Assessment of the Automobile Assembly Paint Process for Energy, Environmental, and Economic Improvement

A coat of paint adds considerable value to an automobile. In addition to consuming up to 60% of the energy needed by automobile assembly plants, however, the painting process also creates both economic and environmental impacts. This study investigated the degree of cost and environmental impact improvement that can be expected when modifications are considered for existing paint processes through heat integration. In order to accomplish this goal, a mathematical model was created to describe the energy use, costs, and environmental impacts from energy consumption in an automobile assembly painting facility. The model agrees with measured energy consumption data for process heating and electricity demand to within about 15% for one Michigan truck facility from which model input parameters were obtained. Thermal pinch analysis determined an energy conservation target of 58% of paint process energy demand. A heat exchanger network optimization study was conducted in order to determine how closely the network design could achieve this target. The resulting heat exchanger network design was profitable based on a discounted cash flow analysis and may achieve reductions in total corporate energy consumption of up to 16% if implemented corporatewide at a major automobile manufacturer.     

Industrial Wastes and By‐products as Alternative Fuels in Cement Plants: Evaluation of an Industrial Symbiosis Option

A ravenous fuel consumer, the cement industry may substitute fossil fuels by industrial wastes and by‐products, identifying the industry as a key example of industrial symbiosis (IS). Benefits from industrial waste alternative fuels (IWAFs) include safe disposal, fossil fuel cost savings, gate fees, and greenhouse gas credits. Poor IWAFs, (high moisture, ash and halogen content) bring higher gate fees, but lessen clinker production. Thermal rating and blower capacity constraints should be satisfied in such a case study of IS. Cement plants must comply with potentially tighter emission limits, compared to fossil fuel utilization, despite higher pollutant precursors in IWAFs. Emissions’ compliance, operational, and production implications are a few among several challenges when assessing multiple IWAF valorization as a symbiotic option from a systems’ perspective. A novel method is proposed to quantitatively assess critical trade‐offs. Species and energy transformations convey a rigorous picture of clinker level, kiln flue gas, and offgas volumes and lay the groundwork for screening, a priori selection, and process tuning. Necessary and sufficient compliance conditions and safety margins are presented in terms of process parameters and actual emissions’ data. Main challenges posed by high flue gas, high offgas volumes, high moisture, low heating value, increased nitrogen oxides emissions, and high halogen and metal content are quantified. As demonstrated in a case study of an actual 1.5 × 10⁶ tonnes per annum clinker plant in this paper, concurrent use of several IWAFs may increase clinker production, while satisfying operational constraints and maintaining compliance. The method may serve for devising IWAF preparation, or tuning mechanisms expanding IWAF valorization.     

Material Flow Optimization in By‐product Synergy Networks

By‐product synergy (BPS) is an industrial ecology practice that involves utilization of industrial by‐products as feedstocks for other industrial processes. A novel decision support tool is developed to analyze BPS networks that involve material processing and transport among regional clusters of companies. Mathematical programming techniques are used to determine the optimal network design and the material flows that minimize total cost or environmental impacts. This methodology is incorporated into a graphical software package called Eco‐Flow?. The tool has been applied to model and analyze available synergies in an existing BPS network centered in Kansas City, Missouri. A base case, which assumes no synergies, is compared with the optimal BPS solution found by Eco‐Flow?. The results for Kansas City suggest that when companies in the network cooperate to optimize the system profitability, up to $15 million per year of savings are possible. The findings also indicate that the BPS approach would result in 29% reduction in total cost, 25.8% reduction in average company cost, 30% reduction in carbon dioxide (CO₂) emissions, and 37% reduction in waste to landfill. The modeling approach is being extended to better represent the dynamics of industrial and ecological processes.     

城市废弃物资源化共生网络:概念、特征及体系解析

挖掘城市废弃物中有价值的资源,已经成为世界各国开展废弃物开发与管理的共同选择。产业共生是推动经济绿色发展和提高资源效率的战略工具,已经成为探讨废弃物资源化利用问题的重要视角。将产业共生理论引入城市废弃物资源化利用领域,提出城市废弃物资源化共生网络的概念,并将其典型特征概括为"四个统一",即价值网络与责任网络的统一,集聚共生与虚拟共生的统一,稳健型与脆弱性的统一以及自组织性与主体建构性的统一。借鉴超网络理论构建城市废弃物资源化共生网络体系的结构模型,并从共生单元、共生模式、共生界面和共生环境4个层面对该模型进行详细解析。城市废弃物资源化共生网络可分为核心网络和外围网络,两者之间存在全方位、多层次的合作机制。在城市废弃物资源化共生网络中,共生单元具有多层次性和多样性特征,它们之间存在着不同类型、效率各异的共生关系,推动共生模式向对称互惠一体化共生进化是破解城市废弃物资源化利用难题的关键;共生界面具有物质交换、能量传递、信息共享、知识传播及利益协调等多样化功能,而共生关系的进化以及共生界面功能发挥又依赖于优越的共生环境。此外,城市废弃物资源化共生网络有依托型、平等型、嵌套型和虚拟型等4种运作模式,国内典型案例分析表明这4种运作模式将长期并存。     

