Private investors

Study on "Industry 4.0 in Sustainable Industrial Areas in Emerging and Developing Countries"

Study on "Industry 4.0 in Sustainable Industrial Areas in Emerging and Developing Countries"
Case Study

The study “Industry 4.0 in Sustainable Industrial Areas in Emerging and Developing Countries - Applicability of Technologies and the Role of the Park Management“ has been developed by the Sustainable Industrial Area Working Group (SIA WG) and the Provadis University (Industrial Park Höchst).

 

Why SIA and Industry 4.0?

 

The SIA WG aims at generating expertise and bringing in new SIA relevant topics. Therefore, it has been seeking for opportunities to integrate the topic Industry 4.0 into their work in industrial areas.

 

What is the study all about?

 

The study is a small scale, practice oriented study on Industry 4.0. The study describes how Industry 4.0 may be used to foster sustainability and to enhance the sustainable performance of industrial areas in developing and emerging countries. Furthermore, the status quo of Industry 4.0 implementation in 6 industrial areas in China, Egypt and India is described, using the Industrial Park Höchst as a benchmark. An overall impression with regard to the readiness of the analyzed industrial areas for Industry 4.0 is also shared within the study.

 

Key findings of the study

 

  • Focusing on the park management of industrial areas, the highest potential of Industry 4.0 applications is seen in the fields of energy management, waste management and logistics.
  • The park management is a catalyst for enhancing Industry 4.0 related technologies and business trends.
  • Next to the need of improving technical expertise and innovation capacity, a national and site-specific roadmap for Industry 4.0 is needed.
  • One core challenge is establishing capacity building initiatives of employees to gain digital literacy.

Characteristics

Phase of intervention
Introducing SIA, Designing SIA, Operating SIA

Level of intervention
Park management

Target groups
Industrial area management and operator, Policy makers, Private investors

Regions
Global

Sustainability Calculator for Industrial Areas

Sustainability Calculator for Industrial Areas
Tool

The Sustainability Calculator for Industrial Areas has been designed to guide the decision making of developers and managers of Industrial Areas (IA), who want to improve environmental and social impacts of their IA, increase their competitiveness in international markets and attract new investors and clients by integrating profitable voluntary measures into the design and management of their IA. The results generated by this tool allow estimating the potential economic benefits of voluntary investments into improving the sustainability of a IA. Additionally, they visualize the impact of potential investments on the sustainability of an IA, generating a diagram for the user that assists in identifying voluntary measures that impact positively on the sustainability of your area while simultaneously generating profits.
The calculator offers measures that can be applied to both new and existing IAs that wish to improve their performance. The tool is embedded in a web page with further information re Sustainable Industrial Areas, Testimonials from other industrial zone developers and managers re the benefits they were able to reap by investing in specific sustainability measures, and contact information for international and local experts.

Main features and components

The Sustainability Calculator itself asks developers or managers of industrial zones to answer about 100 questions re the status quo and/or planning re a specific industrial area, all of them requiring only information readily available to developers and managers of industrial zones, such as location, size, number of companies located or to be located in your area, if the area will be focused on attracting companies from a specific sector or will be open to companies regardless of the sector they belong to, cost for core and shell construction, planned total energy consumption, distance to the nearest community, etc. All captured data is stored and processed anonymously. After finishing the questionnaire, the user can generate a pdf with his/her results for his/her own use or as initial information when contacting one of the specialists enlisted in the “contact” section of this webpage. Experts listed in the “contact” section of the webpage will be able to support the user in concretizing sustainable investment opportunities identified through the calculator. The tool is available in English and Spanish, and its use is free of cost.

Implementation / work steps

Answering all questions included in the Sustainability Calculator takes about 20-45 minutes.

Requirements

Availability of basic data re a specific industrial zone (see above).

Lessons learnt

There is a substantial number of sustainability measures which will probably generate an economic benefit for the developer/manager of industrial areas in the region. However, advanced measures (e.g. industrial symbiosis) require a level of coordination and trust between developers/managers and companies located or to be located in the industrial area that may be difficult to achieve in the region in the short and medium term.

Output

Based on data captured for Mexico and Costa Rica and the information provided by the user re the status quo of a specific industrial area, the Sustainability Calculator generates a diagram that indicates on the x-axis an estimate of the potential economic benefit of investments in specific sustainability measures, and on the y-axis an estimate of the potential impact on the sustainability of the industrial area of each of these sustainability measures. For each measure, a box that pops up when clicking on the point that visualizes the measure in the diagram, includes further information on what exactly can be done, links to websites with further information, and testimonials of developers or managers of industrial areas around the globe that have successfully invested in this specific measure.

