17-CP Duc

Ti liu hng dn
Sn xut sch hn
Ngnh: c kim loi
Phin bn: 09.2011
C quan bin son

Hp phn Sn xut sch hn
trong cng nghip
Chng trnh hp tc pht trin
Vit nam - an mch v mi trng
B CNG THNG
Mc lc
Mc lc ............................................................................................................2
M u ............................................................................................................5
1. Gii thiu chung .......................................................................................6
1.1
M t ngnh c kim loi ...................................................................6
1.2
Quy trnh c kim loi ........................................................................8
1.2.1
Chun b khun, rut (thao), mu ...............................................9
1.2.2
.....................................................................12
1.2.3
c kim loi ..............................................................................14
1.2.4
................................................................................14
2. S dng ti nguyn, tc ng n mi trng v an ton sn xut ........16
2.1
Tiu th nguyn nhin liu ...............................................................16
2.2
Cc vn mi trng v an ton sn xut ....................................17
2.2.1
Kh thi .....................................................................................17
2.2.2
Nc thi .................................................................................18
2.2.3
Cht thi rn .............................................................................18
2.2.4
Ting n ..................................................................................18
2.2.5
Nhit, chy n v an ton trong sn xut ..................................18
2.3
Tim nng p dng sn xut sch hn ............................................18
3. C hi sn xut sch hn.......................................................................19
3.1
.............................................19
3.1.1
Cc gii php qun l nguyn liu ............................................19
3.1.2
...........19
3.1.3
..................................................................21
3.1.4
.............................................21
3.1.5
...................22
3.2
.......23
3.2.1
Cc gii php p dng k thut - cng ngh tin tin ...............23
3.2.2
.....................................24
3.2.3
..........................27
3.2.4
............................27
3.3
..........................27
3.3.1
Lm sch..................................................................................27
3.3.2
X l nhit ................................................................................28
4. Thc hin sn xut sch hn .................................................................30
4.1
Bc 1: Khi ng ..........................................................................30
4.1.1
Nhim v 1: Thnh lp nhm nh gi SXSH...........................30
4.1.2
Nhim v 2: Phn tch cc cng on v xc nh lng ph ......34
4.2
Bc 2: Phn tch cc cng on sn xut .....................................39
4.2.1
Nhim v 3: Chun b s dy chuyn sn xut ....................39
4.2.2
Nhim v 4: Cn bng vt liu ..................................................40
4.2.3
Nhim v 5: Xc nh chi ph ca dng thi ..............................42
4.2.4
.........................................44
4.3
Bc 3: ra cc gii php SXSH .................................................45
4.3.1
Nhim v 7: xut cc c hi SXSH .....................................45
4.3.2
Nhim v 8: La chn cc c hi u tin trin khai ngay .........47
4.4
Bc 4: Chn la cc gii php SXSH ...........................................48
4.4.1
Nhim v 9: Phn tch tnh kh thi v k thut ..........................48
4.4.2
Nhim v 10: Phn tch tnh kh thi v mt kinh t ...................49
4.4.3
Nhim v 11: nh gi nh hng n mi trng .................50
4.4.4
Nhim v 12: La chn cc gii php thc hin .......................51
4.5
Bc 5: Thc hin cc gii php SXSH ..........................................52
4.5.1
Nhim v 13: Chun b thc hin .............................................52
Ti liu hng dn Sn xut sch hn trong ngnh cng nghip c kim loi
Trang 2/61
4.5.2
Nhim v 14: Thc hin cc gii php......................................52
4.5.3
Nhim v 15: Quan trc v nh gi cc kt qu .....................53
4.6
Bc 6: Duy tr SXSH .....................................................................54
4.6.1
Nhim v 16: Duy tr SXSH ......................................................54
4.7
Cc yu t bt li cho vic thc hin SXSH ....................................54
4.8
Cc yu t thnh cng ca chng trnh SXSH ..............................55
5. X l mi trng ....................................................................................56
5.1
X l kh thi ...................................................................................56
5.1.1
X l bi trong kh thi l nu luyn ..........................................56
5.1.2
X l kh c hi trong kh thi .................................................59
5.2
X l nc thi ................................................................................60
5.3
X l cht thi rn ...........................................................................60
6. Ti liu tham kho ..................................................................................61
Trang 3/61
Danh mc cc bng
Bng 1. Sn lng cc hp kim c Vit nam giai on 2020 - 2025 ..........7
Bng 2. D tnh sn lng vt c ca Vit Nam giai on 2011-2020...........8
...........................16
Bng 4. Thnh phn ca than cc ti Nh my cc ha ................................20
............................................................21
.....................................................21
...........27
Danh mc cc hnh
Hnh 1. S dy chuyn c kim loi............................................................8
Hnh 2. Nguyn liu u vo v pht thi trong qu trnh c kim loi ...........16
Hnh 3. Cc loi bung lng bi .....................................................................57
Hnh 4 Cyclon lc bi .....................................................................................57
Hnh 5. Lc bi ti vi ....................................................................................58
Hnh 6. Lc bi kiu tnh in ........................................................................58
Trang 4/61
M u
Theo nh ngha ca Chng trnh Mi trng ca Lin hp quc (UNEP),
sn xut sch hn (SXSH) l vic p dng lin tc chin lc phng nga
tng hp v mi trng vo cc qu trnh sn xut, sn phm v dch v
nhm nng cao hiu sut sinh thi v gim thiu ri ro cho con ngi v mi
trng.
, sn xut sch hn l tip cn nhm mc tiu gim thiu
nhim ti ngun thng qua vic s dng nguyn nhin liu c hiu qu hn.
Vic p dng sn xut sch hn khng ch gip cc doanh nghip ct gim
chi ph sn xut, m cn ng gp vo vic ci thin hin trng mi trng,
qua gim bt chi ph x l mi trng.
Ti liu hng dn sn xut sch hn trong ngnh c kim loi c bin
son trong khun kh
Hp phn sn xut sch hn trong Cng
nghip (CPI), thuc chng trnh Hp tc Vit Nam - an Mch v Mi
trng (DCE), B Cng thng nhm cung cp nhng kin thc c bn cng
nh trnh t trin khai p dng sn xut sch hn trong ngnh c kim loi.
Tu thuc vo loi vt liu c, qui m mt hng sn phm, tim lc v ti
chnh v ngun nhn lc, cc doanh nghip c s la chn, p dng nhng
gii php SXSH ph hp vi n v mnh.
Cc chuyn gia dnh n lc cao nht tng hp thng tin lin quan n
hin trng sn xut ngnh c Vit nam, cc vn lin quan n sn xut v
mi trng cng nh nhng phng php vn hnh tt nht c th p dng
c trong iu kin nc ta.
Mc d Sn xut sch hn c gii hn trong vic thc hin gim thiu
nhim ti ngun, ti liu ny
thm mt chng v x l mi trng
tham kho khi tch hp
sn xut sch hn
nhng yu cu ca cng tc bo v
Hp phn Sn xut sch hn trong Cng nghip v Cng ty C phn T vn
EPRO xin chn thnh cm n s ng gp ca cn b Cng ty TNHH Nh
Cng ty C phn Cng ngh cao Sao
X
c bit l chnh ph an
Mch, thng qua t chc DANIDA h tr thc hin ti liu ny.
Mi kin ng gp, xy dng ti liu xin gi v: Vn Phng Hp phn Sn
xut sch hn trong Cng nghip, email: cpi.cde@hn.vnn.vn
Trang 5/61
1. Gii thiu chung

Chng ny cung cp thng tin v tnh hnh ngnh c kim loi Vit nam, xu hng pht trin
ca th trng, cng nh thng tin c bn v quy trnh sn xut.
1.1 M t ngnh c kim loi

cng ngh truyn thng
p ng c
rt cao tnh cht c, l, ho, ng thi t c
cao ca cc ngnh cng nghip.
- .
Vit Nam, ngh c kim loi xut hin cch y trn 3.000 nm
ru, mi gio, mi tn bng
ng
c
khun (1.500 - 1.000 nm trc Cng nguyn), trng
ng ng Sn
c
khun t (t 500 - 300 nm trc Cng
nguyn). T cui thp nin 50 ca th k 20, cc xng c gang, c thp,
c hp kim mu
.
t s nh m
nh nh my C kh H Ni, nh my ng tu Bch
ng, c kh trung tm Cm Ph, khu gang thp Thi Nguyn, nh my phn
m Bc Giang, nh my izen Sng Cng.
ch yu phc v sn phm chnh ca n v (nh bng my tin,
v/thn ng c, chn vt, rng gu xc, bm, trc cn v.v...) thiu tnh mm
do, a dng theo yu cu th trng. Thit b cng ngh
t l
ph phm cao nn li nhun kinh doanh thp.
theo, ngnh c kim loi thiu s quan tm v vn u t pht trin.
Gn y, n
c
t s
doanh nghip u t vo cng ngh c mi,
thit b kim tra, phn tch nhanh
, nng
cao
c
Mt s dy chuyn, thit b cng ngh mi
c a vo u t, lp t ti Vit Nam nh:
-
Dy chuyn lm khun t ng DISAMATIC ca Cng ty C kh ng

Anh;
H thng thit b hon chnh lm khun Furan cht lng cao, dy chuyn
c khun ti c nh c kh ha
; Cng ty
C phn C kh Luyn kim (SADAKIM);
Cng ngh c mu chy, mu chy cc chi tit phc tp cht lng cao
cho ngnh c kh, vi cng sut 600 tn/nm
Cng ty c phn c kh
& c kim loi Si Gn (SAMECO); Cng ty lin doanh VIDPOL v.v...
Mt s my c p lc hin i cng c nhp v s dng, mang li

hiu qu c mt s chi tit cho ngnh xe my, kha, qut in.
Trang 6/61
V quy m cng sut, cc doanh nghip
chia thnh 3 nhm:
Doanh nghip quy m ln (sn lng > 5000

Thi Nguyn, Bin Ha, Hi Phng);
/nm tp trung H Ni,
Doanh nghip quy m nh v va (sn lng 1000 n 4000

);
D
nh Yn Nam nh, Thy Nguyn Hi Phng, Phng c Hu).
/nm
Trong 3 nhm trn, cc d

.
Theo cc thng tin t trang Web ca B Cng Thng, sn lng c nm
2000 ca Vit Nam l 41.000 tn; nm 2004 l 295.000 tn v nm 2006 t
370.000 tn (theo thng l quc t, ch tnh c hnh, k c ng nc m
khng tnh cc sn phm c cn phi tip tc to hnh bng cc phng
php bin dng khc nh cn, ko dy thp, ng hoc p chy nhm hnh.
Nh vy, bnh qun t l trng lng vt c/u ngi nm 2006 ca Vit
Nam mi t khong 4,5 kg/ngi. Trong khi , nm 2003 Thi Lan t 5,13
kg; Trung Quc: 14,5 kg; i Loan: 65,12 kg; nm 2007 Trung Quc t
ch s 23,75 kg/ngi.1
Cho n thi im ny, Vit Nam cha c s liu thng k, bc tch phn loi
cc dng hp kim s dng trong ngnh sn xut c. Trn c s cc s liu
thng k t ti liu Nghin cu xut m hnh pht trin ngnh c Vit
Nam p ng yu cu cng nghip ha hin i ha t nc do Hi c Luyn kim Vit Nam thc hin nm 2009 cho thy: lng hp kim nhm c
v cc loi hp kim mu khc ch chim 10 - 12% trong tng sn lng vt
c (xem bng 1 di y). Do vy, ti liu ny, chng ti ch cp n
vt c kim loi en (gang, thp).
Bng 1. Sn lng cc hp kim c Vit nam giai on 2020 - 2025
Nm
2020
2025
Gang xm
Gang cu
Gang do
Thp c
HK nhm
103
Tn
950
1.250
103
Tn
570
625
103
Tn
19
50
103
Tn
114
200
103
Tn
190
250
%
50
50
%
30
28
%
1
2
%
8
8
%
10
10
HK mu
Tng
khc
103
%
103
Tn
Tn
19
1 1.900
50
2 2.500
Ngnh c Vit Nam ang

thay th sn phm ngoi
nhp cho ngnh cng nghip c kh, xi mng, khai thc m. v bc u
xut khu cc sn phm cht lng cao ra nc ngoi. D bo v mc
tng trng bnh qun vt c trn u ngi ca Vit Nam trong 10 nm ti
nh sau:
1
D tho Quy hoch pht trin ngnh c Vit Nam giai on 2009-2020, c xt n
nm 2025.
Trang 7/61
Bng 2. D tnh sn lng vt c ca Vit Nam giai on 2011-2020

