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.