Evaluation of the cleaner production strategies eficiency in carton paper production in hoan van thu paper joint stock company, thai nguyen city

THAI NGUYEN UNIVERSITY UNIVERSITY OF AGRICULTURE AND FORESTRY - - NGUYEN VAN HOA EVALUATION OF THE CLEANER PRODUCTION STRATEGIES EFFICIENCY IN CARTON PAPER PRODUCTION IN HOANG VAN THU PAPER JOINT STOCK COMPANY, THAI NGUYEN CITY BACHELOR THESIS Study mode: Full-time Major: Environmental Science and Management Faculty: Advanced Education Program Office Batch: 2014-2018 Thai Nguyen, / /2018 DOCUMENTATION PAGE WITH ABSTRACT Thai Nguyen University of Agriculture and Forestry Degree Program Bachelor of Environmental Science and Management Student name Nguyen Van Hoa Studen ID DTN 1554290040 Thesis Title EVALUATION OF THE CLEANER PRODUCTION STRATEGIES EFFICIENCY IN CARTON PAPER PRODUCTION IN HOANG VAN THU PAPER JOINT STOCK COMPANY, THAI NGUYEN CITY PhD Nguyen Thanh Hai – Deputy Dean of The Faculty of Supervisor Environment, Thai Nguyen University of Agriculture and Foresttry, VietNam Abstract: Hoang Van Thu Paper Company is considered as one of the cradles of the paper industry in Vietnam, with a long history of development The company has been asserting its name and position in the domestic and international market and contributing to the economic development of Thai Nguyen in particular and of Vietnam in general This thesis encompasses the way that the company has been making efforts to minimize the impact of pollutants, emission, transportation of solid waste and hazardous waste on the environment through the investment in the construction of waste water treatment systems It also comprises the recycling of some waste as input materials for production by implementing the CP and bringing benefits to the economy, technology and environment Moreover, the thesis also gives the highest grades of proposed cleaner production solutions in the production process Key-words: Cleaner production; water treatment; waste treatment; high performance; Number of pages: Date of submission: September 25,2018 Supervisor’s signature i ACKNOWLEAGEMENT First of all, I would like to thank the Hoang Van Thu Paper Joint Stock Company for providing me an amazing opportunity to conduct my internship in the company I sincerely thanks to PhD Nguyen Thanh Hai for his advices and assistance, helping me to understand and completing my proposal and thesis He also helped me a lot by spending precious time for checking my thesis report I consider it is an honor to work with Ms Nguyen Thi Dung, environmental engineer of Hoang Van Thu Company who was particularly helpful in guiding me towards a qualitative methodology and inspiring me the whole period of my internship time She was always helpful, friendly and very kind with me Without her guidance, I could not have accomplished this thesis Finally, I would like to express my deep gratitude to my family and friends for providing me emotional, unceasing encouragement, as well as physical and financial support I would like to thank all those other people who helped me in completing this report Because of my lack of knowledge, the mistakes are inevitable, I would be very grateful if I receive the comments and suggestions from teachers and others to contribute to the betterment of my report Sincerely, Nguyen Van Hoa ii TABLE OF CONTENTS DOCUMENTATION PAGE WITH ABSTRACT i ACKNOWLEAGEMENT ii TABLE OF CONTENTS iii LIST OF FIGURES v LIST OF ABBREVIATIONS vi LIST OF TABLES vii PART 1: INTRODUCTION 1.1 Research rationale: 1.2 Research’s objectives PART 2: LITERATURE REVIEW 2.1 Cleaner production review 2.1.1 The formation and development of cleaner production 2.1.2 The general concept of cleaner production 2.1.3 Related concepts and terminology 2.1.4 Technical solutions for cleaner production 2.2 The situation of the Implementation of cleaner production in the world and Vietnam 2.2.1 Implementation of CP in the world 2.2.2 Implementation of Cleaner Production in Vietnam 2.3 Implementation of CP to the paper industry in Vietnam 13 PART 3: SCOPES, CONTENTS AND METHODOLOGIES 14 3.1 Research’s scopes 14 3.2 Research’s contents 14 3.3 Research’s