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Case study

Vinh Phu Battery Joint Stock Company

19/02/2012

Vinh Phu Battery Joint Stock Company has its headquarters in Chu Hoa commune, Lam Thao, Vietnam Tri City, Phu Tho Province. The company was officially commenced in 1978 with the production capacity of 70,000 kWh batteries for automobile per year with the total employees of 160 persons. The company specializes in production of automotive and motor batteries.

In 2008, the company received the support from the Ministry of Industry and Trade via the Cleaner Production in Industry Component (CPI) and Vietnam Cleaner Production Centre to conduct Cleaner Production assessment.

During the first phase (from May to December 2011), the company established a CP team led by Mr. Trieu Dinh Thach –Technical Deputy Director of the company and other 8 members 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 some no-cost and low-cost good housekeeping options with a total budget of VND 197 millions. Such application has annually brought 236 million dong. In addition, the Company has actively implemented high-investment options to improve the product quality and solve completely the environmental issues at place.  The company had invested 8.8 billion dong for 7 big options as in the plate pasting process, the rejected plates should be separated, avoiding the exposure to water that could reduce the plate recycling and recovering possibility as well as chemically contaminating the wastewater effluent, replace ball-casting machine system, replace the  mixer and pasting machine. Benefits from those solutions are 1.44 billion dong per year after deducting new system operation costs.

Particular benefits derived from Cleaner Production are as follows:

Technical benefit Economic benefit Environmental benefit
 Phase 1:
Annual reduction of 260 tons of CO2

Annual reduction of 14,000 kg of lead dross generates in production process.

Dust concentration of exhaust fumes meet Environment National standard

Mitigation environmental impacts in production area and surrounding the company
Annual reduction of 47,000 kwh of electricity consumption      
   
 
 
      


Annual saving of 47 million VND 
 Reduction of 1.74 tons/year of lead consumption Annual saving of 52 million VND  
  Reduction of 530 litters/year of acid consumption Annual saving of 5.3 million VND    
 Reduction of 14,900m3/year of water consumption   Annual saving of 52 million VND   
Switch from coal to burn biomassBring benefit 1.83 billion dong  per
 Phase 2:   
 Annual reduction of 364,000 kwh of electricity consumptionAnnual saving of 364 million VND
Annual reduction of 2.100 kg of gas consumption     Annual saving of 410 million VND
 Annual reduction of 12,800 tons of lead consumption    Annual saving of 358 million VND   
 Annual reduction of 10,225 kg of rejected produced      Annual saving of 305 million VND   

Typical Cleaner Production options of the Company are as follows:

No.CP OptionInvestmentPerformanceCP technique
 1Increasing bags for collecting lead dust in the melting process, thus, recovering partly lead materials and reducing lead emissions to the atmosphere15,5 million dongAnnual saving of 30 billion dong

Reduction of 1200 kg of dust generation
  PC
 3Separating wastewater effluent from each battery manufacturing process         

7,5 million dongImprove wastewater  quality PC
 4Treating rejected plates in pasting process. The rejected plates should be separated and make the tanks to eliminate lead power from grids and then lead powder back to use for pasting and eliminated grids is used for grid casting      
     

5 million dong Annual saving of 75 billion

Annually reduction of 100m3 of waste water 1500 Kwh of electricity consumption
 OR
 5Making tanks and trays to catch spillage acid solution during play and charge battery4,5 million dongAnnual saving of 5,3 million dong

Reduction of 527 liters of  acid solution spilled into environment
EM
 6Circulating and reusing cooling water in  grid casting, lead powder, pasting process
         
 
80 million dongAnnual saving of 37 million dong
Reduction of 10,800 m3 of wastewater
  OR
 7Substituting corrosive water valves by the new ones
           


10 million dongAnnual saving of 6,4 million dong
Reduction of 1825m3 of wastewater 
 EM
 8Sealing the leaks in the water supply network        

5 million dongAnnual saving of 5,1 million dong
Reduction of 1460m3 of wastewater  
GH
 9Studying to change to a new charging regime to avoid air emissions containing acidic mists and reduce fail products762 million dong   Annual saving of 166 million dong
 
Significant reduction in emissions, energy, greenhouse gas
GH
 10Replacing the existing lead ball-casting machine, milling and pasting machine using more power and environmental pollution by the modern, closed and uninterrupted, low power consumption

1,7 billion dong Saving of 473 million dong/year
Annually reduction of 51.625 Kwh of electricity consumption and reduction of 4200 kg of lead dross
Annually reduction of 10.224 kg of fail semi-finished product 
EM
 11Changing the existing grid-casting machine, which is highly energy consuming and creates large amount of dross and rejected grids by a new to reduce material and electricity consumption1,6 billion dong   Annual saving of 381 million dong
Annual reduction of 140,350 kwh of electricity consumption
Annually reduction of 8640 kg of lead dross
EM

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

Perceiving the benefits from CP application, the company 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 Company 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 Company 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 battery production in Vietnam./.