Tiu ch
2011 2015
2016 2020
14,11
19,92
90
95
1,2 1,4
1,8 2,0
c bnh qun (kg/ngi)

Dn s d kin, (triu ngi)
Sn lng vt c bnh qun, (triu tn)
th
l/thnh phm
(
lng,
nghip.
nhiu nhin liu,

) cng nh
c tim nng v ti ch
kim loi np
vn v
, v sinh mi trng cng
quay vng.
hn.
1.2 Quy trnh c kim loi

c
khi qut bao gm
Chun b khun, rut, mu (khun ct, khun mu t chy, khun kim

loi);
Nu
(gang, thp, ng, nhm) trong cc thit b ph hp (l
in h quang, l cm ng, l quibil, l cao, l ch v.v...);
(c lng, bn lng km theo p, c ly tm v.v...);
, x l nhit nu cn.
mc
Nguyn nhin liu chnh
Cc cng on chnh
Cc vn mi trng chnh
ng
n
Khun,
Ba via
Sn phm
Hnh 1. S dy chuyn c kim loi
Trang 8/61
1.2.1 Chun b khun, rut (thao), mu
hun
thao
ct
t st, cht kt dnh v cc cht ph gia.
ca
ct l SiO2 (thch anh), t st l cao lanh (mAl2O3.nSiO2.qH2O). Cht kt
dnh lm tng do, bn ca hn hp lm khun, t
du thc vt
(du lanh, du tru, du bng); cht ha tan trong nc (ng, mt ma,
bt h), cc cht kt dnh ha cng (nha thng, xi mng, b hc n)
nc thy tinh. Cht ph gia
tng tnh ln, tnh thng kh, tng
bng b mt khun, thao v tng kh nng chu nhit ca hn hp.
ht
(bt graphit, bt than, nc thy tinh, bt thch anh).
cng ch ph hp
chi tit
n chic hoc chi tit phc tp
P
Nhit sy khun
175 450 C. C th sy
trc tip trn nn nh xng bng
ci, rm, r hoc sy trong cc l sy than, du
o
Khun ct:
Khun ct vn gi mt vai tr quan trng trong ngnh c. Khun ct c
dng nhiu v d lm, r, vn u t thp. Hn na khun ct
c th dng c vt nh t 10 gram cho ti vt ln c khi lng
hng trm tn, dng c bt k hp kim no nh: thp, gang cu, gang
sm, ng thau, ng thanh, hp kim niken, hp kim nhm, magi, 90%
sn lng c ca th gii c sn xut bng khun ct, phn cn li c
c bng khun kim loi
sau:
-
Khun ct ti: vt liu lm khun l ct st

nc
. Khun ct ti c c im d s dng, b mt vt c mn nu
ct o nh.
d
c
Khun ct nc thu tinh ng rn bng kh ccbonc: nc thu tinh

(dung dch silicat natri) c trn vo ct
khun. Sau khi
khun
thi kh ccbonc cho khun
. Khun ct
nc thu tinh d lm, d s dng, sn phm c d gia cng t hn
, c ng dng rng ri trong hu ht cc cng ty c trn
Trang 9/61
ton quc. Khun c nc thu tinh sau khi c nn c ti ch nhm

gim lng ph thi rn;
-
Khun ct nha: s
c bc nha; c 2 loi l khun
(trn ct vi axit formaldehit) v k
(nung
);
Khun Furan: ct s c trn vi nha Furan v axit

nhanh, sn phm nhn bng b mt
mi nha Furan khng d chu
Khun mu chy:
y l phng php c c bit, mu ch qua mt ln c. Thc cht ca
c trong khun mu chy l tng t nh c trong khun ct nhng c
nhng im khc bit sau:
-
Lng khun c to nn bi vt liu d chy. Do , vic ly mu ra khi

lng khun c thc hin bng cch nung cho chy mu ri rt ra theo
h thng rt;
Vt liu ch to khun bng cht liu c bit nn ch cn dy nh (6 8 mm) nhng li rt bn, thng kh tt v chu nhit;
Vt c c chnh xc cao nh lng khun khng phi lp rp theo mt

phn khun, khng cn ch to thao ring;
nhn b mt m bo do b mt lng khun nhn, khng c hin

tng chy khun;
Hp kim c c th l loi vt liu kh nng chy, nhit rt cao.
Nhc im ca phng php c khun mu chy l:

-
Quy trnh ch to khun phi qua nhiu cng on nn nng sut khng
cao. Do vy, mun p dng phng php c mu chy cn c kh ho
hoc t ng ho mt s khu then cht;
c khun mu chy ch ph hp vi vt c l kim loi qu, cn c mc

tit kim kim loi cao hoc nhng chi tit i hi chnh xc rt cao.
Khun v mng:
c trong khun v mng l dng c trong khun ct c bit, c chiu dy
thnh khun mng 6 - 8 mm. Thng c ch to t hn hp 4 - 6% bt
thch anh, trn vi Punvebakelit (l hn hp ca Phenol v Uetropin). nhit
cao (200 - 250oC, cc phn t Fenol chy ra, dnh kt cc ht ct vi nhau
v ho cng to nn bn cao cho khun v mng.
c im ca khun c v mng l:
-
t c bng v chnh xc cao;
Trang 10/61
Khun v mng l dng khun kh, nhn bng, thng kh tt, truyn nhit
km, khng ht nc, bn cao nn thu c vt c t b r, nt v cc
dng khuyt tt khc;
Khng cn h thng rt ln nh i vi khun ct, gim c hao ph kim

loi;
Khun truyn nhit km nn vt c khng b bin trng;
Qu trnh d khun, lm sch vt c n gin;
Qu trnh c d c kh ho v t ng ho;
Chu trnh lm khun di, gi thnh khun cao, ch ph hp vi sn xut

hng lot ln.
Khun mu chy/mu t thiu:

Khun mu chy l mt bc tin b kh xa ca cng ngh c. Mu c
ch to t vt liu xp (Polysteron) ging y ht vt c thc, sau a vo
hm khun . Vt liu lm khun in y sau c ht chn khng to
nn cht cn thit cho khun c. Qu trnh ny khc vi khun mu chy
l khng cn sy lm chy mu. i vi khun mu chy, mu c gi
nguyn sau qu trnh lm khun. Khi c, vi nhit ca kim loi lng, mu
s chy to khi thot ra ngoi nhng li khong khng gian cho kim loi
in y khun.
Phng php c trong khun mu chy c nhng u im sau:
-
Gi thnh ch to mu r, khng dng n g ch to mu, nng sut

lao ng cao;
Ch to mu bng phng php rt chn khng, gim nh sc lao ng,

gim lng bi pht sinh t khu m khun so vi phng php c
trong khun ct m th cng, tng nng sut lao ng;
Sn phm c c chnh xc, bng cao, lng d gia cng cc thp.

Nhiu dng sn phm c th a i lp rp, dng ngay m khng cn qua
gia cng c kh;
Trng lng vt c t nh n trung bnh, c th ph hp vi sn xut

chi tit n l hoc hng lot.
Nhc im ca phng php c trong khun mu chy l:

-
Cn c h thng thu ht khi bi tt trnh khi bi c hi do

Polysteron chy;
Khi cn c cc vt c ln gp kh khn trong khu lm khun (thit b

ht chn khng, bn ca muv...v...)
Khun kim loi

c bng khun kim loi thc cht l vic in y kim loi lng vo khun
Trang 11/61
c ch to bng kim loi. Do khun kim loi c tnh cht c l cao, khc vi
vt liu lm khun ct nn c nhng c im sau:
-
Tc kt tinh ca hp kim nhanh nh kh nng trao i nhit ca hp

kim lng vi thnh khun kim loi, do c tnh ca vt c cao hn;
bng b mt, chnh xc ca lng khun cao to nn cht lng vt

c tt;
Tui th khun kim loi cao;
Do tit kim c thi gian lm khun, to nng sut cao, h gi thnh

sn phm.
Mt s nhc im ca phng php c trong khun kim loi l:

-
Khun kim loi khng c c cc vt c c hnh dng qu phc tp,

thnh mng v khi lng ln;
Khun kim loi khng c tnh ln v khng c kh nng thot kh. iu ny

s gy kh khn cho cng ngh c;
Gi thnh ch to khun cao.
Phng php c trong khun kim loi p dng thch hp trong sn xut hng
lot vi vt c n gin, trng lng vt c nh n trung bnh, di 2
tn/vt c.
Mu c lm t cc vt liu to hnh nh g, thch cao, xi mng,
sn phm n l
1.2.2
L ch nu gang hoc kim loi mu
y l loi l th cng, tiu tn nhiu nhin liu, nng lng. Thng nhng
doanh nghip u t loi l ny t c kh nng u t h thng lc bi gim
thiu tc ng ti mi trng do iu kin v sinh cng nghip, mi trng
lao ng ca cng nhn cng khng c m bo yu cu.
L ng/l Quibil
L loi l tin b hn l ch, dng nu gang vi nhin lu l than dng
cc/than cc hoc du. Loi l ny qua nhiu th h c nhng ci tin
ng k nhm tng nng sut l, tng hiu qu s dng nhit bng cch thu
Trang 12/61
hi ti s dng nhit tha ca kh thi sy liu, gi nng v c c trang

b h thng lc bi, h thng np liu kiu c kh v.v... Loi l ny thng
c cc doanh nghip c trung u t c sn lng trn 500 tn/nm;
L in cm ng (cao tn, trung tn v tn s cng nghip)
y l loi l s dng nng lng in nu chy kim loi. L cao tn c
hn ch v dung lng l (tn/m) nhng vi l tn s cng nghip v l
trung tn cho php trng lng m nu ln hn (> 10 tn/m) ;
Cc loi l cm ng tn s ch m nhn c vic nu chy l chnh nn,
c c thnh phn ho hc hp kim c nh mong mun, i hi vic tnh
ton phi liu phi chun xc; nguyn liu a vo l cng phi c la
chn k v m bo sch.
Ngy nay, vi s tin b ca khoa hc - cng ngh, cc l cm ng t dng
ng c - my pht to tn s cao m thng s dng h thng in t.
Loi l ny c u im l d ph hp vi cc qui m xng c (t nh n
ln), iu kin v sinh mi trng lao ng tt hn (t bi) do s dng nng
lng sch l in;
Nhc im ca loi l ny l yu cu nc lm mt vng cm ng v Diode
(KK) phi sch (nc mm) nhm trnh hin tng ng cn gy chy cc
linh kin in t v vng cm ng; tui th lp lt vt liu chu la thp, khi
nu kim loi mu cn c ni l bng graphit; khng c giai on hon nguyn
nn kh iu chnh thnh phn ho hc ca hp kim c.
L in h quang (EAF)
y l loi l c tnh c ng cao, c th nu cc mc hp kim theo yu cu
v c th ch ng to mi trng oxy ho hoc kh, c nhiu di cng sut
ng vi tng qui m sn lng vt c. Ngy nay vi cc loi l EAF, hng
lot cc tin b k thut v ang c p dng, nng cao nng sut l,
gim tiu hao nguyn nhin vt liu nh cng ho bng xy; phun thm
nhin liu, ph gia (du, kh thin nhin, than bt, cht to x bt...); lm ngui
in cc; lm ngui tng, np l; l tho kim loi t y lch tm; tinh luyn
ngoi l (LF); sc kh tr v.v...
L cao
Thng thng, l cao thng c dng sn xut gang lng cp cho
luyn thp hoc gang c (dng mi) cp cho cc xng c. Ngy nay, mt
s c s luyn kim nc ngoi kt hp lp t cc dy chuyn c ng
gang cu bn cnh l cao (thit b cu ho v dn c ng ly tm...) gim
bt khu nu chy gang lng, m rng mt hng v tng sc cnh tranh cho
sn phm. Vit Nam, cha c l cao no kt hp vi c ng hoc cc chi
tit dng sn phm c.
Trang 13/61
1.2.3 c kim loi