Characteristics

Phase of intervention
Designing SIA, Master planning, Retrofitting, Technical infrastructure, Operating SIA, Management

Level of intervention
Park management, Planning level

Themes
Economic Viability & Marketing, Management, Technical infrastructure

Target groups
Industrial area management and operator, Local and international consultants and advisors, Private investors

Networks & local partners
The Mexican Association of Industrial Parks (AMPIP), IN SITE BAVARIA

Countries
Costa Rica, Mexico

Regions
Latin America and the Caribbean

GIZ project
COPLAN – Cooperation Platform Northern Latin America II

Duration
20-45 minutes

Complexity
medium

Related tools
Climate Expert

Further information

Useful links
http://www.sustainability-calculator.com

Site Assessment

Site Assessment
Tool

For siting of industries economic factors, such as availability of raw materials, market for finished product, transportation networks, water supply, electricity, labour availability etc., the environmental factors, such as possible adverse effects on biodiversity, natural resources, and ecosystem services, exposure to climate hazards and short- as well as long-term impacts of climate change, and social factors need to be considered.

The industries are to be benchmarked by the degree of pollution potential. Relating their degree of potential risk with the distance to site sensitivities, the suitable sites can be found. To make the tool cost effective, the assessments are undertaken at regional level followed by at site level. The regional level or macro level studies eliminate unsuitable areas and identify potential alternate sites/zones for which detailed micro level studies are then conducted to arrive at the best suitable site.

The best practice examples and manuals from India help to apply guidelines to take environmental aspects into account when setting up new industrial parks. Thus, environmental regulatory authorities are specially addressed.

Consideration of climate change aspects (Climate Risk Assessment) is presented in more detail in the Climate Change Section.

 

© GIZ

© GIZ

Main features and components

Ideally, the planning of industrial areas should follow a three-step approach:

(1) a regional assessment to identify potential industrial sites/zones;

(2) a subsequent detailed comparative site suitability assessment of these pre-selected sites; and finally,

(3) the selection the best suited one for implementation planning.

The regional assessment is geared to identify sites suitable for siting of industries at a regional level and follows a three-step approach which is reflected in the guideline.

  • In the first step environmental sensitive zones to be avoided for location of industries or to be protected from direct impacts of industrial activities are identified. Part A of the Guidelines for Regional Environmental Assessment provides criteria to be considered in this selection analysis; i.e. the biological diversity of an area, and sensitive or incompatible land uses.

  • After having eliminated these sensitive zones, the remaining areas are classified according to their suitability for location of industries. The suitability is assessed using the sensitivity of the areas against two types of industrial impacts: Air pollution, and water pollution. Parts B and C of the Guidelines for Regional Environmental Assessment provide criteria to be considered in this suitability analysis.

  • The last step of the regional assessment is the synthesis of the preceding steps to compile a regional suitability assessment for the siting of industries. Part D. of the Guidelines for Regional Environmental Assessment provides guidance for the implementation of the synthesis analysis.

  • In days of climate change the regional assessment should be further supported by climate adaptation and mitigation related considerations. These are further detailed in the Climate Change Section.

A regional assessment requires a minimum of data and information input. Only in a few cases respective environmental databases or atlases might be available. The Themes for State and District Environmental Atlases provide reference data catalogues to facilitate data collection.

To consistently execute the subsequent detailed site suitability assessment, more detailed information on the industries to be sited is required. The core task of this step is to benchmark the environmental sensitivity of the pre-selected sites against the environmental performance and impacts of the industries to be sited. In fact, the approach applied at the regional level is to be applied again in more detail on the local level using more detailed information and data.

As a pre-requisite criteria and rules for the definition of the pollution potential and environmental risk caused by the specific industries have to be agreed upon and defined.

Implementation / work steps

Topics for the regional assessment:

Regional level environmental assessments (Macro-level Zoning Atlas studies) in 1:250,000 scale taking into consideration:

  • Physical and geographical aspects of land, viz. land use, drainage, topography, soils etc.
  • Sensitive zones to be avoided, including legally restricted areas, environmentally sensitive areas, sensitive areas based on historic/religious/social considerations.
  • Air pollution sensitivity based on land use sensitivity, dispersion sensitivity (topography, meteorology) and pollution potential of industries.
  • Surface water pollution sensitivity based on flow in rivers/lakes, water use sensitivity (public supplies, drinking etc.), water quality and pollution potential of industries.

Identification of a search area from the suitable areas of macro-level studies in 1:250,000 scale taking into consideration:

  • Land availability - extent of land to suit to the industrialisation demand, preferably wastelands
  • Land ownership - government or private land lease in acquisition
  • Electricity - nearness or distance of various pre-final sites from nearest existing sub-station/power plant
  • Nearness to the major settlement - distance of nearest major settlement from all the pre-final candidate sites
  • Water availability - distance from source of water supply for domestic and industrial purposes
  • Distance from existing industrial areas
  • Distance from sensitive zone
  • Drainage - distance of major rivers or drains from the pre-final sites
  • Nearness to transportation network for economic handling of both raw materials and finished goods
  • Environmental sensitivity of the area to suit to the needed industrial development
  • Transportation facility: distance from existing railway line and highway

Results of the regional assessment:

