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Case study

Kim Anh Production and Trading Service Limited Company

19/02/2012

Kim Anh Co., Ltd was established in 2003 as private own and is located in Nghe An province. Kim Anh produce steel ingot to supply to domestic construction purposes in Nghe An province and nearby provinces. The company produces over 3024 tons of steel ingot per year. Its total employees is 80.

Before applying cleaner production, the company often had to face the problem of air emission and noise pollutions. Gas exhaust derived from processes of melting and refining contained dust, lead with CO2, SO2 exceeding permitted levels. Dust in producing areas was  2.5 – 2.7 times higher than the standard of hygiene and occupational safety. Noise exposed continuously in 8 hours exceeded 1.05 – 1.07 times in comparison with Vietnamese Standards. In 2008, the company received complaining document from residents in Hong Thinh village, Dien Hong Commune, Dien Chau District about gas exhaust and dust pollutions in the residential area.

Besides, before applying cleaner production, the company had to face the problems of occupational health safety. Workers had to do hard work: carrying steel scraps up to the working floor to input material, pouring melting steel from hand ladles into casting moulds, liquid steel spilling at high temperature of 1,600 0C; High noise level in workplace (90dBA), and high dust concentration in workplace (10-11mg/m3), workers do not use personal protection equipment. To solve these problems the company accessed the component Cleaner Production in Industries of Ministry of Industry and Trade.

With the support from Ministry of Industry and Trade, in October 2008, the company started to carry out the cleaner production assessment. In stage 1 (from October 2008 to December 2009), the company established cleaner production team led by Mr. Chu Quang Hung -  Director of the company– and other 3 members to carry out the cleaner production assessment on the whole of the starch production line.  The assessment of the production lines, the verification of waste streams, the balance of materials and energy were worked out. Then all data collected were used for analyzing to find out the cleaner production options for each production process.

After the assessment and the determination of improving solution options, the company conducted 19 solution options which required low cost and no cos with the total investment of 169 million dong. Financial benefit received in 2009 was 966 million dong. In stage 2 (January 2010),  the company invested 8.4 billion dong to develop solutions to thoroughly solve the environmental problems. The solutions included: constructing cement ground for material store to prevent soil and rocks from mingling into the material, installing scarp pressure machine with capacity big enough for 3 sets of furnaces (6 furnaces), replacing 3 pairs of 1-ton furnaces by 1 pair of 5-ton furnaces, installing continuous casting system, and installing dust collection and treatment system.

Benefits brought in to the company from cleaner production are briefly described as follows: 
        

Technical benefitEconomic benefitEnvironmental benefit
Reducing 2.75% of specific scrap consumption Saving 830 million dong  Reducing 25.23% of specific solid consumption
Reducing 6.17% of specific electricity consumption Saving 150 million dongReducing 0.33% of specific refractory lining material consumption
Reducing 6.04% of CO2 emission (147 tons)

Typical cleaner production options of the company are detailed below:

 No.   Option Investment  Performance CP technique
 1 Identification and regulating proper scrap pressed size to furnace (800x400x350)No cost Easier for transport and charging PC
 2Purchasing good scrap (high density, less rust & impurities) No costReducing electricity consumptionMC
 3Separating non-metallic matters is mainly  conducted in daytime No cost  Better separation, lower scrap consumption and dust PC
  4Using forklifts to transport scrap to working  floor  100 million dong Reducing labor requirement EC
 5Assigning one person in charge of power management Salary of 1.5  million dong/monthBetter incident prevention and treatment. Furnace stop time reduced from 15 minutes to 5 minutes PC
 6Setting up a separate cooling water system for Thyristor63 million dongLess incidents of KK   EC
 7Adjusting power voltage of the first melt from 380V to 420V No cost Reduced melting time for first batch PC
8 Installation of electricity meters on all 3 pair of furnaces8 million dong Identified the operating situation of each furnace in order to have coordination in operation  GH
 9Regulating and enforcing the wear of workers protective gears  10 million dong  Safety assurance in working environment GH
 10 Creating storage area for asbestos fiber after using for special treatmentNo cost Separation of hazardous waste GH

Remarks: GH: Good Housekeeping, EC: Equipment Change;  PC: Process Change; EOP: End-of-pipe      

Being aware of the benefits from the cleaner production, the company decided to maintain the operation of the cleaner production team, and put the cleaner production activities into the general management system of the company. To do this, a simple environment management system was established. Also, the company made an environmental policy which stipulates the strict implementation of the Law of Environmental Protection and regulations to ensure the sustainable development and minimize the causes of waste. Besides, the company integrated the production management system and the environmental management system so that the consumption of materials and energy were controlled by monitoring the criteria in waste streams. A system of sampling and legal procedure was also built to be applied in collecting, checking, and analyzing environmental data.

An environmental monitoring plan has been conducted. It aims to monitor the considerable improvements brought in by the cleaner production options, and to adjust them in case some environmental benefits are reduced. The environmental monitoring system comprises air monitoring and waste water monitoring.

Cleaner Production not only brings in benefits from energy saving, emission reduction, water consumption reduction, but also helps the company to develop production, improve product quality, and affirm the company reputation. The cleaner production options which have been implemented at the company are typical examples for steel production sector in Vietnam./.