methodologies 14 3.3.1 Method of collecting secondary data 14 3.3.2 Method of primary data collection 15 3.3.3 Total weighting method 16 3.3.4 Method of balancing matter and energy 16 3.3.5 Cost-benefit method 16 3.3.6 Data processing method 17 iii 3.3.7 Group discussion method 17 3.3.8 Environmental assessment methods 17 PART 4: RESULT AND DISCUSIONS 18 4.1 Introduction about Hoang Van Thu Paper Joint Stock Company 18 4.1.1 Geographical location and history of formation 18 4.1.2 Characteristics of the production process 20 4.1.3 New technological lines and input materials 21 4.1.4 Waste sources and treatment methods 24 4.2 The current state of application of cleaner production solutions 31 4.2.1 Recovery, recycled paper, auxiliary chemicals 31 4.2.2 Reuse of waste products and waste in production stages 32 4.3 Evaluate the effectiveness of cleaner production solutions 34 4.3.1 Evaluation of economic efficiency before and after cleaner production 34 4.2.2 Results of production and business over the years 35 4.2.3 Evaluation of the NPV value over the years 36 4.3 Evaluation of technical efficiency before and after cleaner production 37 4.3.1 Equalization of inputs and outputs of old technology 37 4.3.2 The shortcomings of the old line 38 4.3.3 Balance material input and output of the new line 39 4.3.4 Evaluate the performance achieved between the two technologies before and after cleaner production 41 4.4 Evaluate environmental performance before and after cleaner production 42 4.4.1 Waste generation, waste treatment and environmental status of the company prior to cleaner production 42 4.4.2 Assessment of environmental performance before and after implementation of cleaner production 45 4.5 Proposed cleaner production solutions in the production process 46 PART 5: CONCLUSION 49 REFERENCES 52 iv LIST OF FIGURES Figure 1: General diagram of industrial producing process Figure 2: The logical development of the response to pollution Figure 3: Geographical location of Hoang Van Thu Paper Joint Stock Company 18 Figure 5: Diagram of wastewater treatment system in cleaner production 26 Figure Paper output of all kinds of paper through the years of Hoang Van Thu Paper Company 34 Figure 7: Cost and revenue charts over the years 35 Figure 8: Chart of business results of Hoang Van Thu Paper Company 36 Figure Environmental performance chart before and after cleaner production 46 Figure 10: Wood pellets 47 v LIST OF ABBREVIATIONS CP Cleaner production BOD Biochemical Oxygen Demand BTNMT Ministry of Natural Resources and Environment COD Chemical Oxygen Demand CP Cleaner Production PP Pollution Prevention TSS Total Suspended Solid SS Suspended Solid WM Waste Minimization vi LIST OF TABLES Table 1: Effectiveness of applying cleaner production at Thai Nguyen Export Paper Company 10 Table Effectiveness of Cleaner Production of Luu Xa Cement Plant, Thai Nguyen City 12 Table : Solid waste production and solutions 25 Table 4: Quality of air environment in Hoang Van Thu company in 2018 28 Table 5: Measurement results, chimney flue gas analysis 29 Table 6: Production and turnover of various types of paper over the years 34 Table 7: Production and business results in the last years 35 Table Cost and benefit analysis over the years 36 Table 9: Material balance for the production of cement paper before CP of Hoang Van Thu Paper Company 37 Table 10: Balance of materials for cement production line for 1000 kg of product after applying CP 39 Table 11: Comparison of the differences between the two technologies before CP and when CP applying in Hoang Van Thu Paper Company 41 Table 12 Technical efficiency before and after implementation of CP 42 Table 13 Water quality of upper and lower Cau River in 2018 43 Table 14 Quality of waste water after treatment Hoang Van Thu Paper Joint Stock Company in 2018 44 Table 15: Environmental benefits before and after implementation of cleaner production 45 vii PART 1: INTRODUCTION 1.1 Research rationale: In the whole process, the business background will be going hand in hand with the environmental protection When the living standards of people are on the rise and their learning level