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Breaking Silos

Trash · Trophy

Kalundborg

Fifty years of handshakes in a small Danish town

Kalundborg, Denmark · 1972–today

Aerial view of Asnæs Power Station on the Kalundborg fjord, with its coal yard, chimneys, storage tanks and the surrounding industrial area and farmland.
Asnæs Power Station, Kalundborg. Photo: Bob Collowan, CC BY-SA 3.0

€24Ma year in bottom-line savings, shared across the partners

Kalundborg is a small Danish industrial town of sixteen thousand people, two hours west of Copenhagen. It has a refinery, a power station, the world's largest insulin factory, a plasterboard plant, and the municipality itself.

Around 1961, the refinery needed water and the town had a lake; someone proposed a pipeline. In 1972 the first real waste deal followed: the refinery's excess gas, instead of being flared, went next door to the plasterboard factory as fuel. After that, steam went from the power station to the refinery and the pharma plant, and warm cooling water to a fish farm. Gypsum from scrubbing the power station's flue gas went to the plasterboard plant as raw material. Yeast slurry from insulin production went to local farmers as pig feed. Link by link, handshake by handshake.

Today seventeen partners trade more than twenty exchange streams. Together they avoid 586,000 tonnes of CO2 a year and share about €24 million a year in bottom-line savings.

Run the method over it

The legend hides three practical lessons.

First, there was no master plan. Every link was a bilateral deal that made money for both ends. If you wait for the grand ecosystem design, you will wait forever. Close one two-party deal that pays, and the next one gets easier.

Second, proximity did the heavy lifting. Steam, gypsum and warm water are cheap and heavy. They can cross a fence, but they cannot cross a country.

Third, and least told, it took time. Trust is built at the speed of kept promises.

A power station with a tall white chimney and coal cranes on the waterfront at Kalundborg, seen across the water.
Industrial waterfront, Kalundborg. Photo: Mr3641, Public domain
Kalundborg's exchange network: water from the town to the refinery; the refinery's excess gas to the plasterboard plant as fuel; steam from the power station to the refinery and the insulin factory; warm cooling water to a fish farm; gypsum to the plasterboard plant; yeast slurry from insulin production to local farmers as pig feed.waterexcess gas → fuelsteamsteamwarm cooling watergypsumyeast → pig feedThe townand its lakeRefineryPower stationInsulin factoryworld's largestPlasterboard plantFish farmLocal farmers
water energy materialsSelected streams, as described in chapter 8.
Fig. 1: Kalundborg's exchange streams as described in chapter 8.

Sources

  • Kalundborg Symbiosis: 586,000 t CO2/yr avoided, 4M m³ groundwater/yr saved, 62,000 t materials/yr recycled, ~€24M/yr partner savings plus ~€14M/yr socio-economic benefit; 17 partners, 20–30 exchange streams

What's your version of this?

Somewhere in your organisation, a trash leak is waiting for its address. Start with the scan question.