1.2.1
rt vo
v a i c
c p lc
di
c
, chi tit phc tp.
c lin tc
20.000 tn/nm.
c li tm
khun quay, kim loi s phn b ng u trn thnh khun v ng c ti

.
1.2.4
Trn 90% c s c
ngt v u hi c th c
khun v lm sch th cng.
p nh
thng rt, u
ct.
km
theo bi lm sch
Trang 14/61
km theo
my mi 2 c nh, my mi lc
my mi di ng
X l nhit
theo
ca
i
mc vt liu:
cc
, thng ho, ti,
, thm Nit hoc cc hp cht,
kim loi khc, gi chung l x l nhit
c c cc ch tiu c, l, kim
tng theo yu cu. Dung dch ti thng dng l nc, du...
Trang 15/61
2. S dng ti nguyn, tc ng n mi trng v

an ton sn xut
Chng ny cung cp thng tin c th v tiu th nguyn, nhin, vt liu v tc ng ca qu
trnh sn xut n mi trng, cng nh tim nng p dng SXSH trong ngnh c kim loi.
Phn ny m t cc hot ng c tiu th ti nguyn v pht thi ca cc c

s c. Hnh 2 miu t cc dng ti ngu
Ting n
Vt c
c kim loi
Nc
,
thao,
Hnh 2. Nguyn liu u vo v pht thi trong qu trnh c kim loi
2.1 Tiu th nguyn nhin liu
sn phm
Bng 3
g
m3
Ct ti sinh
700 1100
520 800
500 700
750 - 1300
1300 - 1800
0,76 - 0,90
-
4,0 - 5,0
3,7 20,4
312 349
94 96
126 - 1473
80 - 98%
Trang 16/61
:
-
ngh cao Sao Xanh v cng ty TNHH mt thnh vin C kh ng Anh.
2.2 Cc vn mi trng v an ton sn xut

ang phi i mt vi
lin quan n
v
lao ng. Trong ng quan
tm nht l
,
v cht thi rn (x thi, vt liu lm khun
- rut, vt liu xy l). Ngoi ra cn vn ting n v nc thi nu khng
c x l, tun hon.
, ti s dng. T
st sao
2.2.1 Kh thi
Cc cht
Bi: bi v khi kim loi

thi ra mi trng trong qu trnh np liu
vo l v qu trnh lm sch vt c. Cc ht bi silic
nh bng, mi hoc
lm khun, rut, d
v lm sch vt c, ti sinh ct v chun b ct.
VOCs: cc hp cht hu c d bay hi bao gm mt s cc Hydrocacbon

b oxi ha mt phn v mt s hydrocarbon thm a vng (PAHs) c
pht hin
lm khun, c, lm ngui v d
vt c.
Dioxin, Furan (PCDD/PCDF) v cc hp cht mui hu c bn vng:

PCDD/PCDF hnh thnh trong hu ht cc qu trnh chy thng qua c
ch tng hp de novo bi s chy ca cc cht phi Clo hu c nh nha,
than v ht cacbon vi s c mt tnh c ca Clo. Nhng hp cht ny
c cha trong ph liu vi hm lng thp, dng vt hoc trong nguyn
liu th nh khi phun ccbon.
Ch, km, cadimi v cc kim loi nng khc: c kim loi

khi phn tch bi t h thng lc bi ca cc c s sn xut c.
Cc loi kh khc: CO, SO2, NO, hp cht Clorit, Florit, H2S, CH4, N,
Formaldehyde
Trang 17/61
2.2.2 Nc thi
Ngnh c kim loi s dng nc cho h thng lm mt cc thit b cng
ngh, lm ngui sn phm, x l kh thi, x l v lm mt nh xng bng
mnh nc trong qu trnh cNc
, ti
2.2.3 Cht thi rn

lng tp cht
, ti s dng
qui nh v bo v mi trng.
theo cc
2.2.4 Ting n
khun, thit b lm sch,
d
nu
, lm sch
nhng
gy
v mt s khu
khc
Mc n o c t 82dB (A) n 116 dB (A). n v rung thng i km

vi nhau v gy tc ng trc tip n cng nhn
.
2.2.5 Nhit, chy n v an ton trong sn xut

,
cao
2.3 Tim nng p dng sn xut sch hn

So snh v trnh cng ngh, trnh qun l v ngun nhn lc trong
ngnh sn xut c ca Vit Nam v th gii cho thy tim nng tit kim ti
nguyn (nguyn, nhin vt liu, nc v nng lng) c th t 10 20% so
vi mc tiu th hin ti.
Trang 18/61
3. C hi sn xut sch hn
Chng ny dn ra mt s v d v gii php SXSH c th p dng thnh cng trong ngnh
c kim loi. Ni dung ny s tip tc c cp nht khi c thm cc doanh nghip p dng
SXSH.
Di y l mt s gii php qun l ni vi trong ngnh c kim loi, phn

theo
3.1
3.1.1 Cc gii php qun l nguyn liu
tn tht
do b oxy ho trong qu trnh lu kho/bi
n ch nhim t, nhim nc
qun
l sau:
-
Phn hoc s dng cc thng cha phn bit v lu tr ring cc

loi kim loi khc nhau theo bn cht, t trng. p dng nguyn tc FIFO
(liu vo trc s dng trc);
S dng my p ph tng t trng ph liu gang, thp trc khi np l;
Kho/bi cha ph liu gang, thp cn c btng ho nhm hn ch t

ct vo trong m liu ca l. Nu l bi khng c mi che cn c rnh
thot nc thm trn, h t nc tch ring trnh nhim ngun nc
mt;
Trong iu kin kh hu ca Vit Nam, nn c mi che cho khu cha

nguyn liu (kim loi, tr dung ph gia, fer, vt liu lm khun, rut v
c bit l vt liu chu la).
ra
c Philippine
lng
2.700 USD mi nm v
115 tn x thi.
ng (Quibil)
3.1.2
3.1.2.1
Kch thc liu khng c php ln hn 1/3 ng knh l;
Tun th ng quy trnh np liu (kim loi, nhin liu, tr dung...);
Trang 19/61
Sa cha v bo dng lp lt l sau mi ln nu;
nhit
ph hp vi mc gang yu cu.
3.1.2.2
ca l ng, c bit
ca than cc nh hng n hiu sut hot ng

nhit bt chy ca cacbon.
Hin nay Nh my luyn gang Cng ty C phn Gang thp Thi Nguyn
ang vn hnh l cao vi than cc sn xut ti Nh my cc ha, c thnh
phnh v cht lng nh bng di:
Bng 4. Thnh phn ca than cc ti Nh my cc ha
Thnh phn
Gi tr
tro
<15%
Cht bc
<1%
Lu hunh
<1,6%
C ht
15-40mm
Hm lng cacbon c nh
>80%
Kch thc than nh lm tng tr lc gi, gy b l. Kch thc than cc l

tng t 50 - 80mm.
3.1.2.3 Lp tuye gi th cp
Hiu sut nhit ca l ng cp gi lnh (CBC) c th c ci thin nh lp
thm dy tuye gi th cp. Gii php ny cung cp oxy d t tip kh CO
c trong l, ci thin hiu qu s dng nhit ca l.
So vi l thng thng (c mt hng tuye gi), l c hai dy tuye gi em li
nhng li ch sau:
- 50oC vi cng lng cc a
vo;
-
Tiu th cc gim 20 - 32% v hiu qu nu chy tng 11 - 23%.
Mi dy tuye cn c cp gi vi h thng cp gi ring bit.

3.1.2.4
vo l
Hiu sut nhit ca l cp gi lnh c th c ci thin nh gi giu oxy. So

snh vi l ng thi gi lnh thng thng, vic s dng gi giu oxy em
li li ch tng nng sut l, gim tiu hao than cc.
Trang 20/61
Lm giu trc tip trn ng gi cp: Oxy c cp vo ng

;
Bm oxy qua l khoan trn thn l;
Bm Oxy ti cc ca gi: Oxy c a vo l qua cc vi phun t trong

mi tuye gi. Phng php ny
s dng
.
Bng 5
ng knh
trong ca l
(mm)
Phng php lm
giu oxy (lng
oxy thm vo %)
Nng sut nu
(tn/gi)
T l than cc (%)
Trc
Sau
Trc
Sau
1014
Lm giu (2,5%)
14
12
912
Lm giu (3%)
15
10
1166
Lm giu (4%)
10
12
12,5
9,4
1216
Bm oxy (3%)
12,5
9,4
811
Lm giu (2%)
2,5
2,5
17
14
3.1.3 G
ci tin
Tng chiu cao ca l ng

Hiu sut nhit ca l ng cp gi lnh (CBC) c th c ci tin nh tng
chiu cao l. L cng cao, kh l tip xc vi nguyn liu cng lu v nhit
c truyn sang nguyn liu cng nhiu. Vic tng th tch khu vc pha
trn ln hai ln gip
knh l (khu vc tuye gi).
Bng 6
ng knh phn nu (m)

ng knh phn trn
chy (m)
Chiu cao trn tuye gi (m)
T l than cc (kg/tn)
ng
L trc khi ci to
L sau khi ci to
1,4
1,4
1,4
1,7
6,5
140
115
3.1.4
3.1.4.1 L ng
Nhit kh thi ra khi l ng dao ng t 500 - 800oC tu thuc lng
than trong phi liu, t l H/D ca l (chiu cao/ng knh l). C th p
Trang 21/61
dng cc gii php sau tn dng nhit thi :

-
Lp b trao i nhit
nhit vt l ca kh thi
Tun hon kh thi cp vo l gi nng
Kh thi
tn dng nhit n
tip CO
trong l gi nng gia nhit cho khng kh trc khi thi vo l ng.
u im
gi nng thi vo l:
- Gim t l cc, ci thin hiu sut nhit;

