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Green Productivity

Business Coach

Green Productivity

Green productivity demonstration program

Hoang Thach Cement Company, Viet Nam

demonstration program Hoang Thach Cement Company, Viet Nam Viet Nam National Cement Association, Viet Nam Web:

Viet Nam National Cement Association, Viet Nam


  Special   dust   collection   system   for   the   conveyors  to   extract   dust and collect it in the bag filters;

  change  of  bags  with  holes  that  are  used  for  packing  cement  

hoang Thach cement company, a state-owned enterprise under 

Viet  n am  n ational  cement  corporation.  i t   is   one   of   the   largest  and   most  technologically  advanced  cement   companies  in   Viet  

n am,  and   has  two   lines   of   production  with   a   total   installed  ca -

pacity of  2.3  million tons  of  cement  per  year.  i t  employs around   2,700   employees  who   work   on   three   shifts. 

Areas of GP intervention

The   Green   Productivity   (GP)   team   identified   the   following   key   areas  of   concern  in h oang  Thach cement company,  after  con - ducting the initial environmental review:

Dust:  Measurement  of  dust  showed  serious  violation  of Viet-

in Line 1 to bags without holes;

  Dust filter in system replaced by bag filter and in future to be   replaced by electrostatic Precipitator (eSP);

  collection  of  waste  oil  from  vehicles  in  a  separate  tank  to  be   used in kiln;

  collect and burn all oily rays in kilns;

  Waste water from vehicle washing to be treated in an oil sepa- ration system and then discharged;

namese industrial hygiene and air quality standards in crush-   Modify  the  shape  of  lifting  liner  in  a  planetary  clinker  cooler  

ing, kiln and packing areas. This not only caused bad working  environment and health hazard for workers but also results in   product loss;

  reduce  rock  size  by  screening  in  the  crushing  machine  or  by   manually breaking larger sized rocks.

where  around  8000  m 3   of  water  is  used  for  cooling  of  clinker

and equipments. All the waste water except for sewage is dis-

charged directly to the back river. The oil content in the waste 

water was also found to be on the higher side;

in Line 1;

  Use of coarser raw material for kiln; and

Waste Water:  Waste  water  is  emanated  primarily  from  unit  1  

h oang  Thach  cement  company   has   implemented   most   of   the

immediately   implementable   GP   solutions.  i t   has   also   imple - mented  e nvironmental   M anagement   S ystem s   ( e MS)   and   has  

been awarded with iSo 14001 certificate. The implementation of 

GP  options has been successfully  achieved,  and  at  both  the  com - panies   dust   generation   and   water   pollution   has   been   reduced  

while   increased   efficiency   of   the   equipment   and   procedures  have   been   achieved.  Waste   oil   is   now   reused   as   fuel   in   the   kiln   and   a   solid   waste   collection   system   has   been   setup.  e specially,   an  e MS   was   established   in  h oang   Thach   c ement   c ompany,   which   will   enable   the   GP   implementation   in   the   company   to   be sustainable. Another GP option implemented at hoang Thach   cement  company  was  a  dust-collection  equipment  at  the  junc - tion   of   the   two   conveyors.  This   resulted   in   savings   of   four   tons 

of   cement   per   month   with   an   investment   to   V n D   100   million  

Noise: noise is generated from equipments such as limestone   and clay crushers, air compressors, raw mill, kilns and cement   mills. The noise generated in the compressed air section was 

104–108 dB higher than the standard when four compressors

were working; and

Low Productivity:  Low  productivity  was  of  major  significance   in   production   line  n o.1.   This   is   due   to   the   old   technology   of   the   satellite   coolers   of   the   kiln,   pre-heater,   and   crushing  machine.

GP options

After   detailed  analysis   of   the   production   process   and   material  balance,  the  GP  team  identified  26  GP  options  in hoang  Thach 

cement company, out of which 17 were found to be appropriate 

for immediate implementation. The major GP solutions that were

identified are listed below:

  Water spraying on the trucks carries mined limestone and clay   to reduce dust in unloading areas;

 operation of two vacuum cleaner vehicles all along the trans- portation route to reduce dust, and save clean water;

(USD   6410)   and   a   payback   of   10   months.   The   sustainability   of  the   program   also   derives   from   the   improvement   in   the   aware - ness  of  the  employees  of  both  the  companies  regarding  Green   Productivity.

