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Case study

Luu Xa cement factory

19/02/2012

Luu Xa Cement Factory, a member of Construction materials Company – Vietnam Industrial Construction Cooperation, was established and started to operate in 1995 with blast furnace technology. In 2006, the company was changed into joint stock ownership and renamed as Industrial Production and Investment JSC., including Luu Xa Cement Factory as one independent member.

Beginning with a Vietnamese designed and installed line, the factory has been continuously improving and applying new technology to better production and increase designed capacity from 60,000 tons/year to more than 100,000 tons/year, providing stable jobs for more than 400 people.

Limestone, clay, coal and adjustment additive, mineral additive were goes to a scale system through the outlets at the bottom of silos. The company received ISO 9001: 2000 certificate in quality management system in 2001 (now is ISO 9001: 2008) with main product of clinker, cement PCB 30, cement PCB 40. Its products have gained consumer confidence and created credibility in the market in and outside of the province

Beside the successes and important contribution of the factory, the old technology of blast furnace caused many environmental problems due to dust generation, smoke and noise in the working environment and surrounding environment.

Recognizing the need to implement cleaner production to improve productivity and solve environmental problems, the factory has been actively involved in cleaner production demonstration projects component of cleaner production in industry from 2007.

The company established a CP with 13 members, is tasked to review and identify obstacles and analysis solutions to save energy and natural resources. The CP team had cooperated with CP expert to assess the whole production line. The result is 19 CP options to implement in the period 1 and 15 energy saving solutions have been applied so far.

Particular benefits derived from Cleaner Production in 2006 are as follows:

Technical benefit Economic benefit Environmental benefit
 Reduction calories consumption from 1100 Kcalo/Kg clinker to 1000 - 1050 kcalo/kg clinker      Saving of 53,665,085 dong/year.

Payback time: 6 year
 
 Reduction of 48 tons of dust/year
Reduction electricity consumption from 82.83 Kwh/ton product to 76.67 Kwh/ton product      

  Reduction of 1509.3 tons of CO2, reuse 825 tons of material
Recirculate 55,000m3 water per year for consumption

Typical Cleaner Production options of the Company are as follows:


No.CP OptionInvestmentPerformanceCP technique
 1







Improve material drying system - Replace water spray method of dust filtering by bag filtering (to recover material), including1,589,318,000 dong, among them 50% of total investment cost is funded by CPI

 
 
 
 Reduction calories consumption from 1100 Kcalo/Kg clinker to 1000 - 1050 kcalo/kg clinker

Reduction electricity consumption from 82.83 Kwh/ton product to 76.67 Kwh/ton product 
   EC -OR
Add an automatic drying temperature control system for hot air supplier to the drying machine by controlling fan speed of the present responsive brazier    Reduction electricity consumption from 82.83 Kwh/ton product to 76.67 Kwh/ton product EC -OR
Optimize drying machine to increase efficiency   EC -OR
 Insulate pipelines, drying machine case to reduce heat lost and improve working conditions  EC -OR
Install dust filer system using bag filter technology to reduce dust in exhausted fume and recycle dust that used to be wasted   EC -OR
 2 Issue oven operation regulation: water content in coal, avoid opening oven door, air supplying mode     

No costSaving of 25 million dong/year by saving 40 tons coal/year (in 2007)GH

Remarks: GH: Good Housekeeping; EC: Equipment Change; PC: Process Control; OR: Onsite Recovery

With the benefits of CP has been brought to help Luu Xa Cement Factory ensure sustainable development and secure production, enhance the prestige of the partners at home and abroad is when the economy demands the integration of quality standards, management and social responsibility of enterprises producing communities to increasingly high demands. /.