A Process Perspective on Industrial Symbiosis

It has been long recognized in the conceptual literature that industrial symbiosis requires a perspective that focuses on long‐term evolution. This has not yet been matched by adopting an adequate process‐oriented research methodology. This article provides the underpinnings for such a methodology, presents a developed methodology, event sequence analysis, and shows its added value through a set of research questions and an empirical example. It shows how the process perspective leads to asking new research questions as well as the uncovering of new insights about the emergence, evolution, and dissolution of symbiotic relationships and the institutional capacity required to build such relationships.     

Exploring the emergence of waste recovery and exchange in industrial clusters

Self-organized industrial symbiosis (IS) starts with one actor's decision to invest in a waste recovery plant and the other actors' decision to buy the recovered flow. Technical and institutional conditions of the cluster influence actors' decisions. This paper explores the emergence of IS collaborations in industrial clusters under different techno-economic conditions in the long term. We propose a mixed-integer linear programming model that incorporates costs and constraints associated with waste recovery and exchange to study actors' investment decisions and investigate shaped symbiotic exchanges under rising energy prices and limited electricity supply. The approach is implemented in Iran's Persian Gulf Mining and Metals Special Economic Zone as a case study. The results revealed that changes in internal or external condition simultaneously influence the industrial and waste recovery plants. For instance, increasing energy prices without raising product prices significantly decreased the production level of industrial plants and, consequently, heat recovery potential. Furthermore, the waste heat recovery plants' contribution to improving the cluster's economic and environmental performance was not the same. Electricity recovery from a power plant's waste heat can result in 55 PJ grid electricity intake reduction and 720 M€ cluster cash flow increase. Recovered cooling or electricity from the steelmaking plant waste heat was consumed internally rather than shaping IS. These model outcomes show its capability to study IS within the socio-technical structure of the cluster, not a standalone phenomenon. Implemented conceptualization offers a novel system-level approach, which could be adjusted to assess other industrial development strategies.     

Revealing the Environmental Advantages of Industrial Symbiosis in Wood‐Based Bioeconomy Networks: An Assessment From a Life Cycle Perspective

The German government has recently initiated funding schemes that incentivize strategies for wood‐based bioeconomy regions. Regional wood and chemical industries have been encouraged to act symbiotically, that is, share pilot plant facilities, couple processes where feasible, and cascade woody feedstock throughout their process networks. However, during the planning stages of these bioeconomy regions, options need to be assessed for sustainably integrating processes and energy integration between the various industries that produce bio‐based polymers and engineered wood products. The aim of this paper is to identify the environmental sustainability of industrial symbiosis for producing high‐value‐added, bio‐based products in the wood‐based bioeconomy region of Central Germany. An analysis was conducted of three possible future scenarios with varying degrees of symbiosis in the bioeconomy network. A life cycle assessment (LCA) approach was used to compare these three scenarios to a traditional fossil‐based production system. Eleven environmental impact categories were considered. The results show that, in most cases, the bioeconomy network outperformed the fossil‐based production system, mitigating environmental impacts by 25% to 130%.     

Industrial Recycling Networks as Starting Points for Broader Sustainability‐Oriented Cooperation?

Closing loops by intercompany recycling of by‐products is a core theme of industrial ecology (IE). This article considers whether industrial recycling networks or industrial symbiosis projects can be used as a starting point for much broader intercompany cooperation for sustainable development. Evidence presented is based on the results of an empirical investigation of the recycling network Styria in Austria, the recycling network Oldenburger Münsterland in Germany, and the manufacturing sector in Austria. Statistical analysis shows that the percentage of by‐products that are passed on to other companies for recycling purposes is not higher in member companies of the recycling networks than in the other companies of the manufacturing sector in Austria. In terms of cooperation, the relationships with the respective recycling partners are found to be very similar to regular customer relations. Furthermore, the companies of the recycling networks remain unaware of the network to which they belong. Instead, one of the main findings of this study is that intercompany recycling activities are regarded by the company representatives as bilateral market transactions, not as collaborative network activities. This has potentially significant implications for the use of industrial symbiosis networks as starting points for sustainability networks with broader cooperation toward sustainability. The findings raise interesting questions as to whether such broader cooperation might result from a conscious planning process or might emerge largely spontaneously as part of normal market coordination. In any case, intercompany recycling is clearly considered to be a very important field of collaborative action for sustainability in industry.     