The   Green   Productivity  Program   has   been   successfully  imple - mented in the cement company in Viet nam. The results achieved  have  contributed  significantly  to  the  improvement  of  the  envi- ronmental  performance  of  the  factories  and  have,  additionally,   positive impacts on their efficiency.

additionally,   positive impacts on their efficiency. 50   Tech   Moni Tor   •   Apr-Jun   2012

50  Tech   Moni Tor   •   Apr-Jun   2012

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Green Productivity

Green Productivity

Business Coach Green Productivity Green Productivity LCA, green productivity, and sustainable management activity Palm

LCA, green productivity, and sustainable management activity

Palm oil industry

ASEAN + Network on LCA and Carbon Footprint, Thailand


c limate   change   has   emerged   as   a   driver   of   change   for   global   industries  in  the  twenty-first  century.  From  the  landmark  Kyoto  

Protocol framework established in 1997 to the coP 15 in copen-

hagen,  Denmark,  a  cohesive  global  effort  has  been  undertaken  to  reduce  the  greenhouse  gas  emissions  in  developed  nations,  in  particular  its  energy  use  and  transportation  sector  to  reduce greenhouse gas emissions.

  opportunity   to   make   a   significant   contribution   in   mitigating   the  climate  change  effects  through  the  production  of  its  palm oil,   which   is   produced   with   good   agricultural   practices   and   management   that   ensures   a   consistent   high   yield   with   mini - mal  environmental  pollution,  and  waste  while  adhering  to  the   sustainability   principles   of   the   3Ps.  The   high   yield   of   the   palm  oil,  compared  to  competing  oilseed  crop  ensures  that  less  land   expansion  for  planting  is  needed,  if  compared  to  planting  other  oilseed   crops.

r esearch   undertaken   by   the   Malaysian   Palm  o il   Board   (MP o B)  to   narrow   the   gap   between   current   yield,   which   is   20   tons   of   Fresh  Fruit  Bunch  (FFB)/hectare,  and  the  genetic  yield  potential   of   the   oil   palm,   estimated   to   be   46   tons   of   Fresh   Fruit   Bunch/ hectare   and   successful   ongoing   palm   genome   sequencing   re - search  findings  are  expected  to  accelerate  this  process  naturally  without   venturing   into   genetic   modifications   (GM).   This   indi - rectly   reduces   the   deforestation   and   land   use   change   effects   that   would   significantly   increase   the   world’s   greenhouse   gas   emissions.

Palm oil is also used as a biofuels feedstock. Under the european   commission’s renewable energy Directive (reD), which places a   target   for  european   Union   members   to   have   a   10%   renewable  energy share in the transportation sector by 2020, biofuels used  

in the eU would need to have a minimum rate of 35% greenhouse 

gas  savings,   where   the  greenhouse   gas  savings  of  the   biofuels

  are  calculated  through  the  use  of  Life cycle  Assessment  (LcA),  a  

technique to determine a product’s environmental load, includ-

ing its greenhouse gas emissions.

The   Malaysian   palm   oil   industry   sees   this   development   as   an

Malaysian Palm oil Board (MPoB) through its ‘national  committee on Lc A for Palm oil’ and progressive plantation companies, vari- ous   Lc A   studies   have   been   commissioned   and   undertaken   —    primarily   to   meet   the   Greenhouse   Gas   (G h G)   savings   require - ments set by the reD. 

i n the assessment, it is noted that the main source of GhG emis-

sions   comes   from   the   milling   sector   (if   land   use   change   is   ex- cluded)   or  the   oil   palm  plantation   (if   land   use  change  of   forest   conversion is  considered).

Recommendations and conclusion

As  a  conclusion,  there  is  a  strong  urgency  for  a  set  of  consistent   data  in  the  form  of  a  national   life  cycle   inventory   for  Malaysian  palm oil to harmonize the different results of its greenhouse gas   savings.

i t  is  also  of  paramount  importance  for  international  authorities/

agencies drafting biofuels legislations and standards to note the different   methodologies   to   be   applied   in   their   calculations   by   referring  to  a  wider  scope  of  studies  undertaken  to  ensure  that   it  is  able  to  benchmark  palm  oil’s  greenhouse  gas  savings  more   accurately.

once a localized date is available through the establishment of a   national standard database, leading authorities working on palm   oil’s  LcA  must  then  establish  the  specific  pathways  of  palm  oil’s  Lc A   to   differentiate   the   different   processes   involved,   so   that   a   more reflective value can be established. This will also give credit   where it is due to processes which are more energy and biomass   efficient.

examples of pathways:

  Palm oil without methane trapping;

  Palm oil with methane trapping; and

  Palm oil with methane trapping and co-products (conversion   of  eFB   into   bio-energy   and/or   biomass   utilization   into   MDF,   etc.).

Finally,   the   industry   would   also   need   to   brace   itself   for   land   use   change   and   indirect   land   use   change   concepts,   in   which   the  understanding  is  still  vague  amongst  Lc A  practitioners  but   would have a huge impact on the overall results of assessments  if   it   is   taken   into   consideration   without   proper   guidelines   and    conditions.

Current status of LCA activities

Lc A  is  now  used  extensively   in  the  Malaysian   palm  oil  industry   to quantify the Greenhouse Gas emissions in its production. Led  initially by the Standards and i ndustrial r esearch i nstitute of Ma- laysia  (SiriM),  the  national  standards  body  and  currently  by  the  

national  standards  body  and  currently  by  the   Tech   Moni Tor   •   Apr-Jun

Tech   Moni Tor   •   Apr-Jun   2012  51