  • Identification of areas to be avoided for siting of industrial estates
  • Identification of candidate sites based on socio-economic factors from the areas other than those areas to be avoided.
  • Rapid environmental assessment of the candidate sites and identification of potential site(s)
  • Assessment of sensitivity of land use and air/water pollution sensitivity and suitability to industries
  • Recommendations on:
  • Site(s) for industrial estates
  • Suitability to industries

 

Topics for the detailed local site suitability assessment:

Mapping of the study area (25 km around the candidate site) in 1:50,000 scale, including:

  • Base Map
  • Village reference Map
  • Land use/Land cover Map
  • Slope Map or Drainage Map
  • Hydrogeomorphology Map
  • Existing industries map
  • Infrastructure map (transportation network, water availability, electricity etc.)
  • Air quality map
  • Surface water quality map
  • Ground water quality map
  • Environmentally sensitive zones and resource areas
  • Land use development concept around the site

Requirements

  • Information about the environmental impact of industries.
  • Detailed geographical information about the land and its attributes (geography, drainage, hydro- geomorphology etc.), surface and ground water features, environmentally sensitive zones, major sources of pollution and environmental quality attributes.
  • The willingness of the stakeholders, industries or industrial park developer for sustainable land allotment.
  • Information about the environmental impact of industries
  • Detailed geographical information about the land and its attributes (geography, drainage, hydro- geomorphology etc.), surface and ground water features, environmentally sensitive zones, major sources of pollution and environmental quality attributes
  • The willingness of the stakeholders, industries or industrial park developer for sustainable land allotment

Lessons learnt

The Central Pollution Control Board, Delhi (apex body in India for prevention & control of pollution, an agency under the Indian Ministry of Environment & Forests) has undertaken regional level assessments (Zoning Atlases) for over 150 districts in India and identified potential zones for siting of industries and industrial estates.

Output

The exact analysis of the environmental situation will give first ideas about future impacts on the natural environment and the local community as well as requires limits and preventive measures to minimise the risks.

Guideline for decision makers including industrial park developers, industrial entrepreneurs, regulatory authorities and public use.

Characteristics

Phase of intervention
Introducing SIA, Analysis, Designing SIA, Master planning

Level of intervention
Planning level

Themes
Environmental Clearence

Target groups
Industrial area management and operator, Local and international consultants and advisors, Municipalities, Private investors

Countries
India

Regions
Asia

GIZ project
Advisory Services in Environmental Management (ASEM)

Duration
Depending on data availability and existing structures, approx. 6 months

Complexity
complex

Related tools
Guideline for Adaptation and Increasing Resilience of Industrial Parks to the Impacts of Climate Change, Manual for Adaption and Increasing Resilience of Industrial Parks to the Impacts of Climate Change

Sustainable Port Development in the ASEAN Region

Sustainable Port Development in the ASEAN Region
Manual

The sustainable port development programme in the ASEAN region assists to shift the emphasis from mere reactive complying with minimum standards to a pro-active approach to achieve quality and sustainability in safety, health and environmental (SHE) management in the participating ports.

© GIZ

© GIZ

Main features and components

The project signed a collaboration agreement with the Partnerships in Environmental Management for the Seas of East Asia (PEMSEA) with the objective to jointly assist partner ports to implement and continually improve Safety, Health and Environmental (SHE) management under an integrated systematic approach in accordance with the provisions of the Port Safety, Health and Environmental Management (PSHEM) Code, a standard developed by PEMSEA. The project strengthens port authorities, private terminal operators and other public or private companies.

The project intends to focus on the following key areas:

  • National level SHE policies, regulations and inspections involvement
  • Corporate Social Responsibility (CSR)
  • Green / Sustainable port policies
  • Stakeholder involvement in SHE
  • Exchange and dissemination of experience and of best practices

Implementation / work steps

ASEAN Ports Association (APA)

  • Responsible for coordinating the implementation of the project
  • Associated personnel to support the project will be made available when necessary

Participating Ports

  • Provide a regional project office (Port Authority of Thailand)
  • Provide management support
  • Actively participate in project activities
  • Assigns focal persons to the project
  • Provide training facilities

National Level

  • Provides a platform for discussion on key legislative issues and international regulations and conventions
  • Actively participate in project activities
  • Assigns focal persons to the project
  • Provide training facilities

Output

Project Achievements 2009-2012:

  • 7 ports developed, improved and/or implemented a Port SHE Management System (PSHEMS)
  • 2 ports established a SHE department
  • 3 ports improved Ship Waste Reception and Waste Management (MARPOL 73/78); awareness towards a regional approach was realized
  • 7 port emission inventories were completed
  • a guideline for efficient traffic management in the port area was developed
  • a platform for ports and ministries to discuss technical and regulatory issues in a regional context was organized

Further benefits:

  • Enhanced compliance with international conventions
  • Stable, transparent and regionally harmonized legal framework
  • Efficient Management Systems that reduce risks and pollution at source to prevent environmental and socio-economic damages
  • Risk Management and Contingency Planning
  • Improved Safety and health conditions through the provision of adequate training
  • Close cooperation and consultation between all stakeholders
  • Improved trading conditions

Characteristics

Phase of intervention
Designing SIA, Technical infrastructure

Level of intervention
Park management

Themes
Policies & Regulations, Technical infrastructure, Transport & Logistics

Target groups
Companies, SME, Industrial area management and operator, Municipalities, Private investors

Regions
Asia

Wastewater management in industrial parks

Wastewater management in industrial parks
Best Practice Example

Common effluent collection and treatment systems in industrial parks are often either not existing, dysfunctional or not functioning properly in many developing countries. The causes are diverse and must be thoroughly examined from case to case.