Modeling and Optimization of a Coal‐Chemical Eco‐industrial System in China

China is coal dependent, and this situation will persist for a long time. Because more and more attention has been paid to energy security, the coal‐chemical industry has become a hot topic and has developed quickly. To improve efficiency and reduce emissions, industrial symbiosis (IS) can be introduced when establishing a coal‐chemical eco‐industrial system to achieve harmonious development between nature, industry, and society. In order to learn the influence of IS on the current industrial system, a model of coal‐chemical eco‐industrial systems was built. Using scenario optimization and linear programming, the behaviors and optimal industrial structures of the system under different scenario settings were compared, and industrial ecological analysis was performed. By comparative analysis, results showed that the greatest proportional decrease in the use of coal for coking was 15% compared with actual data for 2005. The resource‐productivity and eco‐productivity were 828 yuan/ton and 2.51, which are much higher than the values of 548 yuan/ton and 1.23 in 2005. The symbiosis index and the link density were found to be 0.675 and 1.67, compared with 0.588 and 0.94 in 2005. Research results showed that the coal‐chemical eco‐industrial system achieved a high value‐added utilization of coal and an updated product profile. Such systems will constitute the main direction and the inevitable trend of China's coal utilization in the future, which will reduce the harm to the environment from increased coal use and benefit the energy industry, the economy, and society.     

Final Energy Requirements of Steam for Use in Environmental Life Cycle Assessment

Steam is an important utility that is required in nearly all industrial process chains and hence needs to be modeled in life cycle assessment studies. Industrial steam systems are often very complex, with different steam flows varying in pressure and temperature and being transported over different distances. This should be accounted for when calculating the energy requirements related to steam supply. In this article, we constructed a generic model that allows estimating final energy requirements (i.e., gate‐to‐gate energy required to generate the steam) of various types of single‐fuel steam systems without turbines (i.e., open and closed cycles) with or without flash steam and expressed per tonne (t) of steam supplied to a process (before heat exchange) or per gigajoule (GJ) heat delivered within the process (after heat exchange, i.e., as useful energy). The model focuses on steam provided for covering process heat requirements and hence excludes cogeneration schemes with steam turbines. Based on the final energy requirements estimated with our generic model, primary energy requirements and environmental impacts can be calculated for various circumstances. Depending on the conditions chosen, final energy requirements for natural gas–fueled systems, as estimated in this study, are 2.71 to 3.44 GJ/t produced steam or 1.33 to 1.78 GJ/GJ delivered heat.     

Industrial symbiosis in the forestry sector: A case study in southern Brazil

Industrial symbiosis (IS) is an important concept in the field of industrial ecology that has disseminated worldwide as a practice to decrease the ecological impact of industrial processes through the exchange of by‐products and waste between units in a system. The forestry industry is the main economic activity in the region of Lages in southern Brazil. IS relationships have expanded with the use of waste material from wood processing and strengthened cooperation between companies in different sectors. The aims of this article were to: a) quantify the level of IS in the system, b) identify the benefits of IS for participants, and c) explain why the network further developed IS to the formation of an industrial ecosystem. A questionnaire was administered during visits to 24 forestry companies in order to analyze their products and processes, commercial relations, positive impacts, and local insertion. The industrial symbiosis indicator (ISI) was determined using waste stream data from the system to represent the level of symbiosis among the companies in this region. The results show that the companies participate in a symbiotic network, mainly involving the exchange of chips, bark, sawdust and shavings. In most cases, these exchanges occur between nearby companies, constituting an extensive industrial ecosystem.     

