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Case study

Gia Sang Steel Making and Rolling Joint Stock Company

19/02/2012

Gia Sang Steel Making and Rolling JSC., was formerly Gia Sang Steel Making and Rolling Factory, a member of Thai nguyen Steel and Iron Corporation (TISCO).


From the first batch of steel produced in 1975 to date, the Company has  upgraded steel making technology with 04 electric arc furnaces (EAF) with capacity of 70,000 ton/year each and the rolling line was upgraded to the capacity of 100,000 ton/year. The company is focus on producing construction steels and high quality steel based on advanced technology. The Company has been applying international standard (ISO 9001:2000) for quality management.


Despite that the Company has been fully applied all environmental protection requirement s but during production process, a large amount of dust and volume of wastewater were discharged which adversely affect the surrounding environment and workers' health.


In order to increase the resource efficiency and reduce environmental pollution to communities, improve working environment, safety for employees and equipment, ensure the health of the workers during production process, the Company has participated in Cleaner Production Demonstration Project of the Cleaner Production in Industry Component (CPI). With itself efforts (especially the efforts of the 14-member CP team) and technical assistance from CPI, international and national CP experts, Gia Sang has been implementing 32 out of 43 CP options with total investment of 654 million dong.


Benefits derived from Cleaner Production options which were applied in the first phase of the Project are as follows:


Technical benefit Economic benefit Environmental benefit
5% reduction of steel scrap and iron
 


Annual saving of 58 billion dong

 
 
 
 
 Reduction of 25% solid wastes
 8% reduction of auxiliaries (Fe-Mn, Fe-Si, Al) 
  Reduction of 14% Green House Gases (GHG)
 
 
17% reduction of flux
1% reduction of lining and casting materials
4% reduction of total converted energy

Typical Cleaner Production options of the Company are as follows:


No.CP OptionInvestmentPerformanceCP technique
 1Installation of oxygen pipes to scraps cutting positions 40 million dongIncreasing preparation capacity, reducing  riskGH
 2Extension of crane rail to increasing the scraps preparation area 35 million dong GH
 3Design and installation of electrode cooling system7 million dongReducing electrode consumption

 EM
 4 Installation of a balance (20 tons) to weight and control rate of scrap before charging 30 million dong Reducing to 2 charging basket/batch PC
 5 Melting test with higher rate of shredded scraps to identify the optimizing rate No cost Reducing 180 kWh/ton of billet, 0,85 kg electrode/ton of billet, 31 kg of scrap loss/ton of billet.
Shorten 48 minutes of Melting time
 MC
 6 Checking loss of the electricity line drop No cost Electricity loss caused by line drop is 2,2-2,3% GH
 7 Dredging the circulation tank  to enhance the useful volume 30 million VND Reducing over flow GH

Remarks: GH: Good Housekeeping; PC: Process Control; EM: Equipment Modification


With benefits from CP application, Gia Sang has come up with a CP application plan in the time to come, which includes the CP options of Improving dust collecting and treatment system at EAF to meet environmental standards; Improving the capacity of the current furnaces, using one of them as Ladle Furnace; Replacing old, low efficient engines by new, high efficient ones with total investment of 50 billion dong./.