The tool includes case studies, best practice examples and management manuals elaborated by GIZ and KfW projects in various Asian countries.

© GIZ

© GIZ

Main features and components

The tool presents experiences from four Asian countries:

India

Under the Water (Prevention and Control of Pollution) Act of India, 1974, every industry must provide adequate treatment of its effluents before disposal, irrespective of whether it is discharged to river, land, sewerage system or sea. The Common Effluent Treatment Plants (CETP) are considered a viable treatment solution for collective treatment of effluents, from small and medium scale industries particularly. CETPs could potentially help in achieving treatment of combined wastewater from various industries at lower unit costs and help facilitating better compliance and monitoring according to standards. However, there are several challenges associated with CETPs. As per a report of the Central Pollution Control Board (2005), less than 7% of CETPs in India is complying with wastewater discharge standards.

The GIZ technical cooperation programme/project IGEP/SEIP supports pilot projects demonstrating financially sustainable solutions for waste water treatment in selected industrial areas through CETPs. The solutions focus on technical, business and management issues for successful operation of CETPs. The pilot activities are focused in the states of Andhra Pradesh, Telangana and Gujarat. The experiences of the pilot examples are documented, and their actual replication is targeted in different industrial areas of different states.

The approach includes comprehensive stakeholder consultations. Capacity building and knowledge management activities are undertaken simultaneously. Finally, solutions demonstrated, and lessons learned shall be incorporated into policies, planning processes and guidelines.

Pakistan

(To be amended in case materials are made available)

Philippines

The Philippine Economic Zone Authority (PEZA) developed a Guideline for Wastewater Management under the cooperation programme “Management Approach to Eco-Industrial Development of Philippine Economic Zones” with GIZ. The guideline provides orientation regarding the relevant laws and regulations and assists management of industrial estates and companies as well as service providers in managing their wastewater.

The Guideline contains general requirements for economic zones and their companies generating wastewater, instructions on managing wastewater, connecting to the CWTF (Centralized Wastewater Treatment Facility), pre-treatment of wastewater, securing wastewater discharge permit, and self-regulation, monitoring and reporting among others. During the project a technical audit of the Sewage Treatment Plant and the Sewerage System was executed to identify reasons for improper functioning. Based on the results and the technology implemented a Standard Manual of Operation was developed and set in force by PEZA with assistance from GIZ.

To establish the required capacities and skills for proper operation some technical training was executed. The main topic was the proper operation of the activated sludge process.

Vietnam

There are around 200 registered industrial zones (IZ) in Vietnam lacking a sustainably functioning waste water concept. This has serious consequences for the environment. The Federal Ministry of Education and Research (BMBF) in cooperation with KfW Entwicklungsbank developed an integrated wastewater management concept for the industrial area Tra Noc in the City of Can Tho in the Mekong Delta.

The integrated wastewater concept ensures the efficient functioning of the integral system with all its components in an economically and ecologically sustainable way. An essential component of the integrated concept is not only the combination of central and decentral technological approaches but also the direct linkage of the technical and the financial planning following fee and cost allocation models that are oriented towards decision-making and apply the ‘user pays’ principle.

Implementation / work steps

The following steps are decisive for the success of activities related to management of waste water:

  • Execution of a baseline survey and/or situation analysis to identify the exact problems to be tackled with respect to ‘Industrial Waste Water Management’ (Common Effluent Treatment Plants).
  • Based on this, appropriate pilots are planned and implemented to demonstrate and generate knowledge on financially sustainable solutions for CETPs.
  • Stakeholder consultations are facilitated through workshops, and information on CETPs is shared and exchanged.
  • Policy dialogues are undertaken for development of nationally and locally relevant standards, rules and policies.
  • Building knowledge based on CETPs and the development of capacities at various levels underlie all the above-mentioned activities.
  • Feedback from the pilot measures and practical experience will be guided into the formulation/review of policy guidelines (standards, rules, policies etc.) at national/state/local level.

Output

  • Development of a Guideline for Wastewater Management
  • Development of a Standard Manual of Operation for Sewage Treatment Plants

Characteristics

Phase of intervention
Designing SIA, Master planning, Retrofitting, Technical infrastructure, Operating SIA, Management

Level of intervention
Company, Park management

Themes
Participation and Stakeholder Management, Policies & Regulations, Retrofitting, Technical infrastructure, Technology, Technology Transfer

Target groups
Community representatives, Companies, SME, Industrial area management and operator, Municipalities, Policy makers, Private investors

Countries
India, Pakistan, Philippines, Vietnam

Regions
Asia

Duration
varying

Complexity
complex

Brown-field development

Brown-field development
Best Practice Example

The tool refers to methodology and guidelines to reactivate brownfields for industrial development. Investors looking for real estate should benefit from a shorter process for planning and locating their businesses compared to setting up on green-fields. Furthermore, green-fields can be saved, jobs created and the quality of life for surrounding neighbourhoods improved.