The Impact of Scale,Recycling Boundary,and Type of Waste on Symbiosis and Recycling

Innovative waste recycling through industrial processes such as industrial and urban symbiosis has long been practiced and recently received much attention in the field of industrial ecology, with researchers making efforts to identify key contributing factors to successful industrial symbiosis. By analyzing 88 sample recycling projects in 23 eco‐towns in Japan, this article focuses on the factors of project scale, recycling boundary, and types of waste in relationship to environmental benefits and operational performance. The results showed that larger eco‐towns achieved more savings of virgin materials and higher stability in operation. Large‐scale projects tended to locate closer to the users of recycled products than did small‐scale projects. For treating similar types of waste, projects producing recycled products for special users (e.g., feedstock to a blast furnace for iron production) tended to locate closer to the users than those not producing for special users. The type of waste had a strong effect on the savings of virgin materials and recycling boundaries, while local factors had significant impacts on operational performance. The results also showed that agglomeration did not significantly contribute to the environmental benefits or operational performance of eco‐town projects. Another finding was that national agencies were helpful for facilitating cross‐prefecture transportation and long‐distance transaction of wastes. Implications of the findings are also discussed.     

Genetic-evolutionary basis of symbiosis doctrine

The author presents the current notion of symbiosis as one of the main adaptation of an organism to changeable environment. Symbiosis is considered as a super organism genetic system within which there are different interactions (including mutualism and antagonism). Genetic integration of symbiotic partners can be realized as cross regulation of their genes, exchange of gene products (proteins, RNA), gene amplification and sometimes gene transfer between organisms. On the phenotypic level these processes result in signal interactions, integration of partner metabolic systems and development of symbiotic organs. Co-evolution is considered as an assemblage of micro- and macroevolution processes basing on pre-adaptations and proceeding under influence of different forms of natural selection (individual, frequency-depended and kin selection). Symbiosis can be compared with sexual process since both are the forms of organism integration characterized by different genetic mechanisms and evolutionary consequences. The genome evolution in symbiotic microorganisms can proceed by: 1) simplification of genome in obligate symbiosis (loss of genes that are necessary for independent existence, transfer of some genes to the host organism); 2) complication of genome in facultative symbiosis (increase in genome plasticity, structural and functional differentiation of genome into systems controlling free-living and symbiotic parts of life cycle). Most of symbiotic interactions are correlated to an increase in genetic plasticity of an organism that can lead to evolutionary saltations and origin of new forms of life.     

Assessment of Trading Partners for China's Rare Earth Exports Using a Decision Analytic Approach

Chinese rare earth export policies currently result in accelerating its depletion. Thus adopting an optimal export trade selection strategy is crucial to determining and ultimately identifying the ideal trading partners. This paper introduces a multi-attribute decision-making methodology which is then used to select the optimal trading partner. In the method, an evaluation criteria system is established to assess the seven top trading partners based on three dimensions: political relationships, economic benefits and industrial security. Specifically, a simple additive weighing model derived from an additive utility function is utilized to calculate, rank and select alternatives. Results show that Japan would be the optimal trading partner for Chinese rare earths. The criteria evaluation method of trading partners for China''s rare earth exports provides the Chinese government with a tool to enhance rare earth industrial policies.     

“Uncovering” Industrial Symbiosis

Since 1989, efforts to understand the nature of interfirm resource sharing in the form of industrial symbiosis and to replicate in a deliberate way what was largely self‐organizing in Kalundborg, Denmark have followed many paths, some with much success and some with very little. This article provides a historical view of the motivations and means for pursuing industrial symbiosis—defined to include physical exchanges of materials, energy, water, and by‐products among diversified clusters of firms. It finds that “uncovering” existing symbioses has led to more sustainable industrial development than attempts to design and build eco‐industrial parks incorporating physical exchanges. By examining 15 proposed projects brought to national and international attention by the U.S. President's Council on Sustainable Development beginning in the early 1990s, and contrasting these with another 12 projects observed to share more elements of self‐organization, recommendations are offered to stimulate the identification and uncovering of already existing “kernels” of symbiosis. In addition, policies and practices are suggested to identify early‐stage precursors of potentially larger symbioses that can be nurtured and developed further. The article concludes that environmentally and economically desirable symbiotic exchanges are all around us and now we must shift our gaze to find and foster them.     

Reductions in complexity of mitochondrial genomes in lichen‐forming fungi shed light on genome architecture of obligate symbioses

Symbioses among co‐evolving taxa are often marked by genome reductions such as a loss of protein‐coding genes in at least one of the partners as a means of reducing redundancy or intergenomic conflict. To explore this phenomenon in an iconic yet under‐studied group of obligate symbiotic organisms, mitochondrial genomes of 22 newly sequenced and annotated species of lichenized fungi were compared to 167 mitochondrial genomes of nonlichenized fungi. Our results demonstrate the first broad‐scale loss of atp9 from mitochondria of lichenized fungi. Despite key functions in mitochondrial energy production, we show that atp9 has been independently lost in three different lineages spanning 10 of the 22 studied species. A search for predicted, functional copies of atp9 among genomes of other symbionts involved in each lichen revealed the full‐length, presumably functional copies of atp9 in either the photosynthetic algal partner or in other symbiotic fungi in all 10 instances. Together, these data yield evidence of an obligate symbiotic relationship in which core genomic processes have been streamlined, likely due to co‐evolution.     