- D dng iu chnh nhit cho gang ra l, ci thin cht lng kim loi
lng;
- Tng tc nu, tng nng sut nu;
-
;
.
3.1.4.2 L in (l cm ng, l h quang)
c l ht th 4 trn nc l).
3.1.5
Kh thi pht sinh t qu trnh nu luyn l cm ng v l in h quang
thng cha nhiu loi kh c hi, trong phi k n Dioxin v Furan
(PCDD/PCDF). cc nc cng nghip pht trin thng p dng cc bin
php sau gim pht thi (PCDD/PCDF) :
+ Loi tr n mc ti a nhng loi vt cht c tim nng gy nhim
ln nh nha, sn, du, m, linh kin in t/t in;
+ C gng loi b nhng kim loi mu trong thp ph v chng l nhng
cht xc tc thc y vic to thnh Dioxin/Furan;
+ S ch thp ph tng t trng ng, gim s ln m np l np
liu gy tn tht nng lng v pht thi kh, bi ra mi trng quanh l v
ton b nh xng;
+ Bi cha thp ph cn c btng ho trnh t ct ln vo l lm
tng ph gia to x, tng lng x v tiu hao in nhiu hn;
+ Lng d tr thp ph khng nn qu 45-50 ngy v thp ph
ngoi tri vi thi tit nng, m, ma, nng v.v... s thc y qu trnh to g
(b xy ho gy tn tht v trng lng v tiu tn nng lng, cht ph gia);
+ Nn tm mi cch c lp/ bt kn cc ngun pht tn bi d ht v
x l (EAF&LF). a s cc l in h quang EAF ca Vit Nam thng p
Trang 22/61
dng k thut ht kiu Chung ch/ Doghouse kt hp vi chp ht trn

cao/Canopy trong khi Chu u, ch c 2% s nh my p dng k thut ny
(km theo bt kn nh xng v h thng x l kh hon ho).2
+ Cn kim tra nng lc ht ca chp ht trn cao/Canopy nhm m
bo kh nng ht ht lng kh thi cng ngh v lng kh xm nhp vo
nh xng. Nu chp ht lm vic tt s ci thin iu kin lm vic ca cng
nhn v gim phi bi ra mi trng ngoi nh xng;.
+ Vi nhng l cha c m t ph, nn c thit k ci to b sung m
t ph tn thu nng lng ho hc ca cc kh chy nh CO v
hydrocarbon. t trong l c th ngn nga s to thnh Dioxin/Furan, tng
nng xut l.
+ Vi nhng l thu kh thi EAF t l th 4 trn nc l (hoc ht trc
tip t l trn tng l, ni tip gip vi nh) c th xem xt vic lp t
bung t ph ngoi l nu khng gian cho php v nhit kh thi ht trc
tip t l > 800 oC, duy tr nhit ny khong 2 giy (c th phi phun
thm 1 lng nh nhin liu), sau lm ngui nhanh (trong vng 2 giy)
xung < 200 oC phn hu PCDD/F;
+ Vi nhng l EAF ht kh thi gin tip (kiu Chung ch/Doghouse)
kt hp vi chp ht trn cao/Canopy, vic lp thm bung t ph khng kh
thi v nhit kh thi thp (khong <200 oC), s tiu tn mt lng ln nhin
liu nng nhit > 800 oC nhm phn hu PCDD/F;
+ Gii php lp t h thng phun cacbon hot tnh trc b lc ti vi
cho cc loi l EAF l cn thit thu gi PCDD/F hp ph trn b mt cc
ht cacbon, gim pht thi PCDD/F ra mi trng.
3.2
3.2.1 Cc gii php p dng k thut - cng ngh tin tin
Ci thin hiu qu sn xut c trn c s p dng cc gii php sau:
-
ng dng cng ngh CAD/CAM trong vic thit k khun, mu, tnh ton
h thng u ngt, rt, gim lng d gia cng, m bo kch thc hnh
hc cho cc vt c phc tp;
S dng cc my lm khun v rut/thao hin i: Cc my lm khun v

rut/thao hin i c phn mm lu tr cc thng s v chng trnh ci
t cho cc sn phm khc nhau. Do , khi thay i sn phm, s gim
thiu c thi gian v s ln chy th nghim, gim c lng vt liu
lm khun, rut v tit kim nng lng.
trang 448 Integrated Pollution Prevention and Control Draft Reference Document
on Best Available Techniques for the Production of Iron and Steel Draft July 2009.
Trang 23/61
lm khun, rut, nu luyn, c rt, x l nhit v x l cht thi (kh, rn,

lng) trc khi thi ra mi trng, Lm tt cc bc cng vic ny s m
bo c nng xut, cht lng, gim t l sai hng, h gi thnh, tng
sc cnh tranh cho sn phm.
Cng ty TNHH Fishercast, mt cng ty sn xut van thp M ang s dng cng ngh thit
k truyn thng trn c s k thut mun (v d s dng tiu chun k thut v cng thc
tnh ton kch thc thch hp cho vt c). Cng ty u t phn mm m phng c
MAGMASOFT thit k li vt c.
Cng ty
xung cn 4,3 gi v tng chi ph sn xut gim
12%.
3.2.2 Cc gii php trong

3.2.2.1 Cc gii php gim cht kt dnh
t
Cc phng php hn ch s dng cht kt dnh gm:
-
Thc hin lu kho cht kt dnh
Qun l tt vic lu tr ct v kim tra ct ( sch, kch thc ht, hnh

dng, m) l nhn t quan trng. S dng
tn dng ct tun hon cng s gim thiu lng cht kt dnh cn s
dng;
im st lng cht kt dnh trong ct thu hi

lng cht kt dnh cn b sung;
Lm mt ct thu hi trc khi s dng gim cht kt dnh b chy;
Nhit ca ct phi c duy tr trong mt di hp, cng vi vic thng

xuyn kim tra v iu chnh lng cht lm cng thm vo. t my sy
ct ngay trc my trn ct gip kim sot nhit cht ch hn;
Bo dng v v sinh my trn; ti u ho hiu sut my trn nh gim

st v iu khin qu trnh vn hnh my.
Cht lng khun: kim tra, gii quyt v ngn nga khuyt tt khun;
Li ch mi trng: Hp cht hu c d bay hi chim ti 50 - 60% trng

lng cht kt dnh. Phn ln cc cht hu c d bay hi ny s dng trong
qu trnh trn ct v rt kim loi. Do , gim s dng cht kt dnh tng
ng gim pht thi cc cht hu c d bay hi (VOC).
Trang 24/61
ng h thng Pemacol gip gim 0,85% cht kt dnh,

thnh phn axit gim, dn n gim 50% pht thi ti khu vc ny.
3.2.2.2
Mt s li th ca
gc nc so vi keo gc ru:
An ton (khng c nguy c chy n);
t nh hng ti sc kho ca cng nhn (do t tip xc vi dung mi hu

c);
Gim chi ph thuc th (nc thay v ru);
Cho b mt vt c tt hn;
Tuy nhin, khi thay th keo ph gc ru bng keo ph gc nc, cn ch

n mt s kh khn sau:
-
Cn thi gian v khng gian ln hn;
- 2 tun) v pht thi mi.
Cc phng php lm kh c th p dng: s dng khng kh cng bc,

sng ngn, sng hng ngoi v sy.
3.2.2.3 Cc gii php gim ct s dng
T l ct/kim loi
-
S dng nhiu hm khun c kch thc khc nhau ph hp vi tng

sn phm c
Chn cc khi hoc vt liu khc thay ct cho cc l rng trn hm khun
gim nhu cu s dng ct
b mt kim loi. Ct thu hi, ct cht

lng thp s dng cc phn cn li;
Gim thiu tht thot ct trong qu trnh vn chuyn;
Ti u ha h thng trn ct.
V d: H thng kim sot ct bng my vi tnh

Beijing Jeep, mt cng ty c ct ti Trung Quc, sn lng 6000 tn/nm, ph liu ct cc
loi chim 4,8% sn phm c. Sau khi kt hp h thng kim tra ct v h thng iu khin
thng minh trc tuyn my trn ct:
-
t l sn phm li gim 46%
t l ph liu ct cc loi gim cn 3% trong hai nm thc hin ci tin
gim 63 kg bentonit/tn vt c
Trang 25/61
3.2.2.4 Cc gii php ti s dng ct
rong h thng bnh mi, lp

trn ct
Trc khi x l, ct phi c lm kh m di 0,2%. Bi
sinh ra
c kh bng h thng xyclon hoc ti lc. Bi
cha cn bentonite v bi than c th c tun hon lm
.
sc cng b mt
,
gim lng khun ph v b mt vt c bng hn.
Nhit c s dng t cht kt dnh v cc tp cht ln trong ct tun

hon. Trc khi a vo nung, ct tun hon cn c x l t kch thc
chun v loi b kim loi
Cng ty thp Shinhokoku Steel thc hin gii php thay th ct silic thng bng ct zircon
chu nhit v kt hp lp t thit b nung ti sinh ct (x l ct bng nhit)
Ti cng ty, sn phm thp hp kim v thp khng r yu cu nhit cao, thng ln qu
1500oC trong cng on c. Trong khi ct silic thng thng t c kh nng chu nhit cao
n 1500oC v dn n nhiu khuyt tt trong sn phm c. Do , cng ty p dng gii
php s dng ct zircon, l loi ct c c tnh chu nhit tt; v kt hp x l ct bng nhit
ti s dng (do gi ct zircon t gp 5 ln ct silic thng).
Chi ph u t: 8 triu Yn. Chi ph vn hnh trc khi thc hin gii php: 28 triu Yn/nm.
Chi ph vn hnh sau khi thc hin gii php: 2,5 triu Yn/nm (do gim khuyt tt trn sn
phm, d tng chi ph mua ct). Li nhun hng nm: 25,5 triu Yn.
Gim s dng ct: gim t 360 tn ct/nm v 330 tn ct/nm. Gim ct thi: T 360 tn
ct/nm v 30 tn ct/nm (gim 330 tn ct/nm).
Trang 26/61
3.2.3 p dng cng ngh

s dng ct khng c cht kt dnh. Nng lng s dng
trong cng ngh c khun mu chy nh hn nhiu so vi cng ngh c
truyn thng. Nng lng ny gim khi c, nu chy v chun b ct.
So snh
tiu th khi c mt v my nn bng cng ngh c ct

c a ra trong bng di
y. Bng ny ch ra: ti cng on nu kim loi, cng ngh c khun mu
chy tn dng c nhiu ph c ti s dng hn.
Bng 7
Nguyn liu
98,0
Cng ngh c
dng hn hp ct
cht kt dnh
(kg)
98,0
30,0
30,0
38,1
68,0
68,0
58,0
256,8
122,0
233,0
150,7
1101,4
-
0,212
Cng ngh c
dng Khun ct
ti (kg)
Gang
Ph c ti s
dng
Trng lng vt
c
Khun ct
Li ct
Trng lng mu
xp v ng rt
Cng ngh c
khun mu chy
(kg)
96,1
3.2.4 p dng cng ngh

Cng ngh ny
gim pht thi bi so vi cng ngh c khun ct
. Pht thi kh
VOC c hn ch, lng cht thi (bi v kim loi) gim, sn lng c
tng.
3.3 Cc gii php lin quan n h

3.3.1 Lm sch
3.3.1.1 Lm sch nh hiu ng kt hp gia c ch in v thy lc
Hiu ng ny c p dng lm sch vt c v c th gim bi v gim
in nng tiu th so vi lm sch bng phng php phun bi.
Theo , vt c c nhng vo b cha nc. Ngi ta to ra mt in th
gia vt c v in cc trong nc, lm hnh thnh mt p lc mnh (c th
ln ti 3 Kbar 300 MN/m2). p lc ny to ra hiu ng c hc ln b mt vt
c v loi b ct khi vt c.
Hiu qu ca gii php:
Trang 27/61
Vic lm sch hon thnh trong thi gian ngn (10-40 giy) v tiu tn rt
t nng lng.
Gii php ny khng yu cu h thng thu bi, v do gim lng kh
thng gi cn lm sch khng kh.
Xung in pht sinh trong nc c th lm nng nc trong b, nc sau
lm sch c th tn dng s dng trong nh my.
Tuy nhin, cn quan tm qun l ct t ti sinh.