© GIZ

© GIZ

Main features and components

  • Guidelines for land recycling, implications for urban development, project management, financing issues
  • Management cycle
  • Description of steps to apply for public funds

Implementation / work steps

  • Identification of a suitable site
  • Cost calculation
  • Land recycling
  • Marketing

Requirements

  • Demand for real estate from companies
  • Brownfields
  • Data about the derelict sites as a basis of investment decisions:
    • Former usage of the site
    • Kind of pollution
    • Available infrastructure

Output

  • Attractive sites for new investments (less costly and faster to make use of, infrastructural setup already existent)
  • Less demand for green-fields
  • Job creation
  • Rising quality of life for surrounding neighbourhoods

Characteristics

Phase of intervention
Designing SIA, Retrofitting

Level of intervention
Planning level

Themes
Brown-field Recycling

Target groups
Municipalities, Private investors

Countries
Germany, Romania

Regions
Europe

Duration
5-10 months planning period; 2-5 years until reactivated site can be used

Complexity
complex

Related tools
Baseline Analysis Tool

Sustainable planning and retrofitting of industrial parks in Tunisia

Sustainable planning and retrofitting of industrial parks in Tunisia
Case Study

During a workshop in December 2012, the most affected Ministries articulated the priorities concerning the planning, design and setting up of industrial parks in Tunisia. The top priorities identified were the establishment of a feasibility study before setting up an industrial park, the elaboration of a Site Master Plan for each industrial park (including existing ones), the elaboration of an exhaustive list of criteria for selecting a site for industrial parks, and the elaboration of propositions for a better management within industrial parks. The elaboration of a manual that helps policy makers and planning departments to develop a Site Master Plan as a strategic tool for each industrial park followed.

© GIZ

© GIZ

Main features and components

A Site Master Plan was elaborated as a strategic tool for the development of industrial parks that take into consideration the elements mentioned above. A Site Master Plan integrates the concept of sustainable development throughout development operations, brings coherence to interventions, defines the kind of project to be implemented, proposes objectives and means and gives them priority, and assesses the projects’ feasibility while introducing elements of a context as broad as possible (international, national, regional, local) and a territorial scope.

The Site Master Plan is conceived as a reference document and an analysis tool that precedes the establishment of an industrial park. It aims at eliminating, or at least considerably reducing, the negative effects that the activities of an industrial park might cause. At the same time it highlights the assets and the environment of the industrial park in order to render it an economic and commercial success.

The results can lay the ground for following planning steps and for a future sustainable management of the park. The objective is to generalise this approach after having tested it on the creation of a new industrial park and on the requalification of an already existing one. This means that the elaboration of a Site Master Plan can become a new standard for the design of industrial parks in Tunisia.

Implementation / work steps

  • Develop a Site Master Plan for the industrial park focussing on sustainability principles, economic, ecologic and social objectives, well planned and integrated infrastructure, and an efficient management.
  • SWOT analysis (Strengths, Weaknesses, Opportunities, Threats) at five levels: international, national, regional, local and host site.

Output

  • Elaboration of a manual that helps policy makers and planning departments to develop a Site Master Plan as a strategic tool for each industrial park (new and already existing)
  • Contribution to the standardisation of the design of industrial parks

Characteristics

Phase of intervention
Designing SIA, Master planning, Retrofitting

Level of intervention
Planning level

Themes
Master planning

Target groups
Industrial area management and operator, Local and international consultants and advisors, Municipalities, Private investors

Countries
Tunisia

Regions
MENA

GIZ project
Sustainable Management of Industrial Areas (ReCapZI)

Related tools
International practice in site master planning

Pathways to industrial symbiosis in China

Pathways to industrial symbiosis in China
Case Study

So far GIZ implemented several projects in China promoting concepts of industrial symbiosis. The tool presents a series of case studies and best practice examples generated by various projects.

© GIZ

© GIZ

Main features and components

  1. The BMUB financed project “Energy efficiency and climate-friendly development in a province and selected cities” explored potentials to promote an Industrial Symbiosis programme in Jiangsu province and the development of SIAs in the province, within the context of Circular Economy (CE). The case study looks at the history of CE in China, highlighting the seven pillars of current implementation; how the concept of extending the industrial chain can lead to increased resource efficiency; how a facilitated programme could impact EIPs in China and what risks may be associated with introducing such a programme.

EIPs are seen by the National Development and Reform Commission (NDRC) as being pilot locations where the practical application of CE can be developed. Within this view, the plans have moved from enabling policies to finding ways to further develop parks given the current challenges. To that end within the plan there are seven tasks or pillars which are seen as being key to this success.

