Turning an industrial area into an eco industrial park: case study of harare

1. Turning Industrial Area into an
Eco –Industrial Park:
Case study of Harare
Presentation by
Taurai Mpaso R113641T
Supervisor : Eng K Mugwindiri

2. PROBLEM STATEMENT
Problems
More waste in land fills
Money lost in form of waste
Extensive use of virgin materials
Waste - loss of something valuable that occurs because too much of it
is being used or because it is being used in a way that is not necessary
or effective
(Merriamwebstardictionary.com)

3. Aim
•Assessment of Harare industrial sites
setup and practices to develop possible
industrial symbiosis connections.

4. OBJECTIVES
• To identify current eco-related activities
• To identify common inputs required, by products, wastes
produced and the potential major users of the by-products
and waste in the same industries
• To identify possible material exchange with the view of
improving energy efficiencies, recycling water and materials,
waste management and dematerialisation

5. ECO INDUSTRIAL PARKS
Resource (Material) Flow in Today’s Society Ideal Resource (Material) Flow

6. CASE STUDY FINDINGS
Industrial Composition
30%
12%
10%
32%
16%
MANUFACTURING PROCESSING RECYCLING SERVICE CONSTRUCTION
Chart Title

7. Current symbiotic practice
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
Never Rarely Often Always
The company physically change materials with other companies
The company re-use, recycle and reduce waste products and by- products
The company sell by products to
other company for re-use
The company re-use/reuse water

8. Water consumption
35%
41%
24%
LESS THAN 2CUBIC METERS MORE THA 2 BUT LESS THAN
7 CUBIC METERS
ABOVE 7 CUBIC METERS
Waste Generated
63%
17%
20%
solid waste fluid effluents other

9. Development of Prototype
Due to geographical location of the identified potential
members the best type was a Virtual Eco Industrial Park
The final model is a combination of two development
scenarios, it is a combination of existing organisational
relationships and Anchor tenant model. The models take the
following assumptions:
• Members chosen are willing to participate fully
• Technical feasibility
• Economic feasibility
• Portfolio feasibility

10. Stage one: Baseline Activities
Cement
industry
(Lafarge)
Fertiliser and
chemical industry
(ZimPhos)
Power Generation
(ZPC)
Capacity
450 000 tonnes per annum
Current substitute raw material use
0.18% fly ash and 9.6% for brick rubble.
Processes
103kg of coal to produce a tonne of cement
And this produce a tonne of CO2
Capacity
200 000 tonnes of fertilisers and
65 000 tonnes of phosphoric acid
Current outputs
Operating at 20% capacity
Process
325 000 tonnes of gypsum is produced
Deposited in 2 dumps
Capacity
50MW of electricity
Current
25MW of electricity
Process
16 250 tonnes fly ash
4 225 tonnes bottom ash
65 000-81 250 tonnes of coal

11. Stage two
•The stage identifies production practices and recycling
opportunities that can provide economic and
environmental benefits if implemented independently
by each member.
•For each major player identified possible methods of
limiting the pollution impacts of their production
methods are proposed.

12. Stage 3: Industrial Symbiosis
Key
Industry located in Msasa
Industry located in Granite site
Industry located in Southerton
Industry located in Workington
Cement
industry
(Lafarge)
Fertiliser and
chemical industry
(ZimPhos)
Power Generation
(ZPC)
Fly ash
11 250 tonnes
Gypsum
13 000 tonnes
CSA specification of fly ash
Type F : 8% CaO
Type CI : 8-20% CaO
Type CH : > 20% CaO
Road
Construction
Max 25% mass
ratio fly ash
Increase fly ash ratio
to 2.5% and
Gypsum composition
To 4%
Remaining
fly ash
Municipal
solid waste
(fuel in the kiln)
Effects of using MSW fuel
CO2 emissions reduced
avoids landfilling waste
reduces methane
emissions

13. Industries identified in Harare
MSASA GRANITE SITE SOUTHERTON WORKINGTON
Lafarge Cement,
Feedmix,
GMB,
Zimphos
Multimanufacuring
Firtst Plastics
Prime Sole
Gyproc
Delta-Coca cola
Art Corporation
National Tyre Service
PG industries
Pro- Plastics
Delta-Beer brew
Schewpess
Hunyani Papers
ZLT
Cairns
Savanna
BAT
Craster International
Cochraine
Brown Enginnering
Windmill
ZFC
Turnall
CAFCA
National Foods
Verspak
Dairiboard
Zimbabwe sugar refinery
Unilever
Cottco
Colcom
Zesa thermal power plant

14. Key
Industry located in Msasa
Industry located in Granite site
Industry located in Southerton
Industry located in Workington
Stage 4: New Members
Cement
industry
(Lafarge)
Fertiliser and
chemical industry
(ZimPhos)
Stock feeds
(Feedmix)
Rubber: Sole
manufacturing
(Prime Sole)
Rubber: tire
manufacture
(NTS)
Construction
industry
(PG Industries)
Paper Milling
(Hunyani Holdings)
Power Generation
(ZPC)
Sugar refinery
(Star Sugars)
Colour codesShapes representation
Major Members
New Members
By product exchange
Recycling
Fertiliser
(Windmill)
Fertiliser
(Windmill)
Food processing
(GMB)
Phosphoric acid
Sulphuric acid
Phosphate rock
Waste grain
Bagasse
Calcium
carbonate
Fly ash
Bottom
ash
Waste
tires
Road
Construction

15. Key
Industry located in Msasa
Industry located in Granite site
Industry located in Southerton
Industry located in Workington
Stage 5: Combined Symbiosis and Pollution prevention
Cement
industry
(Lafarge)
Fertiliser and
chemical industry
(ZimPhos)
Stock feeds
(Feedmix)Rubber: Sole
manufacturing
(Prime Sole)
Rubber: tire
manufacture
(NTS)
Construction
industry
(PG Industries)
Paper Milling
(Hunyani Holdings)
Power Generation
(ZPC)
Sugar refinery
(Star Sugars)
Colour codesShapes representation
Major Members
New Members
By product exchange
Recycling
Fertiliser
(Windmill)
Fertiliser
(ZFC)
Food processing
(GMB)
Phosphoric acid
Sulphuric acid
Phosphate rock
Waste grain
Bagasse
Calcium
carbonate
Fly ash
Bottom
ash
Waste
tires
Metal industry
(Craster International)
Heavy Vehicles
(Barzem)
Scrap
metal
Furniture
Clusters
Saw dust
Shavings
Used
paper Additional MembersWaste
Metal
dealer
Scrap
metal
Waste
Rubber
dealer
Used rubber
Waste
paper
dealer
CLEVELAND DAM
Supplementary water for Msasa
water treatment
chemicals
rubble
Road
Construction
Plaster board
Gyproc
gypsum
Fly
ash

16. Recommendations
Technological development
Members acquire technologies specifically to suit the network formulated
Development of administration centres
Formulated and financed by members from companies and interested
groups
Government Intervention
1. Legislation modification
2. Funding initiative
3. Spear heading Project
4. Resuscitation of transport network

17. Conclusion
Eco Industrial Parks are the way to go as it will
deal with 15%-20% of waste-material that will
end up in dumpsites

18. THANK YOU