GREEN PRODUCTIVITY Case Study 1 VIETNAM

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Main areas of losses Hexane loss, Coal consumption, Air emission.

Fishbone Diagram for Hexane Loss

Hexane loss: causes

Hexane loss: Objectives Achieving reduction of Hexane loss to 3 litres per tone of seeds by the end of 2006.

Hexane loss: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selection Residue in Hot air discharged at toasting Better control the toasting temperature HLHYes Install Hexane condensor after cyclone MHLNo Residue in waste water in DT-DC process Improve efficiency of the water- solvent separator MMMYes Residue in water in Distillation process Improve efficiency of the water- solvent separator MMMYes

Hexane loss: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selectio n Residue in DOC Better control the toasting temperature HLHYes Loss at cyclone Better inspection and maintenance HLHYes In-effective separation at water solvent separator Better inspection and maintenance HLHYes

Hexane loss: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selection Extractor leakage Better inspection and maintenance HLHYes Incompetent operator Re-training for operator HLHYes

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 2005s coal consumption per unit of crude oil by the end of 2006.

Coal consumption: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selection Loss in handling Provide covers for conveyor at connection and for trucks. HLHYes Refreshment training for workers HLHYes Low Burning efficiency Install roofing system for storaga area HHLNo Replace the old boiler with new one MHLNo Review and upgrade the inspection and maintenance process HLHYes Refreshment training for operator HLHYes

Coal consumption: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selectio n Loss of steam Replace new inslation material MMHYes Replace the leaked pipe and connectors MMHYes Review and upgrade the inspection and maintenance of insulation and piping system HLHYes Install a system for recycling of boiler-water MHMNo

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 2005s boiler air emission (by volume) per unit of crude oil by the end of 2006.

Air Emission: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selection air emission from coal-firing boiler Buying high quality coal. HMMYes Looking at options for biomass-fuel alternative HLMYes Reducing coal consumption Refering to objective No 2. dust emission from screening Better control of soy bean seed quality HLMYes Better inspection and maintenance of equipment HLMYes

Air Emission: Options CausesOptionsTech Feas Fin. Req. Ben/ Cost Selection dust emission from cracking Better inspection and maintenance of equipment HLMYes dust emission from DOC crushing & packing Better inspection and maintenance of equipment HLMYes

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.