is increasing gradually, human needs are not just satisfied by getting all the material gains they can earn but they also need a good environment This is the reason why they want to redirect strategies to a sustainable development Nowadays, businesses targeting the optimization of profits not stop or care to exploit natural resources, which pose a threat to the depletion of the world’s supply and trigger negative impacts on the environment such as: Air polution, water polution, poisoned waste,etc For manufacturers who invest in waste treatment, environmental protection places a burden on producing cost and reducing competition, thus it can reduce profits For their own benefit, businesses often overlook the common benefit of society So how to accomplish to develop economically to achieve sustainable development? At this time, the primary response for sustainable developement is cleaner production The introduction of cleaner production (CP) has played a significant role on the sustainable development CP helps to save the energy and natural resources, it even removes the waste lines with an effeciency up to 100% Today, the controlling pollution at the end of the pipe does not seem to be an efficient solution due to its low effectiveness and high cost Instead of that, the use of vertical pipes or CP has been prevalent CP is proactive and precautionary before the waste is generated Therefore, if the enterprise applies cleaner production, it not only benefits many businesses but also society CP is one of the most important strategies of many countries Implementing CP technology in the industry is a way to bring benefits to the economy and at the same time contribute to reducing environmental pollution, allowing enterprises to fulfill the requirements of environmental protection The application of cleaner production will also help businesses to build a good reputation and products that can compete in the domestic and foreign markets Hoang Van Thu Paper Joint Stock Company is located in Quan Trieu Ward, Thai Nguyen City Hoang Van Thu Paper Joint Stock Company is considered as one of the cradles of Vietnam paper industry, with a long history of development and a unit that has boldly applied cleaner production in recent years, it has brought about very good results The company has solidified its name and position in the domestic and international market and contributed to the economic development of Thai Nguyen in particular and of Vietnam in general In order to contribute to a sustainable development and promote the application of cleaner production in enterprises located in Thai Nguyen province, I conducted research named: “Evaluation of Cleaner Production strategies efficiency in carton paper production in Hoang Van Thu Paper Joint Stock Company, Thai Nguyen city, Thai Nguyen province” 1.2 Research’s objectives - Understanding the current status of production and the application of cleaner production options at Hoang Van Thu Paper JSC., Thai Nguyen - Evaluating the effectiveness of the company's cleaner production options - Researching to improve and propose new Cleaner Production solutions to the company 4.3.3 Balance material input and output of the new line Table 10: Balance of materials for cement production line for 1000 kg of product after applying CP Input raw material Stage Name Output raw material quantity (kg) Classification - Margin paper of materials Hydraulic - Scrap paper milling - White water Tank - Powder after hydraulic grinding - Water after hydraulic grinding Disc milling - Powder after hydraulic grinding - Water after hydraulic grinding - Alum 35 35 m3 1272 35 m3 1272 35 m3 18.6 - Pine leaf - Powder after grinding disc - Water after grinding disc Dilution tank - Powder after grinding disc - Water after hydraulic grinding - White water Grid box - Powder before xeo - Water before xeo Grid - Powder on the grid 1.4 1292 35 m3 1292 35 m3 35 m3 1292 70 m3 1033 - Water on the grid - Paper after grid - Water after grid 70 m3 1000 20 m3 Tank Vacuum 1250 Name - Classified margin paper Waste streams Quantity (kg) Liquid (m3) 1230 - Powder after hydraulic grinding 1260 - Water after