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Case study

Nonferrous Metal Factory 2 - Thai Nguyen one-member Nonferrous Metal Co. Ltd

20/02/2012

Thai Nguyen Nonferrous Metal Factory 2 is one of 11 member factories of The one-member Thai Nguyen Nonferrous metal Co. Ltd. The factory specializes in producing Zinc oxide powder 60% (4.600 Tons/year). It can be said that before applying CP, the Factory met difficulties due to no storage site for raw materials, ores and limestone and coal. Those materials were mostly store outside, suffered high and changing humidity due to weather.
Narrow workshop for material preparing, low efficiency, high production cost also were factors hindering the quality of material preparation step (composition, grade and humidity). Since the furnace technological criteria were unable to met, its efficiency was low.
Towards a sustainable development and environmental protection culture, the Factory has actively implemented practical solutions such as improving working conditions; changing product recovery technology; building coverage for fuel management site, etc. But most noteworthy is that since participating in CP demonstration project of the Cleaner Prodution in Industry Component (CPI), the Company has achieved higher environmental protection performance as well as economic benefits
With the support of CPI and experts of Vietnam Cleaner Production Centre, the Factory’s CP team has proposed two solutions of improving the rotary kiln no.1 and no.2 at place.

Applying CP since March 2007, some results from the demonstration are as follows:

Technical benefit      Economic benefit Environmental benefit
 Phase 1
 Increment of 40 ton product/month Annual saving of VND 925 millionsReduction of dust, temperature and risk of accident
 Reduction of 0,25 ton of coal per ton of productSignificant reduction of dust release to the environment
Reduction of 0,35 ton of ore per ton of ZnO ore 15%Payback time: 4 yearsImprovement of resource and energy efficiency
 Phase 2
Annual saving of 1080 ton coal
5% annual reduction of Production costs
 
 
 
Reduction of CO2 emissions to the environment
 
 Annual saving of  160.000KWh
 Annual saving of 400 ton of limestonePayback time: 6 months
 Annual saving of 600 ton zinc ore 40%

   
 Typical Cleaner Production options of the Company are as follows:
 

No.CP OptionInvestmentPerformanceCP technique

 Phase 1


 1.1Prolong the kiln: 14 m to 21 m
 

VND 3 millions





Increment of 40 ton product/year
 
  Reduction of 4,45% ore, 7.1% coal and 12% electricity consumption 
M
1.2 Mechanize material input into the kilnEM
1.3Build more roofed-storehouseEM
1.4Change the existed motors to motors with inverters  EM

Phase 2


2.1Change the manual dust collecting system to mechanized one  VND 5.9 billions Saving of 1080 ton coal/year EM
2.2 Prolong the kiln: from 28 m to 34 m Saving of 160.000 KWh/yearEM
2.3Mechanize material input into the kiln Saving of 400 ton limestone/yearEM
2.4Change the existed motors to motors with inverters Saving of 600 ton ZnO 40%/yearEM

Remarks:  EM: Equipment Modification

With the results achieved in the Factory, Cleaner Production will be replicated in Thai Nguyen one-member Nonferrous Metal Co. Ltd./.