Acoustic sensing and signal processing techniques for monitoring milk fouling cleaning operations

Large resource investments are necessary in order to minimize the limiting problems arising from food industrial intensive productivity. One of the most challenging concerns is the cleaning status uncertainty among heat transfer areas in dairy heat exchangers, since the effectiveness of this process cannot be easily validated. The present study aimed to develop a low‐power ultrasound sensing method for monitoring the removal of milk fouling deposits along cleaning processes inside an experimental plate heat exchanger structure, connected to a milk piping unit. For that purpose, signal processing, namely acoustic feature extraction, over different wave patterns combined with artificial neural network techniques was used. Measurements were taken in pulse‐echo mode with a handmade 4 MHz ultrasound transducer. While fouling deposits having initial average thickness values of 250 μm (34.5 ± 4.5 mg/cm²) were removed, the acoustic transmissivity increased. Results showed that the signal features follow the expected trends in both, clean and fouled cases, within right guess detection accuracies above 80%. Therefore, when calibrated well, this could be a very sensitive and noninvasive technique for material characterization, as well as a suitable validation method for industrial cleaning cycle operation optimization that could significantly reduce the associated costs.     

Interaction intimacy affects structure and coevolutionary dynamics in mutualistic networks

The structure of mutualistic networks provides clues to processes shaping biodiversity [1-10]. Among them, interaction intimacy, the degree of biological association between partners, leads to differences in specialization patterns [4, 11] and might affect network organization [12]. Here, we investigated potential consequences of interaction intimacy for the structure and coevolution of mutualistic networks. From observed processes of selection on mutualistic interactions, it is expected that symbiotic interactions (high-interaction intimacy) will form species-poor networks characterized by compartmentalization [12, 13], whereas nonsymbiotic interactions (low intimacy) will lead to species-rich, nested networks in which there is a core of generalists and specialists often interact with generalists [3, 5, 7, 12, 14]. We demonstrated an association between interaction intimacy and structure in 19 ant-plant mutualistic networks. Through numerical simulations, we found that network structure of different forms of mutualism affects evolutionary change in distinct ways. Change in one species affects primarily one mutualistic partner in symbiotic interactions but might affect multiple partners in nonsymbiotic interactions. We hypothesize that coevolution in symbiotic interactions is characterized by frequent reciprocal changes between few partners, but coevolution in nonsymbiotic networks might show rare bursts of changes in which many species respond to evolutionary changes in a single species.     

Levels of Institutional Capacity and Actor Expectations about Industrial Symbiosis

One assumption underlying the work on industrial symbiosis (IS) is that certain social conditions must be fulfilled in order for firms to develop symbiotic linkages. In this article we add depth to this insight by using institutional capacity as an underlying concept for these conditions, and we propose that such capacity influences IS by altering the opportunity set of actors. We then test the assumption on a dataset of 233 projects aiming to develop eco‐industrial parks. We find that the link between institutional capacity and the opportunities for symbiotic linkages perceived by actors is not always present and is more complicated than has been recognized thus far. We discuss potential alternative ways in which institutional capacity might influence IS and present ideas for future research to shed light on this important relationship.     

INTERGENOMIC EPISTASIS AND COEVOLUTIONARY CONSTRAINT IN PLANTS AND RHIZOBIA

Studying how the fitness benefits of mutualism differ among a wide range of partner genotypes, and at multiple spatial scales, can shed light on the processes that maintain mutualism and structure coevolutionary interactions. Using legumes and rhizobia from three natural populations, I studied the symbiotic fitness benefits for both partners in 108 plant maternal family by rhizobium strain combinations. Genotype‐by‐genotype (G × G) interactions among local genotypes and among partner populations determined, in part, the benefits of mutualism for both partners; for example, the fitness effects of particular rhizobium strains ranged from uncooperative to mutualistic depending on the plant family. Correlations between plant and rhizobium fitness benefits suggest a trade off, and therefore a potential conflict, between the interests of the two partners. These results suggest that legume–rhizobium mutualisms are dynamic at multiple spatial scales, and that strictly additive models of mutualism benefits may ignore dynamics potentially important to both the maintenance of genetic variation and the generation of geographic patterns in coevolutionary interactions.