3.3.1.2 Lm sch bng my bn ct quay ly tm thay cho my bn ct
kh nn
C th s dng my bn ct/my bn bi lm sch b mt vt c. My bn
ct/my bn bi c to p lc bn theo hai phng php: phng php s
dng cnh qut quay, to lc ly tm bn bi/ct; hoc phng php s
dng p lc kh bn.
lng v tn nhiu chi ph so vi my bn ct/bi s dng cnh qut. Nguyn

nhn: phn ln cc my nn kh ch chuyn c t hn 20% nng lng u
vo thnh kh nn do khng hiu qu v nng lng.
Mt nh my c ti H Lan s dng phng php bn ct lm sch, trong ct c
tng tc bng cc bnh quay ly tm thay v bng kh nn. Lng nng lng tit kim c khi
lm sch 120.000 m2 b mt vt c l 1 triu kWh/nm v 120.000m3 kh gas/nm. Thi gian
hon vn ca gii php l 2,1 nm.
3.3.2 X l nhit
3.3.2.1
Sn phm sau c v hon thin c nhit luyn theo mt trong hai phng
php: Ram () v ti. Trong cng on Ram, sn phm c c a v l
nhit nhm ng u cu trc sn phm sau lm mt t t. Cng on
ny s dng nhiu nng lng do cn duy tr nhit cao trong l nhit.
V d ci tin l nhit (h thng ram) nhm gim nng lng tiu th:
o
Mt cng ty c ti Quebec, Canada thng nung vt c ln n 1000 C v vt c nhit

ny trong vi gi. Cng on ny tiu th nhiu gas nhin liu.
Gii php ci tin: Cng ty ci tin l , trang b h thng t c kim sot u t bng
mch PLC (pulse-firing system) kt hp s dng si gm trong cu to thnh l, l iu p.
Theo h thng mch PLC, mi m t c t theo mt tn s thit lp trc. Gii php ny
tng o trn trong l (ram) (tng kh nng trao i nhit i lu gia cc vng trong
o
l); ng thi gim s chnh lch nhit gia cc vng (chnh lch < 4 C).
Hiu qu: Tiu th gas gim 31% so vi trc ci tin. L lm vic hiu qu, tng hiu sut,
nng sut v cht lng sn phm
Thi gian hon vn: 10 thng.
Trang 28/61
3.3.2.2 S dng nhin liu sch trong l nhit luyn kt hp vi h

thng kim sot u t bng my vi tnh
Ti l nhit luyn, s dng nhin liu t nhin hoc nhin liu c hm lng
sunfua thp s lm gim nhim kh thi. Ngoi ra, vn hnh l t ng cho
php kim sot c ch lm vic v nhit ca l, cng nh gim thiu nng
lng tiu th.
Thc hin gii php thay th nhin liu v kim sot l t ng s lm gim
c cc cht nhim nh CO, SO 2, NOx.
V d: trc nm 1998 c 3 l nhit luyn (ti Phn Lan) vi u t kim sot theo phng
php th cng. Nhin liu kh than c dn trc tip t l cc v c cht lng khng tt
(hm lng CO dao ng). Do cht lng kh than khng n nh nn trong qu trnh vn hnh
l kh nng kim sot cc thng s nhit km, pht sinh kh thi vi nng cht nhim
cao v c nguy c ng c kh than cho ngi vn hnh.
n nm 1998, 2 trong 3 l c lp u t mi vi h thng kim sot bng my vi tnh.
u t mi s dng nhin liu l kh t nhin. Ngoi ra, tng l cng c lm mi. Do ,
ngi vn hnh c th kim sot t ng thng s nhit l.
Hiu qu 2 l mi ci tin t c:
-
Gim chi ph vn hnh l, do gim 40% nh mc kh nhin liu (theo th tch)
Gim chi ph mua nhin liu do gi kh t nhin r hn chi ph mua than v kh ha than.
Gim pht thi SO2, NOx, CO v hp cht hu c mch vng (bng di)
Trang 29/61
4. Thc hin sn xut sch hn

Chng ny trnh by tng bc tin hnh nh gi SXSH vi v d minh ha ti C
cao Sao xan
Cht thi l nguyn nhin liu u vo khng c t ng ch. Vic thc

hin nh gi SXSH tun theo nguyn tc c bn l mi nguyn nhin liu
vo quy trnh sn xut, nu khng nm li trong sn phm s b thi ra mi
trng, di dng ny hoc dng khc. Vic trin khai nh gi SXSH mt
cch bi bn s h tr doanh nghip tm c ng i cng nh dng
chuyn i ca cc loi nguyn liu tm ra cc phng php gim thiu
lng s dng mt cch hu hiu nht, ng thi c th tng c nng
sut, cht lng ca sn phm v tit kim chi ph x l mi trng.
Vic p dng SXSH yu cu s cam kt v h tr mnh m ca Ban lnh o
doanh nghip, l yu t quyt nh cho thnh cng ca chng trnh. Yu
t quan trng na l thi gian v s n lc ca cc b phn trong ton doanh
nghip dnh cho SXSH. Chng ti khuyn co p dng SXSH ln lt theo 6
bc (gm 16 nhim v) sau y:
Bc 1: Khi ng
Bc 2: Phn tch cc cng on
Bc 3: a ra cc c hi SXSH
Bc 4: Chn cc gii php SXSH
Bc 5: Thc hin cc gii php SXSH
Bc 6: Duy tr SXSH
4.1 Bc 1: Khi ng
Mc ch ca bc ny nhm:
-
Thnh lp c i SXSH.
Thu thp s liu sn xut lm c s d liu ban u.
Tm kim cc bin php ci tin n gin nht, hiu qu nht v c th thc hin ngay.
4.1.1 Nhim v 1: Thnh lp nhm nh gi SXSH

Cam kt ca lnh o cao nh
on th cc cn b cng nhn vi
Vic thnh lp nhm nh gi SXSH l rt cn thit khi trin khai chng trnh
nh gi SXSH. Cc thnh vin ca nhm nn l cn b ca doanh nghip,
c th c thm h tr trin khai ca chuyn gia bn ngoi. Quy m ca nhm
s ph thuc vo quy m ca doanh nghip. Vi doanh nghip ln, nhm
Trang 30/61
nh gi SXSH nn bao gm: i din Ban Lnh o v qun c/trng

phng ca tng phng ban v nhm trin khai c thnh lp ty theo thi
im. Vi doanh nghip nh hn, nhm c th ch gm i din lnh o v
qun c ph trch cc cng vic sn xut hng ngy. Cc thnh vin trong
nhm cn hp nh k, trao i ci m, c tnh sng to, c php xem xt,
nh gi li quy trnh cng ngh v m hnh qun l hin ti cng nh
nng lc p dng trin khai cc tng sn xut sch hn kh thi.
Trong mt cng ty sn xut ta nn xem xt thnh phn nhm SXSH bao gm
cc cn b thuc ban lnh o, k thut v cc b phn sn xut nh cc
phn xng sn xut, c in. Vic mi thm cn b ph trch ti chnh, cn
b t vn ngoi doanh nghip cng nn c cn nhc nhm SXSH c
th thu c cc kin ci tin khch quan. Hot ng u tin ca nhm
SXSH l thu thp cc thng tin sn xut c bn ca doanh nghip cc
thnh vin trong nhm cng nhau phn tch. Vic thu thp thng tin c th s
dng Phiu cng tc s 1.
Phiu cng tc s 1. Cc thng tin c bn
S ngy lm vic
trong nm:
Tn v a ch doanh nghip
Nhm SXSH
Chc v - b phn
Tn
V tr trong nhm
1
2
3
4
5
Thng tin sn xut c bn ca doanh nghip

Sn phm chnh
CS thit k (tn/nm)
Cng sut thc (tn/nm)
Kg/nm
Kg/nm
Kg/nm
Nguyn liu ph
Nguyn liu chnh
Nguyn nhin liu s dng
Vt liu m l
Nc
Than
Gas
m /nm
kg/nm
kWh/nm
kg/nm
Kg/nm
Kg/nm
Cng sut
Thit b
Nc v nng
lng
Lng
Kg/nm
Kg/nm
tn/gi
tn/gi
tn/gi
tn/gi
Trang 31/61
Sau y l v d c trch t bo co nh gi SXSH c thc hin nm

2010 ti Cng ty c phn cng ngh cao Sao Xanh.
V d v Phiu cng tc s 1. Cc thng tin c bn (S liu nm 2009)
Tn doanh nghip: Cng ty c phn cng ngh cao Sao Xanh
Nhm SXSH
H v tn
Chc v - b phn
V tr trong nhm
1
2
3
4
Phng k thut
Phng k thut
6
Ngoi ra, nhm cn c cc thnh vin h tr l mt s cn b, cng nhn lm vic ti cc cng
on sn xut, ti v, chuyn trch an ton v sinh lao ng
Thng tin sn xut c bn ca doanh nghip

Sn phm chnh
CS thit k (tn/nm)
Cng sut thc (tn/nm)
Bi nghin
148
ng trt
32
Tm lt, phi, cc chi tit khc
2.500
Nguyn nhin liu s dng

Lng
St thp ph
kg/nm
2.470.000
Ci
m3/nm
70
Gang
kg/nm
230.000
VL m l
kg/nm
30.672
mi nh
vin/nm
2.500
mi to
vin/nm
156
Vi amiang
kg/nm
625
Ph gia (Fer,
Al)
kg/nm
73.880
Ct
kg/nm
618.000
Nguyn liu ph
Nguyn liu, nng lng chnh
Lng
in
kwh/nm
750.000
t st
kg/nm
87.727
Than
kg/nm
100.000
m3/nm
20
Gas
kg/nm
5.760
Nc thy tinh
lt/nm
64.800
CO2
kg/nm
15.500
Trang 32/61
Nhn xt:
-
Nhm trin khai sn xut sch hn: c cc b phn lin quan. Tuy nhin, ban lnh o
doanh nghip cn m bo cc thnh vin trong i c thi gian trin khai chng
trnh. Vic c ra cc thnh vin h tr l mt tt nhng cc thnh vin ny nn c giao
cng vic mt cch chnh thc c trch nhim vi cng vic.
Vic thu thp s liu cn m bo y cc nguyn nhin liu s dng, l cc s liu

quan trng lin quan n nh gi thnh sn xut v hin trng mi trng. Ti y ci v
vt liu m l c xp vo nguyn liu ph tuy nhin lng tiu th hng nm kh ln
nn cng cn thng k y .
Cn mt s thng tin lin quan sn xut m nhm cn thu thp nh: danh sch thit b, s
gi lm vic, cng sut, s ngy sn xut mt nm c nh gi c bn v hin trng
sn xut ca doanh nghip.
Vic tin hnh nh gi SXSH cn yu cu c thng tin nn, da trn mt s

ti liu, h s thit k, bo co ca doanh nghip hin c. Nu khng c y
thng tin th cn x l, tnh ton hoc thng nht xy dng. Bng kim tra
trong phiu cng tc s 2 gip cho nhm xem xt v tnh sn c ca thng tin.
Phiu cng tc s 2. Tnh sn c ca thng tin
Thng tin
C/khng
Ngun v cch tip cn
Ghi ch
S mt bng
Ti liu thit k
S liu thng k nguyn liu tiu th
S liu thng k tiu th nc, nng
lng
S cng ngh
Cn bng nng lng
Cn bng nc
H s bo dng thit b
H s hin trng mi trng
Cc thng tin cng ngh:
- Quy trnh cng on nu luyn
- Quy trnh cng on rt khun, d
khun v lm sch sn phm
- Quy trnh cng on nhit luyn
- Quy trnh cng on hon tt
- Quy trnh cng on lm khun
Lu : Rt nhiu doanh nghip khng c thng tin ban u v cc thnh vin trong nhm s
phi tho lun cch thc thu thp nhng thng tin ny. Ch c cc ti liu phn nh hin trng
sn xut mi c gi tr cao trong nh gi hiu qu kinh t, k thut v mi trng.
Trang 33/61
4.1.2 Nhim v 2: Phn tch cc cng on v xc nh lng ph

