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Case study

Calcium Carbonate Factory - Huu Nghi Trade-Manufacture JSC.,

19/02/2012

Huu Nghi Trade-Manufacture JSC is located in Phu Tho Province, manufacturing 2 main products of welding rods and calcium carbonate powder.  The welding rods, labeled FS, are to be used for ships and constructional works. The average output is 3,000 ton annually, serving domestic market. Calcium carbonate powder is consisted of two types: superfine powder with and without stearic acid coating.

Due to the nature of superfine product, the emitted dust during production does not only lead to product losses, low environmental performance, but also  endanger the health of the workers. Besides, the stone preparation with wet removal of surface dust, mainly from cement of neighbouring factory, produces not only wastes water but also causes raw material losses. This is one of the reason that the Company decided to apply Cleaner Production (CP) at the Calcium carbonate powder Factory.

The CP team includes 7 members of the Company. The Team has worked with CP experts and CP consulting trainees to identify and propose 48 CP options. However, during the course of project implementation, 36 out of 48 options were applied with the investment of 26.500.000 VND.

Benefits derived from the first phase of CP implementation:

Technical benefit Economic benefit Environmental benefit
 Reduction of 1% of electricity consumptionPay-back value:
 4% of revenue in 2008
 Reduction of solid wastes
(đá tiêu hao + bao tải rách)
379.070kg/năm
 Reduction of 16% of water consumptionPay-back time:
 2,6 months
 Giảm phát thải CO2:
16.426 kg/năm
Reduction of 28% of acid consumption Nước thải: giảm
1.590.264 kg/năm



Some typical CP options are as follows:

No.CP OptionInvestmentPerformanceCP technique
 1Not purchasing fine broken stonesNo costReduced 0,1% of fine broken stones QLNV
 2Installation of the rubber plate that leaned on the surface of the conveyor15.000.000 VNDRecovered 1kg crushed stone/tonEM
 3Improving the capacity of storage silo22.000.000 VND Increased the speed of jaw crushing form 6,5 ton to 10 ton/hour EM
 4Installing a sensor to signal the speed of coarse crushing12.000.000 VNDRecovered 0,5 kg of spilled stone/ton   EM

Remarks: GH: Good Housekeeping; EM: Equipment Modification

Perceiving the benefits from CP application, the factory insisted to maintain the CP team activities and integrate CP in the general management system at place. In order to facilitate CP application, a simple environmental management system has been developed. The factory has also set up environmental policy, whereby it is requested that the environmental protection law and other regulations should be followed strictly, ensuring the sustainable development of the company and reducing waste emission sources. The factory has integrated process management system with the environmental management system, therefore, energy and material consumption is monitored at the same time with the monitoring of pollutant parameters in the waste streams. A sample system and legal procedures are built and applied for environment data collection, checking, classification and data analysis.

An environmental monitoring plan has been initiated. The aim of the plan is to monitor significant improvements from applying CP or to adjust if there is any reduction in environmental benefits. Environment monitoring system includes monitoring air quality and wastewater.

CP not only brings about benefits from energy saving, emission minimization, reduced water consumption, but also helps the Company increase production, improve product quality, and prove prestige. The implemented CP options at the Company are a typical case study for enterprises in the sector of calcium carbonate powder production in Vietnam./.