green productivity case study 1 vietnam. step 1
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GREEN PRODUCTIVITYGREEN PRODUCTIVITY Case Study 1Case Study 1
VIETNAMVIETNAM
Saxena, NakayamaSteering Committee
Nguyen Quoc KhoaCorporate System Manager
Pham Minh ThangLogistics Team Leader
Hoang Viet DungS&M Coordinator
Nguyen Linh HaFinance Team Leader
Hoang Thanh LiemIT Coordinator
Do Dinh ThangManufacturing Team Leader
Nguyen Thi Bich TranHR Coordinator
Do Duy PhuocMaitenance Team Member
Do Huu TaoProduction Team Member
Pham Dinh HauOHS Team Member
Giang Thi Linh ChiProcurement Team Member
Mac Quang Quyen Outbound & Inbound
Logistics Team Member
Nguyen VuProduction Engineering
Coordinator
Nguyen Duy TungQA &Technical Support
Coordinator
STRUCTURE OF PERSONNEL INVOLVED FOR GREEN
PRODUCTIVITY
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
STEP 8
STEP 9
STEP 10
STEP 11
Main areas of losses
• Hexane loss,
• Coal consumption,
• Air emission.
Hexane loss
Materials
Methods
Reverter furnace
Machines
Drying processSeparator hexance
absorber
Cyclone
Men
Waste materials
Unskilled labor
Inappropriate eduction
Mix into water during DT-DC processes
Remove in stripper-cum-dryer
Reverter furnace using
Lost during crushing (oversize DOC)
Waste waterDuring on
distillation
Mineral Oil
Discharged hot air
Mixed with DOC
Mixed with Oil 99%
Extractor
Fishbone Diagram for Hexane Loss
Hexane loss: causes
Hexane loss
Materials
Methods
Reverter furnace
Machines
Drying processSeparator hexance
absorber
Cyclone
Men
Waste materials
Unskilled labor
Inappropriate eduction
Mix into water during DT-DC processes
Remove in stripper-cum-dryer
Reverter furnace using
Lost during crushing (oversize DOC)
Waste waterDuring on distillation
Mineral Oil
Discharged hot air
Mixed with DOC
Mixed with Oil 99%
Extractor
Hexane loss: Objectives
• Achieving reduction of Hexane loss to 3 litres per tone of seeds by the end of 2006.
Hexane loss: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
Residue in Hot air discharged at toasting
Better control the toasting temperature
H L H Yes
Install Hexane condensor after cyclone
M H L No
Residue in waste water in DT-DC process
Improve efficiency of the water-solvent separator
M M M Yes
Residue in water in Distillation process
Improve efficiency of the water-solvent separator
M M M Yes
Hexane loss: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
Residue in DOC
Better control the toasting temperature
H L H Yes
Loss at cyclone
Better inspection and maintenance
H L H Yes
In-effective separation at water solvent separator
Better inspection and maintenance
H L H Yes
Hexane loss: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
Extractor leakage
Better inspection and maintenance
H L H Yes
Incompetent operator
Re-training for operator
H L H Yes
Coal consumption
• Loss in handling:– Droppings in internal transport:
• Equipment:– Open conveyor;– Dropping from trucks;
• Incompetenct loading/undloading worker;
Coal consumption
• Low Burning efficiency:– High moisture content of coal:
• Unsheltered storage area;
– Boiler:• Old Technology;• Inappropriate maintenance.
– Method: • Inappropriate operation standard;
– Operator:• Incompetent;
Coal consumption
• Loss of steam:– Bad insulation:
• Less effective insulation material;• Lack of inspection and maintenance.
– Loss steam:• Leakage of pipe/connection;
– Non-reuse of steam.
Coal consumption: Objectives
• Achieving 10% reduction of 2005’s coal consumption per unit of crude oil by the end of 2006.
Coal consumption: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
Loss in handling
Provide covers for conveyor at connection and for trucks.
H L H Yes
Refreshment training for workers
H L H Yes
Low Burning efficiency
Install roofing system for storaga area
H H L No
Replace the old boiler with new one
M H L No
Review and upgrade the inspection and maintenance process
H L H Yes
Refreshment training for operator
H L H Yes
Coal consumption: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
Loss of steam
Replace new inslation material
M M H Yes
Replace the leaked pipe and connectors
M M H Yes
Review and upgrade the inspection and maintenance of insulation and piping system
H L H Yes
Install a system for recycling of boiler-water
M H M No
Air Emission• Causes:
– air emission from coal-firing boiler;– dust emission from screening;– dust emission from cracking;– dust emission from DOC crushing & packing.
Air Emission: Objectives• Achieving 10% reduction of 2005’s boiler
air emission (by volume) per unit of crude oil by the end of 2006.
Air Emission: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
air emission from coal-firing boiler
Buying high quality coal.
H M M Yes
Looking at options for biomass-fuel alternative
H L M Yes
Reducing coal consumption
Refering to objective No 2.
dust emission from screening
Better control of soy bean seed quality
H L M Yes
Better inspection and maintenance of equipment
H L M Yes
Air Emission: OptionsCauses Options Tech
FeasFin. Req.
Ben/ Cost
Selection
dust emission from cracking
Better inspection and maintenance of equipment
H L M Yes
dust emission from DOC crushing & packing
Better inspection and maintenance of equipment
H L M Yes
GP Policy
Rama Phosphate Limited (oil division) stated following GP policies:
• Commited to complying with relevant environmental legislations and requirements.
• Commited to waste reduction and polution prevention.
• Promote environmental awarness and participation from all.
• Commited to continual improvement of the effectiveness of environmental performance.