Khi c y thng tin c bn v doanh nghip, nhm SXSH nn tin
hnh m t quy trnh sn xut hin ti theo ngn ng chung bng cch lit k
li y cc bc trong cng on sn xut. thc hin cng vic ny,
nhm cn i kho st thng nht li thng tin cng ngh cng nh tm ra
cc c hi ci tin d thy, d lm lm im khi u cho nh gi. y l
c hi r sot li quy trnh sn xut, thng nht v lu trnh ca nguyn
nhin vt liu v nh gi li cc tn tht.
lm c vic ny mt cch h thng, cn kho st ln lt tng cng
on sn xut theo quy trnh cng ngh v quy nh vn hnh, t khu nhp
liu, chun b nguyn liu, nu luyn, c, nhit luyn, hon tt sn phm,
n nhp kho cng nh xem xt li cc h thng ph tr nh khu ni hi, h
thng in... Cn coi cng vic ny mang ngha tch cc m khng phi l
c hi nhm ph bnh hay ch trch. Cc kin a ra t vic tham quan
nn mang tnh xy dng v gi m thc hin.
Trong qu trnh kho st, nhm cn ghi li c cc thng tin chnh:
u vo v u ra ca mi cng on (xem phiu cng tc 3). i vi u
ra, cn ghi r dng pht thi l rn (R), lng (L) hay Kh (K).
Cc quan st v lng ph nguyn nhin liu ti mi cng on (phiu cng
tc 4). y l cc quan st ban u, nhm s tip tc khai thc cc c hi
ci tin. i vi cc doanh nghip c, cc hn ch trong vic qun l ni
vi cng nh tun th theo quy nh vn hnh thit b l mt trong nhng
nguyn nhn chnh dn n tn tht nguyn vt liu v nng lng.
Chi ph cho nguyn vt liu v nng lng (phiu cng tc 5), ghi li gi
cc nguyn vt liu s dng lm c s tnh ton tip theo.
Trang 34/61
Phiu cng tc s 3. Cng on sn xut vi cc dng nguyn nhin liu

v pht thi
Nguyn liu
chnh
Nguyn liu
ph
Nhin liu
CNG ON
1
Nguyn liu
Nhin liu
CNG ON
2
Nguyn liu
Nhin liu
CNG ON
3
Nguyn liu
Nhin liu
Loi cht thi

Nguyn nhin liu
x l
THIT B
PH TR
H THNG
X L
Tn v dng pht thi

(R,L,K)
Tn v dng pht thi

(R,L,K)
Tn v dng pht thi

(R,L,K)
Tn v dng pht thi
(R, L, K)
Tn v dng pht thi

(R, L, K)
Trang 35/61
V d cho phiu cng tc s 3. Cng on sn xut vi cc dng nguyn nhin liu v

pht thi ti Cng ty c phn cng ngh cao Sao Xanh
, nhin liu
ct
Fero
Khun
Than
Nhn xt:
-
nhim v ny, nhm xc nh c cc dng vo v dng ra ca qu trnh sn xut
phn ph tr ca Cng ty c phn cng ngh cao Sao Xanh cha c cp

chi tit nh lm mt nc tun hon, cp nhit cng l cc b phn c tim nng ci
thin, em li tit kim cho doanh nghip khi c kho st v ci tin.
Trang 36/61
Phiu cng tc s 4. Hin trng qun l ni vi

Khu vc
Lm khun
Nhp liu
L in
Quan st
-
B tr mt bng
Cch qun l nguyn liu, ti s dng nguyn liu
B tr mt bng tip nhn nguyn liu
Phn loi v vn chuyn nguyn liu
Ri vi nguyn liu
B tr mt bng
Bo dng thit b
Np liu, kim sot nhit qu trnh nu luyn
Qu trnh ra thp, lng v tnh cht nc lm mt
Nhit mt mt / Kh thi
R r nc, du m
Quy trnh vn hnh, ra sn phm
X l v lu tr bn sn phm
Ph tr
Cch thc vn hnh
Cch x l kh thi, nhit tha.
Nc chy trn
Nhit nc sau lm mt
l nhit
Lu : Cc quan st nu ra khng mang tnh ph bnh (v d ph liu ln xn) m cn th

hin iu quan st c (vic b tr ph liu cha tht hp l). iu ny s h tr vic a ra
cc bin php ci tin c sng to hn.
Sau khi quan st thc t v cch thc vn hnh cng nh qun l sn xut,
nhm nh gi c th a ra c rt nhiu gii php SXSH hin nhin
m cha cn s dng cc k thut phn tch tip theo. y l cc gii php
hin th r rng m trc y cha c lu tm trong sn xut hng ngy.
Vic mi cc chuyn gia bn ngoi tham gia, tham quan, kho st bc ny
l c bit c hiu qu.
Kim sot quy trnh vn hnh iu kin ti u v qun l mt bng trong
nh my thng b b qua v y cng l phn n gin nht, hp dn nht
bt u cc bc tip cn SXSH. Hn na, rt nhiu gii php SXSH
c xc nh l nhng gii php c th thc hin trong thi gian ngn, chi
ph thp, ch cn nhng thay i nh v thit b hoc ci thin v phng thc
v tn sut duy tr bo dng. Vic p dng nhng gii php ny chng
minh l mt khi u tt cho cc c gng SXSH ca nh my, khuyn khch
nh qun l cng nh cc cn b c gng hn na khi tin hnh nh gi
SXSH.
Trang 37/61
Phiu cng tc s 5. Chi ph nguyn liu u vo

Thi im: thng/nm .
Tn nguyn liu,
nhin liu s dng
n v
n gi
ng/n v
Lng s
dng
tn/nm
Lng s dng
n v/tn sn
phm
Chi ph
ng/tn sn
phm
Than
in
Nc
Gas
.
Vt liu m l
Ct
Lu : bng trn ch bao gm chi ph cho cc loi nguyn nhin liu s dng trong qu trnh sn
xut. y l c s dng xc nh hiu qu chng trnh, ng thi cng phn no ch ra t l
tng quan gia cc loi nguyn, nhin vt liu. Bc tranh chi ph sn xut tng th cn c
b sung bi chi ph nhn s, nng lng v vn hnh h thng x l mi trng. y c th
cn thiu chi ph ca mt s nguyn liu do c nhiu loi, nhiu gi khc nhau v lng s
dng nh hoc thay i. Vi cc loi ny ta c th ly gi tr trung bnh hoc b qua ty tng
trng hp.
V d cho Phiu cng tc s 5.

Chi ph nguyn liu u vo khi sn xut 1 tn sn phm bi cu 100
ca Cng ty c phn cng ngh cao Sao Xanh
Thi im: nm 2009
Tn nguyn liu,
nhin liu s dng
n
v
n gi
Lng s dng
Lng s dng
ng/n v
n v/nm
n v/tn sn phm
193.742
1308
St thp ph
kg
12.000
Gang
kg
6.500
Ferro
kg
Al 35.000
1037
Fe 22.000
7
-
Ct
kg
88.132
595
Nc thy tinh
kg
2.410
9.850
66,5
in
Kwh
750
165.896
1120
Than
kg
4.520
37.030
250
Gas
kg
1.018.000
296
CO2
kg
130.000
4.592
31
Vt liu m l
Kg
30.000
30.672
17,2
Trang 38/61
Nhn xt:
-
Bng chi ph nguyn liu cng chi tit v y cng h tr vic xc nh chi ph dng thi
(phiu cng tc s 8) chnh xc.
Bng trn cn cho bit gi cng nh lng s dng mt s nguyn nhin liu, y l
nhng thng tin quan trng cho vic phn tch tip theo.
Khi doanh nghip c nhiu loi chi ph nguyn liu, ch lit k cc chi ph chnh trong bng
ny, phn cn li chuyn xung ph lc.
4.2 Bc 2: Phn tch cc cng on sn xut

Mc ch ca bc ny nhm c c s thng nht chung ca nhm v:
-
Quy trnh sn xut, cc thng s kim sot;
Xc nh cc tn tht quan trng trong dy chuyn sn xut v chi ph tng ng;
Xc nh y cc nguyn nhn sinh ra tn tht .
4.2.1 Nhim v 3: Chun b s dy chuyn sn xut

Vic xy dng s dy chuyn sn xut, quy trnh cng ngh, l mt bc
quan trng trong phn tch nh gi SXSH. S khi ca dy chuyn sn
xut bao gm cc cng on sn xut, theo quy trnh cng ngh vi cc dng
u vo, u ra, cht thi v pht thi. Mi nguyn nhin vt liu s dng u
cn c trong s ny v nguyn liu s nm li trong sn phm v mt
phn tht thot theo dng thi. Cc nguyn nhin vt liu t khi dng cng cn
c nu r tn. Mc d nhm nh gi SXSH quen thuc vi dy chuyn
cng ngh, vn cn phi tin hnh tham quan kho st ni sn xut mt vi
ln trc khi thng nht c s dy chuyn sn xut dng s dng
cho nh gi SXSH.
C th trin khai SXSH vi quy m sn xut ln hoc trin khai SXSH phm
vi hp mang tnh th im, dy chuyn sn xut chi tit s c xy dng cho
khu vc c chn trin khai, c th l khu vc tiu th nhiu nhin liu,
nng lng vt nh mc hoc ang gy nhim, c nhiu tc ng tiu
cc ti mi trng . i vi doanh nghip sn xut c, c th tp trung nh
gi theo sn phm. Sn phm ny phi chim t l ln trong c cu sn phm
ca cng ty, quy trnh tiu th nhiu nguyn nhin vt liu v pht thi lng
ln cht thi; tn tht nguyn liu cao.
Lu : thit lp s dng cng ngh theo cc nguyn tc:
-
Tn cng on sn xut c m t trong hp ch nht gia.
Lit k y cc dng vo ra, bao gm cc dng tun hon nguyn nhin vt liu, thu
hi v ti s dng. Dng vo ghi bn tri, dng ra ghi bn phi hp m t cng on.
Vi cc dng nguyn liu khng c s dng hng ngy cng nh dng pht thi khng
thng xuyn cn c ghi ch.
Nh cp trong phn nhn xt ca phiu cng tc s 4 c thc hin ti cng ty C

phn cng ngh cao Sao Xanh, phn lp s cng ngh ny cn lu ti cc cng on
nh v sinh thit b, np nguyn liu, vn chuyn nguyn liu
Trang 39/61
4.2.2 Nhim v 4: Cn bng vt liu

Cn bng vt liu thc cht l cng c kim k nh lng nguyn vt liu s
dng ti mi cng on sn xut. Cn bng nguyn vt liu tt ng vai tr
quan trng trong nh gi SXSH v nh c th nh lng cc mt mt
hoc pht tn cha bit. Cn bng nguyn vt liu tt cn h tr vic nh
gi li ch chi ph ca gii php SXSH. Nguyn tc c bn ca cn bng
nguyn vt liu l tng nguyn vt liu i vo dy chuyn s phi bng tng
lng ra khi dy chuyn sn xut mt thi im no , di mt dng
no . Nguyn vt liu c th c cn bng di mt trong hai hnh thc
sau:
-
Cn bng tng th: dng cho tt c cc dng nguyn vt liu vo dy

chuyn sn xut. Cn bng c tin hnh qua tng cng on vi s
bin i ca tt c cc thnh phn tham gia vo dy chuyn sn xut.
Cn bng cu t: l vic tnh ton cn bng ring cho mt loi nguyn

liu, thng p dng cho cc nguyn liu c gi tr cao hoc cc loi cht
c c tnh cao. Theo di bin i ca cu t ny ti mi cng on c
cu t tham gia trn ton b quy trnh sn xut.
S dng phiu cng tc s 6 ghi li kt qu ca cn bng nguyn vt liu.

