Case Studies

The following case studies represent a short list of synergy opportunities identified through the BPS work process in active projects around the country.  Click the titles for process diagrams and detailed environmental benefits.


Acetic Acid to Acetate Manufacturing

Two companies have identified a synergy involving the use of Acetic Acid, a manufacturing by-product from Company A’s facilities, for use to manufacture acetates or for descaling operations in Company B. Acetic acid recycling displaces the need for petrochemical feedstock necessary for manufacturing acetates.

Asphalt Recycling

Two companies have identified a synergy involving the recycling of asphalt disposed of by Company A in pits for use by Company B to be remade into roads or parking lots.  Asphalt recycling displaces the need for additional asphalt production.

Bulk Bag Reuse

Two companies have identified a BPS opportunity involving the use of bulk bag from Company A by Company B which displaces the need for use of new bags. Ordinarily, the bulk bag would be disposed in a landfill.

Filter Cake to Brick Colorant

Two companies have identified a BPS opportunity involving the use of filter cake from three facilities of Company A by Company B for brick colorant, which displaces the need for use of virgin brick colorant material. Ordinarily, the filter cake would be disposed in a landfill.

Filter Cake to Composting Material

Two companies have identified a BPS opportunity involving the use of 2,500 tons per year filter cake as a new material for a composting process to produce soil amendments. This by-product synergy involves the diversion from landfill of calcium oxide filter cake generated by Company B’s wastewater filtration operations. The filter cake provides a source of organic nutrients, and will be mixed with soil by Company A for purposes of composting. The resulting compost provides soil nutrients that are an alternative to synthetic fertilizer.

Food Waste for Anaerobic Digestion

Two companies have identified a BPS opportunity involving the use of food waste from Company A as an alternative feedstock for Company B’s anaerobic digestion process. The outputs of anaerobic digestion are soil amendment and biogas which is used for electricity generation. The resulting soil amendment is used as an alternative to synthetic fertilizer and biogas displaces the need for fossil fuels for energy. Ordinarily, the food waste would be disposed in a sanitary landfill.

Foundry Sand to Soil Amendments

Two companies have identified a BPS opportunity involving the use of foundry sand from Company A by Company B for soil amendments, displacing the need for use of virgin sand. Ordinarily, the foundry sand would be disposed in a landfill.

Lime Slurry Reuse for Mine Waste Water Treatment

Two companies have identified a BPS opportunity involving the use of lime slurry produced by Company B by Company A for a replacement of virgin caustic for waste water treatment. Company B produces the lime slurry as a result of treating groundwater for a manufacturing process input.  Ordinarily, the lime slurry would be disposed in a landfill.

Manganese Battery Dust to Brick Colorant

Two companies have identified a BPS opportunity involving the use of manganese battery dust from Company B by Company A for brick colorant which displaces the need for use of virgin brick colorant material. Ordinarily, the manganese battery dust would be disposed in a landfill.

Off-specification Cement for Land Stabilization

Two companies have identified a synergy involving the use of off-specification cement from Company A for use by Company B for land stabilization. This synergy displaces the need for use of virgin stabilization materials.

Off-specification Diesel Recycling

Two companies have identified a synergy involving the use of off-specification diesel from Company A for use by Company B to recycle the material for fuel grade use. This synergy displaces the need for additional petroleum fuels.

Tire Synergy

Three organizations have identified a resource exchange between a fire department, a company with a national vehicle fleet and a large cement company as a way of promoting value-added uses of fire department vehicle fleet tires.

Tungsten Recycling

Two companies have identified a synergy involving the recycling of spent tungsten catalysts from Company A’s refinery operations for use by Company B to recycle the precious metal. This synergy displaces the need for mining additional tungsten.

Vinyl Acetate to Carpet Adhesive

Two companies have identified a synergy opportunity involving the one-time use of 650,000 lbs off-specification vinyl acetate monomer from Company A in the carpet adhesive production process for Company B. Ordinarily, Company A would dispose of off-specification material in an incinerator.