbiosis industries
Gyproc
7
4462
Gyproc RGS 90
Lake Kalundborg Waste water 40
Utilties 59
Tissø treatment plant
24 886
1710 512
1349
2705
? 1464
Water from inluent
12
2,6
178
408
Novo Nordisk
Statoil 622
DONG Energy
?
ASV Novozymes
413 ? 272
?
59
Major vats 247
for reuse
All figures are from 2010, (1000 m3)
1672 Kalundborg Influent water from Statoils own pump station
Fjord
Tissø water Cooling water
Treated Tissø water Drainage water
Additional water (Spædevand) district heating
Steam Technical water
Sea water Waste water Potable water
Dionat Waste water Intern Bio-treatment

18. KALUNDBORG INDUSTRIAL SYMBIOSIS SYSTEM 2012
19 Sludge
Waste water
Farms The Municipality 1998
Lake treatment RGS 90
Tissø 1 Surface water 1961 of Kalundborg
27
Straw 2009 Purifica-
3 7 17 Waste water 1995
tion 24
Surface Heat of water Alko-
Inbicon 26 Steam water 1981 22 holic
2009 1973 Water Residue
25 Sea water 2007 10 Surface water 1987 2004 2006
31 30 Bioethanol
9 Steam 1982 29 Condensate
Lignin
2009 Novozymes
2010 11 Cooling DONG Energy
Statoil
32 water 1987
Asnæs Pyroneer
Refinery 32 Gasifier 2011
C5/C6 15 Gas 1992 Power Station Novo Nordisk
sugars
14 Tech.water 1991 8 Steam 1982
2010 13 Sulphur 1990
Fertilizer 2001 Re-use 6 Heat
1980/89
Fish farm 12 4
basin 20
Fertilizer 18 Drain water 1995 5 Yeast Biomass/
Fly
industry 2 21 Deionized water 2002
Fly ash slurry NovoGro
Ash
Gas 1979 1989-2011 1976
1999
1972 16 Gypsum 1993
Gyproc Recovery of nickel Cement Pig farms Farms
and vanadium industry
23 Waste gypsum The Symbiosis Institute
Kara/Noveren 1996

19. China's top legislature passed a law to promote circular economy on Friday at the closing
of the fourth session of the Standing Committee of the 11th National People's Congress
(NPC).
The draft law was ratified after its third reading, and President Hu Jintao signed it into law.
It will come into force on January 1, 2009. The aim of the law is to boost sustainable
development through energy saving and reduction of pollutant discharges.
Government departments will map out a system for recycling and improve energy-saving
and waster utilization standards. China Daily 2008

21. Danish Climate Commission 28 September 2010:
The answer is ”through wind and biomass”

22. BUT WHERE IS THE
GROWTH TO FINANCE
THIS?

23. Water scarcity – friend or foe?
Globally water is a scarce ressource, also in Kalundborg.
Projections foresee increased costs. Currently the consumption
of ground water in Western Zealand is estimated to exceed the
available capacity by more than 35% ref. Nature Agency. Water scarcity
could jeopardize future industrial growth but it could also spur
resource efficiency and growth

24. Can we afford all this?
E NEED A G AM E
W E NEED
CHA NGER – W IO SI S!
A L S Y MB
I NDUSTRI

25. IS 2.0

26. There is a clear nexus between water and energy
and we need to save both resources:
• Water needs energy in all the steps along the water value chain:
pumping water for supply and sanitation; delivery of irrigation water,
for food- and bio energy production, etc.
• The energy requirements to produce water is significant 586 kWh
electricity to treat 1 mio liters of water. As water is becoming more
scarce it is foreseen that water will be transported over longer
distances (ref. WssTP 2011)
• Clash between EU Directives: Conservative estimates predict
electricity increases of 60-100% over 15 years in order to meet new
EU Directive requirements, which conflicts with energy- and CO2
reduction targets. Alone in the UK energy consumption in the water
sector has doubled since 1990 as a result of the Urban Waste Water
Treatment Directive and Drinking Water Directive due to the required
additional treatment. Further increases are likely to result in ”pollution
displacement” from water bodies to the atmosphere (ref. WssTP2011)