C hai cch ghi th hin cn bng nguyn vt liu: theo bng hoc theo s
quy trnh cng ngh. Khi s dng s cng ngh ghi li cn bng
nguyn vt liu cn ghi r thnh phn, nng ca tng loi nguyn vt liu
vo v ra. Cn bng nguyn vt liu c th da trn o c, ghi chp ca mt
m, mt ngy hoc mt nm sn xut.
Phiu cng tc s 6. Cn bng vt liu
Chu k tnh ton: ngy/thng/nm
Cng on
u vo
Loi
Cng on 1
Nguyn liu
Nguyn liu
u ra
Lng
Loi
Sn
phm 1
Lng
Dng thi
Lng
Rn
Lng
1.1
Rn
2.1
Nhin liu .
Sn phm 1
Nguyn liu
Kh
3.1
Rn
2.2
Nhin liu
Cng on 2
Kh
Sn
phm 2
Nhin liu
Cng on .
Trang 40/61
Lu :
-
Khng c cn bng no l hon thin c. Khi ghp s liu ca tng cng on v s liu
tng th ca c dy chuyn s xut hin sai s do tnh chnh xc ca s liu, do tng ca
nhiu dng thi nh cha c k n nh bay hi, ri vi.... Mc ch ca cn bng vt
liu l tm ra cc dng thi lng ph ln nht tp trung gim thiu.
S liu dng trong cn bng vt liu c th c thu thp t s sch ghi chp hoc o c
trc tip. Cc s liu s dng cn quy i v cng mt n v sn phm.
S liu dng thi trong cn bng vt liu l tng nht l c km thm thng s v nguyn
liu hoc dng bin i mi ca nguyn liu b mt theo dng thi tin cho vic xc nh
chi ph dng thi bc tip theo.
Mi dng thi nn c nh s (v d L1, L2, L3 cho dng thi lng, K cho kh v R cho
rn) tin cho vic xc nh chi ph cng nh phn tch nguyn nhn tip theo.
V d cho Phiu cng tc s 6.

Cn bng vt liu trong qu trnh sn xut bi cu 100 ti Cng ty C
phn cng ngh cao Sao Xanh
C s tnh: nm 2009
Cng on
Nu luyn
u vo
Loi
Lng
Thp ph
1308 kg
u ra
Loi
Lng
Thp
ph
1300 kg
Thp
lng
1227 kg
Thp ph
1300 kg
in
1.120kwh
VL m l
17.3 kg
Nc b
sung
20,96m3
Thp lng
1227 kg
SP c
Khun
660 kg
u hi 277 kg
liu
Dng thi
Lng
Rn (kg)
Kh (kg)
Tp cht
8 kg
Nc
tun
hon
1000 kg
X
l Bi
71,3kg
12,1kg
VL m kg
l 3.7kg
Khun
660kg
Cn bng vt liu cng on lm khun

Lm
khun
Ct
600 kg
Ghp
khun, sy
khun
BTP
662 kg
Gas
2 kg
BTP
662 kg
Khun
660
Nc thy 66 kg
tinh
Nc
thy
tinh ri
vi
Ct ri vi
4kg
Bavia 2kg
Nhn xt:
-
Bng cn bng vt liu nu trn phn tch chi tit cho tng cng on trong sn xut v
ch ra loi v lng ca cc dng thi.
Cn bng nng lng thng c lp trong bng khc.
Trang 41/61
Cn bng nhin liu (cn gi l cn bng nng lng)

Tin hnh cn bng nng lng l mt cng vic phc tp hn cn bng
nguyn vt liu. Nguyn nhn nm ch: ngi ta c th truy tm nguyn liu
u vo cho mt hot ng thng qua cc u ra c th nh lng v quan
st c, cn i vi cc dng nng lng th khng phi lc no cng c th
lm c iu ny. Mc d i vi cc dng nng lng, ngi ta vn p
dng chung mt nguyn l c bn (lng nng lng vo phi bng lng
nng lng ra), nhng cc dng nng lng u ra thng kh nhn bit
hn so vi cc nguyn liu u ra. V th, vic nhn din v nh gi cc
dng tn tht nng lng n v mc khng hiu qu trong s dng nng
lng l mt phn vic kh khn hn rt nhiu. iu ny c bit ng i
vi cc thit b s dng in nh my bm, my nn kh khi nng lng
u vo di dng in nng v c th d dng o c, nhng mc
hiu qu khi chuyn i sang u ra hu ch (nc c bm, kh c
nn) li khng th nh lng trc tip c.
Trong thc t c th khng thc hin c php cn bng nng lng chnh
xc v ng hon ton, ngi ta c th i xc nh cc im, v tr b tn tht
ca cc thit b s dng nng lng nh cc thit b ph tr nh ni hi, l,
thit b ha hi thng qua lp bng cn bng nng lng. Bng cn
bng nng lng s c ch trong vic xc nh v tnh ton cc tn tht nng
lng cc thit b v t cc h thng cng nh nh gi c hiu sut
ca chng.
4.2.3 Nhim v 5: Xc nh chi ph ca dng thi

Mi dng thi ra mi trng u c xut x, bt ngun t nguyn, nhin vt
liu u vo, ng thi c th cn chi ph x l trc khi c php thi vo
mi trng. Vic xc nh chi ph dng thi bao gm xc nh c tng hai
chi ph ny chi ph nguyn liu mt theo dng thi v chi ph x l mi
trng.
Vic xc nh tn tht nguyn vt liu, bn thnh phm, sn phm c trong
dng thi da vo thng tin thu c t cn bng vt liu (phiu cng tc s
6) nhn vi n gi nguyn liu b mt mt (phiu cng tc s 5). Lng v
c tnh dng thi c xc nh trong phiu cng tc s 6 c m t chi tit
ti phiu cng tc s 7 nhm xc nh mc n gi p dng cho cc thnh
phn nguyn liu tng ng. Vi quan nim dng thi chnh l ti nguyn
nhin liu c t khng ng ch, trong phiu cng tc s 7, thnh phn v
ngun gc nguyn liu sinh ra thnh phn thi l c bit quan trng trong
vic xc nh n gi nguyn liu p dng cho dng thi .
Trang 42/61
Phiu cng tc s 7. c tnh dng thi

Cng on
Tn dng thi
Thnh phn
trong dng
thi
Ngun gc
thnh phn
thi
n v
Lng
Nhn xt:
-
Vic tch thnh phn thi v ngun nguyn liu sinh ra dng thi gip cho vic p mc
gi tn tht nguyn liu c d dng hn.
Trong cng vic ny, c th xem xt n lng nguyn liu thu hi nh mt dng thi trong
mt bng ring c phn tch tip theo ring.
Vic chi tit ha s cng ngh v phn tch cn bng vt liu tt s nh hng n kt
qu xc nh chi ph cc dng thi trong cng vic ny.
Trong trng hp ca Cng ty c phn cng ngh cao Sao Xanh cng a ra c bng
c tnh dng thi ca cc cng on sn xut, tuy nhin s liu lng tn tht cn phi
quy ra lng tn tht tnh cho 1 nm.
Chi ph x l mi trng c xc nh bng chi ph vn hnh h thng x l

nhn vi vi lng cht thi c xc nh trong cn bng vt liu (phiu
cng tc s 6).
Tng hp chi ph dng thi c thc hin trong phiu cng tc s 8.
Phiu cng tc s 8. Chi ph dng thi
Tn dng thi
Chi ph nguyn liu

Lng
Tin
Chi ph x l
Lng
TNG
Tin
Thc t nhiu doanh nghip cha xt n chi ph n l chi ph nguyn liu mt mt theo dng
thi m ch xt chi ph x l mi trng i vi cc dng thi lm nh hng n quyt nh u
t mi trng.
xc nh c tt nht tng gi tr dng thi v so snh mc quan trng ca cc dng
thi, cc s liu c xc nh trong phiu cng tc 5 (chi ph nguyn liu) v phiu cng tc s
6 (cn bng vt liu) ng vai tr quan trng.
Trang 43/61
cao Sao xanh

v .gia Chi phi
Thp ph
kg
12.000
15.696.000
Fero
Kg
30.000
210.000
VL m l
kg
10.000
173.000
750
840.000
Nc lm mt
in
kwh
Chun b
ph, np
ph
Nu luyn
Dng
thi
.gia Chi
ph
Tp cht
12.000 96.000
15.696.000
Khi bui
16.919
204.720
Hao
VLL
10.000
37.000
X l
16.919 1.206.325
Nhit thi
750
165.000
16.985
1.573.609
20
13.200
16.919.000
Khun cat
kg
20
13.200
Ra thep,
c
u
VL uc
16.932.200
Chuyn nhit luyn
4.2.4
C nhiu cch thc hin cng vic ny mt cch c h thng thng qua
vic r sot cc phm vi lin quan n tng dng thi. iu cn ch trong
phn tch nguyn nhn dng thi l lun ghi li cc nguyn nhn theo thc t
vn hnh hin ti/quan st c. Cc nguyn nhn xc nh khng mang tnh
ch trch hoc ph phn.
Nguyn nhn ca dng thi c xc nh mt cch c h thng v y
nht khi s dng phng php tho lun nhm v biu Ishikawa (hay cn
gi l biu xng c). Biu Ishikawa l mt trong by loi biu kim
sot cht lng, c coi l cng c ph bin nht thc hin phn tch
nhn- qu. xy dng biu ny cn dng phng php xem xt 4M1E,
bao gm con ngi (Man), phng php thc hin (Method), nguyn liu
(Material), my mc (Machine) v mi trng (Environment).
Cng c th xc nh nguyn nhn dng thi da trn cc cu hi c bn
sau: bn cht ca cng on l g? (vy dng thi sinh ra c phi p
ng mc ch ca cng on khng?); ti sao sinh ra nhim nhiu nh
th? (c phi do nh hng ca cng on trc hay do cng on ny dng
lng ph nguyn nhin vt liu?) v c th lm g c vi dng thi ny (c
thc hin tun hon ti s dng c khng) ? ...
Trang 44/61
D thc hin bng cch ny hay cch khc, cn tin hnh phn tch nguyn
nhn cho mi dng thi trong cng mt h thng v tm cc nguyn nhn
bng cu hi ti sao.
Lu :
Cch r sot nguyn nhn y nht l theo dng thi c nh s phiu cng tc 6.
Mi mt dng thi s c th c mt hoc mt vi nguyn nhn tng ng. Cc nguyn nhn
ny cng s c nh s th t theo s th t ca dng thi. Trong mt s trng hp cn
nh gi nhanh, nguyn nhn c xc nh theo nguyn nhin liu tiu th chnh (nh in,
nc... tiu th cao). y khng khuyn co xc nh nguyn nhn theo cng on m khng
bm theo dng thi v s khng m bo xem xt ht c cc nguyn nhn tim nng. Vic
a ra cc nguyn nhn cng chi tit th cc gii php c xut cng phong ph.
Phiu cng tc s 9 c th c dng ghi li cc nguyn nhn ca dng

thi.
Phiu cng tc s 9. Phn tch nguyn nhn dng thi
Dng thi
s
Cng on
Nguyn nhn
Ch quan
Khch quan
L1
L2
Nhn xt:
-
Vic phn tch mt cch c h thng s dn n nhiu nguyn nhn hn, qua c thm
c hi ci thin, gim dng thi.
Cc kha cnh phn tch nguyn nhn c th c tip tc khai thc thm.
Lu phn ny cn ch ra c nguyn nhn gc r ti sao c dng thi (t gc

cng ngh v vn hnh, qun l sn xut).
Vic phn tch nguyn nhn ca Cng ty c phn cng ngh cao Sao Xanh khng i theo
tng dng thi m phn tch theo tng cng on sn xut. Tuy nhin cc nguyn nhn
c cng ty a ra kh y , c nhng nguyn nhn c a ra m khng phi t bt
k dng thi no c nu trn.
4.3 Bc 3: ra cc gii php SXSH