  1. Optimise spatial layout
  2. Optimise industrial structure
  3. Realise zero emissions trough chain optimization
  4. Efficient utilization of resources
  5. Centralised treatment of pollutants
  6. Green infrastructure
  7. Standardisation of administration, operation and management of parks

2. The China Association of Development Zones (CADZ) signed a cooperation agreement with the GIZ in 2012 in the framework of the Energy Policy and Energy Efficiency (EPEE) Programme. The aim of the cooperation was to introduce modern concepts and policies for energy efficiency, energy management, and emission reduction based on industrial networks in three selected industrial development zones (Chengdu, Kunshan und Dayawan). Major steps of this cooperation were:

  1. To establish energy efficiency networks together with the responsible administrative bodies (CADZ) and other local partners and industrial companies in three development zones in Chengdu, Kunshan and Dayawan.
  2. to build-up a material flow database for the Chengdu Economic and Technological Development Zone (CETDZ) to centralize and disseminate useful information about material and energy flow as base information for industrial symbiosis;
    and to assist the CETDZ park management in identifying, assessing, coordinating and moderating an industrial symbiosis network;
  3. to support the development of a service platform at CETDZ through training in working techniques, discussion of example cases, and practical application of the acquired working techniques.

 

Implementation / work steps

Mission 1: Training on awareness raising and IS procedures

The first main task is to assist engineers from the park administration to gather, upgrade, structure and manage data on material and energy flows. Building an accurate database on material and energy flows facilitates the identification of industrial symbiosis and eco-efficiency opportunities. To develop the capacities, a three days training was delivered.

Mission 2: IS network launching conference and company visits

Mission 2 included the following activities:

  • 1 day IS conference and workshop involving companies from the park
  • 2 days of interviews and production line visits to collect data on material and energy flows for 6 companies
  • Steering committee meeting to identify next steps

The IS launching conference gathered together around 25 companies that are active in the park. Some of those companies expressed motivation for interviews.

Mission 3: Feasibility analysis and implementation

Mission 3 included the following activities:

  • 2 days of companies visit on specific IS potentials to support implementation and mobilize company managers
  • ½ day training on feasibility analysis and project management for industrial symbiosis
  • Steering committee meeting to analyze results and close the project

Lessons learnt

  1. Options for Industrial symbiosis in Jangsu Province
  • Before implementation, however, it would be important to decide what would show as success for such a programme.
  • Taking environmental benefits such as landfill diversion of solid waste as benchmarks against success may be regarded as a rather crude measure that would keep a programme focussed only on heavy, solid waste. If a programme were to be predicated on the introduction of innovative, new technology that enabled the extension of the industrial chain, then the type of resources that could be exploited within a programme would be extended beyond the solid waste while still keeping those resources open to be included.

 

  1. Industrial symbiosis under the EPEE
  • The administration should understand what criteria are important for investors when addressing them. The administration should be aware of that and react to its own advantage.

  • The administration should follow a vision for the future of the CETDZ and specify a minimum threshold that needs to be satisfied considering the master plan of the industrial park.

  • A risk management is needed for settlement projects. Otherwise the administration would leave the control of the development of the CETDZ to companies and could not rectify undesirable developments.

The administration should develop competences regarding the development of the CETDZ into an eco-industrial park or even to a thriving sustainable industrial area. Environmental aspects and a higher level of employment play a decisive role here.

Output

  1. Options for Industrial symbiosis in Jangsu Province

While EIPs have been developed and the concept of extending the industry chain has been introduced and implemented, a number of areas of improvement have been highlighted. These include:

  • Extending the industry chain beyond what has currently been achieved
  • Increased engagement with small and medium sized companies (SMEs)
  • Energy consumption per GDP can be high in some instances
  • Data management with regards to available resources and their potential uses
  • Increased integration of new technology and incubator companies
  • Increase collaboration between companies within and between parks
  • The management ability for implementing CE could be improved in some area

 

  1. Industrial symbiosis under the EPEE
  1. Energy efficiency networks
  • Energy cost savings of more than 36 Mio. RMB were achieved through the 108 measures implemented. However, investments were almost 50 Mio. RMB.
  • 22.347 tonnes of CO2 were saved through the measures implemented in Chengdu.
  • The biggest savings potential can be found in electrical drives, pumps, management and other technical measures. This part constitutes more than 50% of the whole potential. Savings in air conditioning, refrigerating machines and ventilation as well as savings in compressed air account for 12% each.
  • Improved image of participating companies

 

  1. Industrial symbiosis elements
  • Detailed IS opportunities detected during the preliminary workshop, the launching conference, and the company interviews performed by the park administration classified by topic
  • The last steering committee meeting with the park administration at the end of mission 3 opened the discussion about potential future development of the industrial symbiosis network.

 

  1. Development of a service platform
  • Members of the management team participated actively in the interviews and dialogues were oriented towards a fast implementation of initiatives of the administration.
  • The methods learned during the workshops were adopted and positive results from the dialogues were evident.