27. Water and Energy nexus are also low-hanging fruits:
A -Heat recovery where heat from cooling using a heat exchanger can
offer significant energy savings with a return on investments for
industries down to a few months. Heat generated at industrial sites e.g.
from cooling can also be exchanged and used off-site such as district
heating as in Kalundborg
B Anaerobic biogas (CH4) production from industrial waste water is well
suited for industries discharging highly concentrated waste waters
(1,500 mg COD/l) (5MW gasifier) e.g. Novozymes 5MW
C Kalundborg is partner in PPP Flagship project ”E4WAter” where the
partner Dow Chemical’s site in NL re-uses daily 10 mio liters of
municipal household waste water as feed water for several plants. The
water is treated and used as feed water for cooling towers thereby
reducing waste water reduction by 38%, energy use by 60% and CO2
emissions saved 5,000 tons/year Source: WssTP Water and Energy, September 2011, p. 38
D Return on investments – pay back time is often rather short however
many industries tend to overlook the potential synergies embedded in
the coherent interdependent water-energy nexus.
Seen from a sector perspective water improvements have up to five
times longer pay back time than energy due to the cost of kWh saved is
higher than costs on each m3 water saved. However if the nexus is
taken into account there are major saving potentials in both
sectors to be made by introducing water reductions and recycling

28. Energy needs water for energy production (power
and renewables)
• In industries optimisation of the water cycle tends to imply energy
reduction when reusing water with low or high temperatures.
• Expected increases in energy prices impact water supply systems and
will foster industries shifting towards energy efficiency and energy
recovery, and IS is a helping hand
• It all requires for a shift in the way of thinking across society and
industry. We need innovations and changing of our mindsets to deviate
from ”business as usual” by:
• Integrating water and energy systems in our planning
• Assess environmental footprints together with economical
performances (”ESCOs on water” business plans)
• Systematically detect energy efficiency measures including
leackage reduction
• Exploit untapped energy potential in water systems included
embedded energy through resource recovery
• Recover other substances and materials in waste water such as
polymeers for down-stream biorefineries

29. Source: Regeringen, ”Vores Energi”, nov. 2011
2010 DK 22% wind power consumption
2020 DK 52% wind power by adding 2100 MW incl. scrapped capacity

30. Knowing how wind intermittancy affects us today
– and how about tomorrow?
df Source: EnergiNet.dk
• df

31. Smart City Kalundborg also
revolves around shifting
industry power loads within the IS
-
Manufacturing processes can
assist load shifting in a
Symbiotic Energy System
bringing down e.g. waste
water treatment costs and
avert additional CapEx
Shifting energy loads within
Industrial processes, which are
not 24/7 are potential for DER e.g.
• 9 mio m3 water
• 3 mio m3 is recycled
• 7 MW ozon facility never 24/7

32. - align spikes in power grid by use of (bio)gas or CH4

33. EIP Water – site – Kalundborg Symbiosis - Pivotal is cost cutting through resource
efficiency  sustained manufacturing in EU – 5 key challenges with the nexus:
A. Legal barriers as empediments to increased reduction of quantity
1. Water Services by official utilities require partnerships (financial models)
• Water leackages detected
• Water saving remedies and advisory services
2. Industries as ’local utilities’ supplying:
• water (treated above minimum threshold for recycling for diverse purposes);
• heated water/steam/ww (district heating, production steam replacing fossil)
• energy for power and heat (wwt->CH4)
3. Energy efficiency to the benefit of whom?
• Capacity in metric volumes reduced
• Empediment to growth of new and existing industries
• Changes in modalities/methods of WWT due to RES where CH4 is requested
an alternative to active sludge apply algae to lower COD – new biosolutions
• Increase focus on scarce resources vs virgin materials (e.g. phosphorus)
4. Energy and water management: Smart Grid deployment within utilities
• Water pumping e.g. 250 pumping stations and smart pumps
• Waste water treatment incl. ozonuous – time of delay for grid balancing
5. Industries strive to lower water consumption/reuse even further

34. Green Week 24-27 May 2011, Kalundborg Industrial Symbiosis
Environment Commissioner Potocnic &
Climate Commissioner Hedegaard
Photo Patrick Mascart
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35. Thank you for your attention!
Martin Andersen
andersen@kalundborg.dk
www.symbiosis.dk