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Case study

Sao Xanh Paste Technology Joint Stock Company

20/02/2012

Sao Xanh Technology Joint Stock Company have been set up privately in 2004, specializes in manufacturing molded products as ball mill, lining, slipway and machine parts to meet the needs of local consumption and the surrounding provinces. The company covers an area of 2 hectares under Song Cong Industry Zone of Thai Nguyen province. With 110 female workers, in 2009 the company achieved output value of 2600 tons/year.

In 2010, the company received the support from the Ministry of Industry and Trade via the Cleaner Production in Industry Component (CPI) to conduct Cleaner Production assessment and application. The company established a CP team led by Mr. Hoang Hong Quan – Foreman of the company 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.

After conducting CPA and identifying improvement options, the Company has carried out 11 options including 8 good housekeeping options with no-cost and low-cost, 2 process control options (no cost) and 1 equipment modification option. The total budget is 13 millions dong. But the benefit which company gains is huge 1,3 billion dong by reducing damaged product rates from 25-40% to 10-15%, increasing life -span from 30 batch/kiln to 50 batch/kiln and reducing the power energy consumption from 1200 kWh/ton of product to 1100kwh/ton of product.

Particular benefits derived from Cleaner Production are as follows:

Technical benefit Economic benefit Environmental benefit
Reduction of 0,6% specific consumption of steel scarp Saving of 14,4 million dong/year   Reduction of 1200 kg of dust/year
Reduction of 40,1% specific consumption of  refractory materialSaving of 10,3 million dong /year  Reduction of  1035 kg of refractory material/year
Reduction of 1.8% electricity specific consumption  Saving of 2 million dong /year   Reduction of 1770 kg of CO2/year
 Reduction of 7.2% coal specific consumption Saving of 270 million dong /year Reduction of 5508 kg of CO2/year
 Reduction of 5.0% amount of  waste product recovery /ton of product Saving of 1,05 billion dong/year Contribution to reduce fuel consumption

Typical Cleaner Production options of the Company are as follows:

TT Tên giải pháp Đầu tưHiệu quảNhóm giải pháp
 1Install a rain lean-to between the two areas5 million dongGain 1.3 billion dong in 2009 (with the ball mill production of 150 tons)GH
 2Check the ratio of impurities and scrap quality before purchasingNo costGH
 3Add material cleaning process before charging into the furnaceNo costGH
 4Regulate sizes for charging scrap and cut the scraps in line with the regulationsNo costGH
 5Formulate a plan for re-organizing the working planNo costGH
 6Dump the scrap into specified areasNo costGH
 7Increase material charging by craneNo cost  GH
 8Clean up the material charging site and operational platformNo costGH
9 Repair warping doors, seal all leaking points 8 million dong  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.

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 casting production in Vietnam./.