Specifically, it was achieved that some companies are willing to actively participate in initiatives of the administration regarding the following topics: creation of a platform for the joint resolution of problems under the coordination of the administration; formulation of a Charta of companies regarding Corporate Social Responsibility for companies in the CEDTZ; preparation of a joint sustainability report for all companies and the whole CEDTZ.

The park administration can lead an open dialogue based on partnership with companies without external assistance.

Characteristics

Phase of intervention
Operating SIA, Management, Resource efficiency

Level of intervention
Company, Park management

Themes
Energy efficiency, Industrial Symbiosis, Management, Participation and Stakeholder Management, Resource efficiency, Retrofitting, Service Orientation

Target groups
Companies, SME, Industrial area management and operator, Municipalities, Private investors

Countries
China

Regions
Asia

GIZ project
Energy Sector Reform Program: Energy Policy and Energy Efficiency (EPEE)

Training Resource Efficiency and Energy Efficiency in the Building Sector - “Training EIP”

Training Resource Efficiency and Energy Efficiency in the Building Sector - “Training EIP”
Training

The project on “Qualification of Key Actors on Energy Efficiency in the Building Sector”, or simply KABEE project, aims to support China’s path towards a low carbon urban development by providing key actors in Chinese cities with German know-how and experiences through training. One of the training modules (Module 6) focuses on German experiences on energy efficiency gains in urban key sectors through eco-industrial parks.

© GIZ

© GIZ

Main features and components

The project helps familiarise leading policy-makers and administrators in local authorities as well as public and private sector organisations involved in the implementation of policies with knowledge of applications and measures in the area of building energy efficiency and climate change mitigation.

The project combines four approaches to ensure a successful and sustainable knowledge transfer for higher energy efficiency in Chinese cities: training for trainers, development of training courses and local training formats, study tours, and briefing on the inclusion of buildings in the carbon market. The training courses and local training formats consist of six modules. One of which, Module 6, focuses on German experiences on energy efficiency gains in urban key sectors through eco-industrial parks.

The training on German Experiences to obtain Energy Efficiency Gains in Cities through Eco-Industrial Park (EIP) Development contains:

  • Fundamentals
    • Definitions
    • Industrial Parks – Motor of Industrial Development
    • GIZ Proposed Criteria for Sustainable Industrial Areas
  • Int. and German Practice of EIP/SIA
  • Methodology to Introduce Energy and Resource Efficiency in Industrial Areas
    • Factor of Success – The Multilevel Approach
    • Changing Park Management towards Sustainability
    • Introducing Networking for Energy and Resource Efficiency
    • Implementing Measures on Company Level
  • Available Knowhow and Support

Output

Training needs in Chinese cities have been identified in thorough consultations between all partners. German and Chinese knowledge brokers have designed training curricula and formats. More than 2,000 people took part in various training occasions. Chinese trainers attended six seminars. They act as multipliers for transferring German expertise into Chinese cities.

Characteristics

Phase of intervention
Introducing SIA, Sensitisation, Operating SIA, Resource efficiency

Level of intervention
Planning level, Policy level (central), Policy level (decentral)

Themes
Energy efficiency, Resource efficiency, Sensitisation

Target groups
Industrial area management and operator, Local and international consultants and advisors, Municipalities, Policy makers, Private investors

Countries
China

Regions
Asia

GIZ project
Qualification of Key Actors on Energy Efficiency in the Building Sector (KABEE)

Planning of Sustainable Industrial Areas in India

Planning of Sustainable Industrial Areas in India
Case Study

The overall objective of the technical cooperation on the core topic of “Planning of New Industrial Parks and Investment Zones” is to demonstrate innovative planning and designing of new or upgrading of existing industrial parks. This can be achieved by incorporating the aspects of resource efficiency, integrated environment monitoring, management structures of eco-friendly production and gender-sensitive infrastructure design. National and state level stakeholders are supported in considering the results in new strategy papers and guidelines of the government and/ or industry associations.

The pilot activities are focused in the state of Telangana (former Andhra Pradesh).

The tool presents a collection of Site Master Planning experiences from two pilot projects, namely the Green Industrial Park (GIP) Jadcherla and the Association of Lady Entrepreneurs of Andhra Pradesh (ALEAP) Green Industrial Park (A-GRIP). Both are showcases of the successful elaboration of site master planning supported by application of GIZ standards on cooperation (stakeholder involvement), processes (for involvement of stakeholders) and a strategic approach for arriving at customised, yet high quality results.

© GIZ

© GIZ

Main features and components

Both, Site Master Planning, as well as revision of existing Site Master Plans need to take into consideration following key issues:

  • The results of site suitability assessment;
  • The zoning of industries considering the pollution potential of industries, and restrictions on certain types of polluting industries;
  • The definition of block sizes and width of infrastructure corridors as per industrial development requirements, and environmental considerations (green corridors, meso-climatic conditions, Heat Island effects);
  • Planning of common infrastructures considering environmental protection standards and issues (transportation and logistics, water, energy and media supply, waste and waste water management, storm water management, blue-green infrastructures, resource efficiency, social infrastructures, security, and management infrastructures, disaster management);
  • Advanced building standards (energy efficiency, heat waves, etc.)

