Industrial symbiosis and industrial waste management in wood-based industries

1 INTRODUCTION

It is important to know that the trash produced by one business might be a useful input for another. This strategy reduces waste production and encourages resource efficiency. For example, the waste produced by the sugar industry can be repurposed as raw materials for the production of alcohol, paper pulp, cement, and fertilizer. By implementing industrial symbiosis, industries can recycle waste materials, conserve resources, and reduce their overall resource consumption.In industrial development, the availability of raw materials is crucial. Wood, being one such raw material, faces competition from materials like plastic and steel. With rapid industrialization, the demand for fresh wood is increasing, posing challenges for wood-based industries to meet their needs. Pakistan, with limited wood resources and a forest area of about 4.4 million hectares, faces a shortage of wood and relies on imports to fulfill the rising demand.

This study focuses on conserving natural resources, reducing waste, and implementing industrial symbiosis to address these challenges. Specifically, the survey examines waste management in the Hayatabad Industrial Estate (HIE) and its potential for small-scale zonation under the principles of industrial symbiosis. The aim is to protect natural resources and minimize waste output in the industrial sector.

 1.1 SCALE OF THEIR WORK

In order to identify and evaluate groups of industries suitable for industrial symbiosis, a detailed survey was conducted on a selected group comprising four different industries: paper, match, chipboard, and mold. Each industry was closely observed, and data was collected through a questionnaire.

The total number of industries in this group was 25, consisting of 15 match, 2 paper, 6 chipboard, and 2 mold industries. Thirteen questionnaires were filled out by the selected industries. Additionally, 11 industries were personally observed for further verification.

2 TYPES OF PRODUCTS

Output varies and depends on the type of industry. Match industry produces match sticks and waste emissions. Waste is generated in the form of dust, wood-waste, missed sticks, paper, plastic-waste and wastewater.

The output of chipboard industry is dust and wood waste. Dust is collected through gravity chambers. This dust and wood-waste is re-used inside industry or given to community for burning purposes.

The output of paper mill industry is paper waste. Some of the waste is recycled and some of it is given to community they use it for fuel. The output of mold industry is paper waste. The waste is discarded or given to workers on payment. They use this as fuel.

Table 1. Selected group of industries for industrial symbiosis

S .NO	Industry	Number	Wood Demand (Tons / day)	Production capacity (tons/day)	Production capacity of Total Industries (tons/day)	Wood-waste Produced from Total Industries (tons/day)
1	Match	15	13-15	10-12	150-180	45-50
2	Chipboard	06	30-35	25-30	120-150	30-35
3	Paper	02	15-17	13-15	26-30	02-03
4	Mold	02	10-00	08-09	16-18	1.5-2 (paper-waste)

Match Industry                                                  Chipboard industry Paper industry                                            Mold industry

Figure 1: Manufacturing process of selected industries

2.1 Match Industry

 Match industries use poplar wood as basic raw material which is supplied from the surrounding districts include Charsadda and Mardan. The quantity of total raw-material required for industry was calculated as 18,029 Kg/day including wood, cardboard, wrapping paper, plastics, water and chemicals (phosphorous, Potash etc). The industry consumes considerable quantity of cardboard/paper for packing and wrapping purposes depends upon the production capacity of industry.Wood-waste is a good input for paper mill and chipboard industries but due to distance and transportation problems the waste is not shared to the wanted industries and is sold to community. Water is discharged as wastewater, containing chemicals.

2.2 Chipboard Industry

 Chipboard is an important wood-based industry as it is cheaper, denser and attained highest value in economical development (Particle board, 2016). The raw material required for chipboard manufacturing include wood, glue, laminating sheets, resins and chemicals. . Dust is collected through gravity chambers. This dust and wood-waste is re-used inside industry or given to community for burning purpose.

2.3 Paper Mill

There are two paper mills working in Hayatabad industrial estate. These industries are equipped with machinery to prepare paper from both sources such as wood and paper-waste respectively. Both industries consume 23586-27215 Kg (26-30 tons) wood per day. Paper mill needs excessive quantity of water (72 m3 /ton) for processing and generates wastewater consists of cellulose materials. The cellulose matter is recoverable and can be used as a basic input in mold/packing material industry.

2.4 Mold Industry

 Mold industry is important from environmental point of view as it recycles the paper mill waste. These industries prepare packing material for vegetables, fruits, eggs etc. These recycling plants have underground tanks with capacity to store 120- 150 m3 water. The wastewater of paper mill is used as a basic input in mold industry. The suspended load, which is basically cellulose, is settled, concentrated and shaped into packing material. The production capacity was calculated as 7257-8164 Kg/day (8-9 tons) (Fig. 2d). Waste is generated in the form of paper-waste at the rate of 1360-1814 Kg/ day (1.5-2 tons).

2.5 ENERGY CONSUMPTION

S. NO.	Industry type	Production capacity/per day (tons)	Water consumption/per day (m3)	Wastewater discharged/perday
1	Paper mill	13-15	2176-2614	1936.4-2489.5
2	Mold industry	8-9	16-20	120-150

S. No	Type	Electricity unit/day (kw)	Oil use/day (liter)	Water consumption/day (m3)	Fuel use/day (kg)
1	chipboard	466,000	1000	26.3	1100
2	Paper mill	110,000	1700	2614	800
3	match	573,330	1200	50	400
4	mold	55,000	700	ND	ND

3 INDUSTRIAL SYMBIOSIS IN WOOD-BASED INDUSTRIES

In chipboard industry, chip and flake manufacturing require more energy for cutting and chips formation. By using match sticks as raw material, the energy consumption by this machine can be reduced to low level. The average consumption in chipboard is 466,000 kW units of electricity, 1000 liter of oil and 1100 Kg fuel wood per day.

