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Case study

Song Lam Sugar Joint Stock Company

19/02/2012

Song Lam Nghe An Sugar Factory was one of the two sugar factories in the North Vietnam sponsored by China from 1958 and went into operation from 1960. The factory was constructed at Hung Phu - Hung Nguyen - Nghe An with initial capacity of 350 tons of sugar per day and 50.000 liters of alcohol per year. Communes around Lam river Duc Tho - Ha Tinh, Nam Dan, Hung Nguyen - Nghe An) supplied sugarcane to the factory.

From 1999, due to heavy storm and flood in the Center, the sugarcane supply was affected. Nghe An People's Committees after consider the Government’s suggestion decided to move the factory to the new place in Dinh Son commune, Anh Son district and expand the capacity to 500 tons of sugarcane/day and 1 million litter of alcohol per year.
 
Due to backward technology leads to serious pollution of the water environment in the production process. With large amounts of wastewater, about 7.000m3/day from the main production line, the concentration of pollutants exceeded the permitted limit. In addition, hundreds of tons of wastes per day were discharged into environment. This is the source of fermentable wastes, stinking and easily diffused in the wind and drifted by rain, if it no collection and processing will will pollute the environment seriously.

In 2008, the company received the support from the Ministry of Industry & Trade and Vietnam Cleaner Production Centre to conduct Cleaner Production Assessment and Application. From May of 2008, the Company established a CP team led by Mr. Phan Dinh Duc –Director of the company and other 15 members to assess the whole production line. After the Cleaner production assessment (CPA) and identification of waste line, the Team has conducted mass and energy balances for the whole production line. All collected data have been used to analyze and identify Cleaner Production options for each production step.

The CP application in the company had divided into 2 phases. The first phase focused on application of low-cost or no cost options. The second phase focused on investment solutions which required a high cost but economic, social and environmental wise.

Particular benefits derived from Cleaner Production are as follows:

Technical benefit Economic benefit Environmental benefit
  Phase 1
 Reduction of 6% of specific electricity consumption         29.5 million dong/year Reduction of dust and green house gas
 
Reduction of 13.2% of coal specific consumption    215 million dong/year   
Phase 2
 
Utilize sugarcane residues to produce 5,000 tons of fertilizer / year    
  
710 million dong/year   Absolutely treatment of 100 tons of sugarcane residues/year
Limitation odor pollution
Absolutely treatment of 100m3 of wastewater/day

Typical Cleaner Production options of the Company are as follows:

No.CP OptionInvestmentPerformanceCP technique
 1Repair leakage           

15 million dong Annual saving of 58 tons of coal   GH
 2Cover coal in raining days
7 million dong
 
Annual saving of 20 tons of coalGH
 3Replace old lamps by energy-saving lamps2 million dong Annual saving of 16 million dong CTTB
 4Replace old fans by industrial fans with lower capacity 5 million dong Annual saving of 13.5 million dong CTTB
 5Install dust recovering system by pure lime water 
 8.5 billion dong
 
Annual producing 5,000 tons of fertilizer and bring annual benefit of 710 million dong

Reduction dust and odor rat the production site and surroundings

Absolutely treatment of 100m3 of wastewater/day
 EOP
 6Built wastewater treatment system of wort from alcohol making EOP
 7Construct organic fertilizer workshop EOP

Remarks: GH: Good Housekeeping; EI: Equipment innovation; EOP: End of pipe

Perceiving the benefits from CP application, the company insisted to maintain the CP team activities and integrate CP in the general management system at place. According to company management, CP not only helps the company saving energy, reducing emissions, but also to develop production, improves product quality and prestige confirmed. Simultaneously, the CP solutions have helped companies solve basic environmental pollution in recent years. /.