Upgrading of an existing industrial park

The industrial site of Jadcherla already had a Site Master Plan (SMP) that was revised to green the not yet fully implemented first SMP. In a participatory process involving the various stakeholders of the industrial site, GIZ revised the SMP and defined implementation steps for greening Jadcherla industrial park.

Planning of a new eco-industrial park

The Association of Lady Entrepreneurs of Andhra Pradesh (ALEAP), established in 1993, is a state level organisation with the objective of uplifting and empowering women through the establishment of small and medium enterprises. To promote women entrepreneurship, ALEAP decided to develop ‘ALEAP – Green Industrial Park’ (A-GRIP) at Nandigama near Hyderabad in the newly formed State of Telangana. A-GRIP is envisioned to provide an environment conducive for women entrepreneurs and to employ state-of-the-art technologies, including clean technologies, renewable energy technologies, environmental technologies and cost-effective common infrastructure.

     

    Implementation / work steps

    Upgrading of an existing industrial park

    Upgrading of the existing Site Master Plan (SMP) was achieved through a four-step approach based on intense stakeholder participation.

    • Step 1: Training workshop to identify potentials for “Greening” of the existing SMP
    • Step 2: Recommendation by GIZ consultants for “Greening” of the existing SMP
    • Step 3: Participatory planning process:
      • Training Workshop on Planning of New Green Industrial Parks and Investment Zones for park development authority
      • Orientation day for park development authorities: different working groups working on missing
      • infrastructures and missing aspects in the existing industrial park
      • Three-day training programme: analyses of the short-comings of the existing SMP, discussion of appropriated solutions, proposal of a five-year plan to green the industrial park
    • Step 4: Finalizing of the revised SMP according to the norms and standards with detailed measures and values.

    Planning of A-GRIP

    The planning of the Site Master Plan of A-GRIP developed thematic layers taking into consideration the competing goals of environment friendly master planning as well as economic viability through maximization of saleable plots. A technical process had been followed for spatial planning of A-GRIP wherein each stage served as a premise for the stage succeeding it.

    These stages were:

    • Stage 1: Project envisioning exercise – a consultative process with all the stakeholders including ALEAP and future tenants of the industrial park
    • Stage 2: Site analysis – to understand the context of site, topography, drainage pattern, surface water, wind, radiation and rainfall to interpret the site profile to determine its impact on spatial planning and design
    • Stage 3: Need assessment – two site visits provided a better understanding of the physical conditions, transportation connections, access, nature of the surrounding uses
    • Stage 4: Concept development – to reflect upon the integrated planning approach and reconceptualise the plan in order to relate the vision with the design
    • Stage 5: Preparation of thematic plans and report
    • Stage 6: Detailed master plan

    Further steps

    Up-scaling and replication of these demonstrated technologies and experiences is expected to take place under full responsibility of the partners. IGEP coaches the process and offers technical assistance if required. The programme also advises on how to monitor the impact of the up-scaled development measure.

    Requirements

    • The willingness to plan a sustainable industrial park must exist
    • Commitment of the stakeholders to cooperate
    • Information about the industries and possible investments attracted to the park should be available

    Lessons learnt

    • The application of the following quality parameters was found to bring in a number of benefits: economic, technical, environmental, socio-functional, administrative and management quality
    • The participatory approach chosen in Jadcherla allowed achieving a feasible and effective upgrading plan meeting the requirements of the silver standard as per the German Sustainable Building Council rating system.
    • Integration of eco-industrial considerations and standards in the SMP for A-GRID required an iterative consultation and discussion process with the technical planners (realisation) and the customers (development of a vision). Finally, the approach allowed meeting the requirements of the gold standard as per the German Sustainable Building Council rating system.

    Output

    • Revised Site Master Plan for Jadcherla: The application of the quality parameters helped the park in Jadcherla to qualify for a silver rating as per the German Sustainable Building Council rating system.
    • Final detailed master plan for A-GRIP: The application of the quality parameters helped A-GRIP to qualify for a gold rating as per the German Sustainable Building Council rating system.
    • Reference documents are developed to support environment-friendly site master planning of new industrial parks and upgrading of existing ones. Case studies can serve as nationwide best practice examples

    Characteristics

    Phase of intervention
    Designing SIA, Master planning, Operating SIA, Social aspects

    Level of intervention
    Planning level

    Themes
    Master planning

    Target groups
    Industrial area management and operator, Municipalities, Policy makers, Private investors

    Countries
    India

    Regions
    Asia

    GIZ project
    Sustainable environment-friendly industrial production (SEIP II) in India

    Duration
    Upgrading of existing parks: depending on data availability, 6 months ; planning of new indusrial park: several years

    Complexity
    medium

    Related tools
    International practice in site master planning , Sustainable Management of industrial areas (SMIA, GedZI, ProCAIS), Planning of Sustainable Industrial Areas in India