Paper mill consumes energy as at 110,000 units of electricity, 1700 liter oil, 2614 m3 water and fuel wood as 800 Kg/day. If the shredded wood-waste of 15 match industries is used as raw material in 6 chipboard plants and 2 paper mills then receiving industries will consume less energy by 10% saving in paper mill and 20% in chipboard industry.

Chipboard industries are located at a distance of 3-5 km away from match industries. One industry of chipboard needs 4.244 million for installation. If the 7 chipboard industries are brought at one site near to match industries then it will require at least Rs. 29 million. The transportation charges will be reduced at 35000 Rs perday. In this way the supply of waste wood from match industries will become easy that will reduce the demand of fresh wood and will benefit the industry at 10% saving of wood perday. If Paper mills are placed near match and mold industries it will cost Rs. 2 million. By reducing the transportation charges and supply of wastewood from match industries, it will fulfill 90-100% demand of paper mills for wood. The paper mills are located on same drain as mold industries and it is easy to collect the cellulose components for mold industries. But the problem is that mold industries are far apart (5-6 km) from paper mills and the wastewater containing cellulose components is diluted after mixing with industrial drain water.Therefore, much of cellulose content is lost which is not effective in packing manufacturing. By bringing mold industries near to paper mills, it will be helpful to share the waste-paper of packing material from mold industries to paper mills. The cost estimated for shifting of 2 mold industries is 3-4 million.

4 INDUSTRIAL SYMBIOSIS AS A WASTE MANAGEMENT APPROACH FOR HIE

Industrial symbiosisis an approach to waste management that involves the sharing and utilization of waste materials and by-products among different industries. The objective is to minimize waste generation and promote resource efficiency by creating mutually beneficial relationships between companies. In the context of Hayatabad Industrial Estate (HIE), the proposed model suggests reorganizing the estate into different zones or sectors based on the interdependencies among industries and their raw material requirements. By clustering industries with similar needs together, such as chipboard, paper, mold, match, and furniture industries, it becomes more cost-effective for them to relocate while reducing transportation costs for raw materials.

The chipboard industries are currently located 3-5 km away from match industries. If these seven chipboard industries are brought closer to the match industries, it would require an investment of at least Rs. 29 million. However, this relocation would reduce transportation charges by Rs. 35,000 per day and make the supply of waste wood from match industries easier. Consequently, the chipboard industries would benefit from a 10% daily wood saving. To place paper mills near match and mold industries at a cost of Rs. 2 million. This proximity would reduce transportation costs and enhance the supply of waste wood from match industries, thus fulfilling 90-100% of the paper mills’ wood demand. Additionally, the paper mills being located on the same drain as the mold industries would facilitate the collection of cellulose components for the molds. However, the challenge lies in the fact that mold industries are situated far apart (5-6 km) from the paper mills, and the wastewater containing cellulose components gets diluted after mixing with industrial drain water.

To summarize, the proposed model for HIE involves reorganizing the estate into zones based on industry interdependencies, with the aim of reducing waste, optimizing resource utilization, and minimizing transportation costs. By clustering industries with similar raw material requirements together, waste materials can be shared and utilized more efficiently, leading to economic and environmental benefits for the industries involved.

By clustering industries with similar needs together, such as chipboard, paper, mold, match, and furniture industries, transportation costs can be reduced, and waste materials can be shared and utilized more effectively. For example, relocating mold industries closer to paper mills would facilitate the sharing of waste paper for packing materials, reducing waste and improving resource utilization. The cost estimated for shifting two mold industries is estimated to be 3-4 million.

Additionally, the model identifies the benefits of grouping industries such as marbles, cemeent, ceramic, pharmaceutical, plastic, food, steel mill, metal, sugar mill, fertilizer, and beverages in separate zones based on their interdependencies. This arrangement would facilitate waste management, recycling, and the practice of industrial symbiosis. For instance, locating marble industries together would allow for the collection of sludge from a specific site, and the installation of a combined treatment plant could recycle their wastewater. The rich calcium carbonate content in marble waste can be utilized as a raw material in cement, washing powder, and tiles preparation.

By implementing this model, the Hayatabad Industrial Estate can achieve waste minimization, efficient resource utilization, and improved environmental sustainability. The proposed reorganization would significantly reduce waste generation and maximize the utilization of resources, contributing to a more sustainable and economically viable industrial ecosystem.

Figure2Industrial symbiosis model prepared for HIE forwaste management.

5CONCLUSION AND RECOMMENDATIONS

In conclusion, the existing industrial units within the selected group (match, paper, chipboard, and mold industries) generate significant amounts of wood and paper waste, which are currently underutilized and used as fuel. There is a need to explore recycling and reuse options to properly treat this waste and avoid its wastage. The arrangement and placement of industries within the industrial estate need improvement to foster industrial symbiosis, where interdependent industries are located in close proximity. Implementing the concept of industrial symbiosis in the estate would not only benefit the existing industries but also facilitate the installation of future industrial units, promoting waste minimization and effective waste management. Proper institutionalization and coordination of industrial symbiosis initiatives are crucial for its successful implementation.

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