hydraulic grinding 35 m3 - Powder after hydraulic grinding 1272 - Water after hydraulic grinding 35 m3 - Powder after hydraulic grinding 1272 - Water after hydraulic grinding 35 m3 - Powder after grinding disc - Water after grinding disc - Diluted powder - Water after dilution tank 1292 35 m3 1292 70 m3 - Powder on the grid - Water on the grid - Paper after grid 1033 70 m3 1000 - Paper after grid - Paper after vacuum - Water after vacuum 20 m3 980 10 m3 39 Solid (kg) Adhesive tape, pins, plastic: 10 Pin, grit sand, flour: 15 - White - Pulp: 292 water: 50 WW:10 Gas (m3) Input raw material Stage Ép Dry Dry Roll Cut the roll Pack Name Output raw material quantity (kg) - Paper after vacuum - Water after vacuum - Post-intermediate paper - Post-intermediate water - Saturated steam - Post-intermediate paper - Post-intermediate water - Paper after drying1 - Water after drying1 - Saturated steam - Paper after drying - Water after drying -Paper after rolling - Water after rolling 980 10 m3 945 0,82 m3 945 0.72 m3 945 0.4 m3 0.4 m3 945 0.08 935 0.08 - Rolled back paper - Water after rolling back - Straps - Paper core 920 0.08 0.5 Name Waste streams Quantity (kg) - Post-intermediate paper 945 - Post-chest compress paper - Post-chest compress water - Paper after drying - Water after drying 945 0.72m3 945 0.4 m3 - Paper after drying - Water after drying - Water evaporated - Water after rolling - Rolled back paper - Rolled back water 945 0,08 m3 0,32 0,08 920 0.08 - Paper products - Water in the product 920 0.08 40 Liquid (m3) Solid (kg) Gas (m3) White water: White water: 0.1 0.32 0.32 - Broken paper: 10 - Overdraft paper: 10 - Broken paper: 4.3.4 Evaluate the performance achieved between the two technologies before and after cleaner production From the production process, the input and output balance can be seen from the two lines as follows: Table 11: Comparison of the differences between the two technologies before CP and when CP applying in Hoang Van Thu Paper Company Content Technology before CP Technology after CP Capacity 4000 tons/year 15.000 tons/year Originated from China is mainly through the process of use, overhaul, repair and patchwork Device Originated from Federal Republic of Germany Equipment includes cutting Hydraulic grinding system, paper system, bridge pot, cylinder, paper machine, boiler area pulping machine system, boiler area, Recovery of powder by the site selection system, wastewater treatment system combines the Hydraulic grinding system, machine system, boiler area, measures of: physical, chemical, biological Raw material Chemistry Bamboo, wood Waste paper (OCC, UKP, box ) Sodium Hydroxide: 175 kg Alum: 16 kg Alum: 25 kg Pine resin: kg Pine resin: 10 kg Color: 0.5 kg Color: kg Warranty substance: 0.25kg Unfoaming agent: 0.37kg Water 300 m3/Ton of product 70 m3/Ton of product Product Paper weight is unstable, foam Relative stability, high mechanical quality paper, moisture, poor mechanical strength, tearing a lot strength, less tear 41 Table 12 Technical efficiency before and after implementation of CP Name the raw materials to produce ton of paper Technical benefits Before CP After CP Products (tons / year) 4,113 14,000 Pulp, bamboo (tons / year) 14,107 - Recycle margins (tons/year) - 18,443 300 70 1,184 11 - 660 1,019 807 Water (m3 / hour) Coal (kg ) Bamboo, sawdust, wood(kg) Electricity (KWh) 4.4 Evaluate environmental performance before and after cleaner production 4.4.1 Waste generation, waste treatment and environmental status of the company prior to cleaner production Waste water discharged from paper mills is one of the most polluted sources in terms of both flow and concentration With complete production technology, there are two stages: producing paper pulp from bamboo, vermicelli and producing waste paper from the drying plant which is discharged from two sources: - Wastewater discharge from the cooking pots and pulp washing - Waste water discharged from paper machines 42 Environmental status Water enveronment * Surface water: Table 13 Water quality of upper and lower Cau River in 2018 No Name of indicator Unit pH Result X1 X2 QCVN 08:2015/BTNMT Color mg/l 6,7