Mc ch ca bc ny nhm thu c ng gp kin v:
-
Cc c hi sn xut sch hn
Phn loi s b cc c hi theo kh nng thc hin
Trin khai cc c hi c th lm ngay
4.3.1 Nhim v 7: xut cc c hi SXSH

Cc c hi SXSH khng nht thit phi l gii php SXSH. Vic xc nh y
nguyn nhn gc r sinh ra cc dng thi (phiu cng tc s 9) cng vi
vic xc nh chi ph dng thi (phiu cng tc s 8) l c s xut cc
c hi SXSH.
Trang 45/61
Cn c tho lun nhm SXSH nhim v ny. Cng c th mi thm cc

chuyn gia bn ngoi tham gia kin. c th l cc chuyn gia v cng
ngh, nng lng hoc v sn xut sch hn. Ti nhim vny, cn tip nhn
tt c cc tng xut v coi l c hi sn xut sch hn m cha xt
n tnh kh thi ca chng.
Phiu cng tc s 10 ghi li cc c hi do nhm xut. Vi mi nguyn
nhn c xc nh phiu cng tc s 9 c th khng c, c mt hoc
nhiu c hi. Cc c hi nn c tip tc nh s theo s ca nguyn
nhn/ dng thi tng ng.
Phiu cng tc s 10. Cc c hi SXSH
Nguyn
nhn
C hi
1.1.1
QLNV
TDNL
KSQT
CTTB
TDCN
TH
SP
1.1.2
TNG
Ghi ch: QLNV: Qun l ni vi, TDNL: thay i nguyn liu, KSQT: Kim sot qu trnh, CTTB:
ci tin thit b, TDCN: thay i cng ngh, TH: tun hon, ti s dng, SP: ci tin sn phm
Lu :
-
Vic thc hin phn tch nguyn nhn l c bit quan trng i vi kt qu ca cng vic
xut c hi. Phn tch nguyn nhn cng chi tit v khch quan th s c cng nhiu c
hi c a ra.
ng vi mt nguyn nhn c th c nhiu hn 1 c hi thc hin SXSH. Pht trin cc c

hi SXSH cn bm st theo cc nguyn nhn pht sinh ra dng thi v cc k thut thc
hin SXSH.
V d cho Phiu cng tc s

10
Cc c hi SXSH ti Cng ty C phn cng ngh cao Sao Xanh
Nguyn nhn
ln
5. Kh
TT
1
1.1
1.3
2.1
4
5
2.2
3.1
3.2
4.1
5.1
6.1
Trang 46/61
10
7.1
11
7.2
12
13
14
15
7.3
7.4
8.1
8.2
16
9.1
17
9.2
18
19
10.1
10.2
20
10.3
21
22
11.1
11.2
23
11.3
24
11.4
25
14.1
26
15.1
27
15.2
Gia cng l
Khon than dng cho l trnh chy l khng
ti
4.3.2 Nhim v 8: La chn cc c hi u tin trin khai ngay

Ngay sau khi c danh mc cc c hi SXSH, nhm SXSH s phn loi s b
cc c hi theo hng mc c th thc hin ngay, cn nghin cu tip hoc
loi b. Ch cn thc hin nghin cu kh thi vi nhm c hi cn nghin cu
tip. Vi cc c hi b loi, cn nu l do. Phiu cng tc s 11 ghi li kt qu
ca vic phn loi ny.
Phiu cng tc s 11. Sng lc cc c hi SXSH
C hi
Thc hin ngay
Nghin cu tip
Loi b
1.1.1
1.1.2
TNG
Lu : vi cc gii php loi b, cn nu thm l do loi c hi lu h s. Trong mt s

trng hp c th xem xt li cc c hi b loi.
Trang 47/61
4.4 Bc 4: Chn la cc gii php SXSH

Mc ch ca bc ny nhm sp xp th t u tin thc hin cc gii php SXSH da trn:
-
Tnh kh thi v mt k thut
Tnh kh thi v kinh t
Tnh tch cc v mi trng
Cc gii php SXSH khng ch n thun cn phi kh thi v mt k thut,

kinh t, m cn cn mang li li ch v mt mi trng. Do ni dung bc
ny nhm h tr doanh nghip xc nh th t u tin thc hin cc gii php
SXSH mt cch y .
4.4.1 Nhim v 9: Phn tch tnh kh thi v k thut

i vi cc c hi SXSH khng thc hin c ngay cn c phn tch kh
thi. Phn tch tnh kh thi k thut ca c hi SXSH cn c tin hnh trc.
Cng vic ny l kim tra nh hng ca gii php n qu trnh sn xut,
cng sut, cht lng sn phm, nng sut, an ton... Trong trng hp vic
thc hin gii php c th gy nh hng ng k ti quy trnh sn xut th
cn kim tra v chy th quy m phng th nghim hoc trong mt phm vi
hp ri sau mi quyt nh v kh nng trin khai trn thc t. Cc hng
mc kim tra, nh gi k thut in hnh c a ra trong phiu cng tc
s 12.
Cc gii php c xc nh l kh thi v k thut s tip tc c xem xt
cc bc tip theo (phn tch tnh kh thi v kinh t). Cc gii php c xc
nh l khng kh thi v k thut do thiu cng ngh, thit b, din tch...cn
c ghi li trong h s nghin cu tip trong tng lai khi cn.
Phiu cng tc s 12. Phn tch kh thi v k thut
Tn gii php
M t gii php
Kt lun:Kh thi/ Cn kim tra thm/ Loi

1. Yu cu k thut
Ni dung
Yu cu
C
u t phn cng
c sn
Khng
Thit b
Cng c
Cng ngh
Din tch, mt bng

Nhn lc
Thi gian dng hot ng
Trang 48/61
2. Tc ng k thut
Lnh vc
Tc ng
Tch cc
Tiu cc
Nng lc sn xut
Cht lng sn phm
Tit kim ha cht
Tit kim nng lng
Tnh tng thch vi cc thit b trong h thng
An ton
Bo dng
Vn hnh
Khc
Lu : Mi phiu cng tc s dng phn tch cho mt gii php.
4.4.2 Nhim v 10: Phn tch tnh kh thi v mt kinh t

Mt trong nhng yu t quan trng gip ngi qun l ra quyt nh c thc
hin gii php SXSH hay khng l da trn tnh kh thi v mt kinh t ca gii
php. Phn tch tnh kh thi v mt kinh t c th c thc hin bng cch
xc nh cc ch s sinh li ca gii php. i vi u t thp, thi gian hon
vn nhanh l phng php tt v thng c p dng. i vi cc gii
php cn u t ln, cn xc nh cc ch s Gi tr hin ti rng (NPV), T
sut hon vn ni b (IRR). Phiu cng tc s 13 dng xc nh tnh kh
thi v kinh t. Phiu cng tc ny cng c th c sa i cho thch hp
vi cc kh nng khc nhau.
Vi cc gii php SXSH khng c tnh kh thi v mt kinh t, khng nn loi
b ngay m cn ghi li nghin cu thm v nhng gii php c th c
nhng nh hng tch cc ti mi trng.
Trang 49/61
Phiu cng tc s 13. Phn tch kh thi v kinh t

Tn gii php
M t gii php
Kt lun: Kh thi/ Khng kh thi
u t phn cng
Tit kim
VND
VND
Thit b
Nguyn liu
Ph tr
Nng lng
Lp t
Nguyn liu ph
Vn chuyn
Chi ph x l v thi b
Khc
Khc
TNG
TNG
Chi ph vn hnh nm
Khu hao
VND
LI THUN
=
TIT KIM CHI PH VN HNH
Bo dng
Nhn cng
in
THI GIAN HON VN

=
(U T/LI THUN) X 12 THNG
Khc
TNG
Lu vic in thng tin cho mi gii php SXSH vo mt phiu cng tc l l tng trc khi
tng hp danh mc cc gii php kh thi.
4.4.3 Nhim v 11: nh gi nh hng n mi trng

Sau khi xc nh tnh kh thi k thut v kinh t, cc phng n SXSH phi
c nh gi trn phng din nh hng ca chng ti mi trng. Trong
nhiu trng hp, tnh tch cc i vi mi trng ca gii php l hin nhin
v d khi gim hm lng cht c hi hoc lng cht thi. Phiu cng tc
s 14 c th c s dng kim tra tc ng tch cc v mi trng ca
mt gii php.
Trang 50/61
Phiu cng tc s 14. Phn tch nh hng n mi trng

Tn gii php
M t gii php
Kt lun: Tch cc / Tiu cc/ Khng i

Mi trng
Thng s
nh tnh
Kh
Lng tng pht thi

Bi
Kh
Khc
Nc
Lng tng pht thi

Lu lng
COD
Nhit
Khc
Rn
Lng tng pht thi

Ct
X
Khc
nh lng
Ngy nay, vic trin khai gii php SXSH c tc ng tch cc n mi trng ngy cng c
coi trng, thm ch c th c thc hin ngay c khi khng kh thi v mt kinh t.
4.4.4 Nhim v 12: La chn cc gii php thc hin

Sau khi tin hnh nh gi v k thut, kinh t v mi trng, bc tip theo
l la chn cc phng n thc hin. R rng rng nhng phng n hp
dn nht l nhng phng n c li v ti chnh v c tnh kh thi v k thut.
Tuy nhin, tu theo tnh hnh ca doanh nghip, cc yu cu ca cc c quan
hu quan v vn mi trng m tc ng mi trng c nh hng nhiu
hay t n qu trnh ra quyt nh. C th xc nh bng cch cho h s tm
quan trng (trng s) i vi cc yu t k thut, kinh t v mi trng. Phiu
cng tc s 15 h tr vic xem xt th t u tin ny.
Phiu cng tc s 15. La chn cc gii php SXSH thc hin
Gii php
Kh thi k thut
(25)
L
Kh thi kinh t
(50)
L
Kh thi mi
trng (25)
L
Tng
im
Xp hng
1.1.1
im cho cc mc thp (L: 0-5), trung bnh (M: 6-14), cao (H: 15-20)
Trng s 25 (kh thi k thut), 50 (kh thi kinh t), 25 (kh thi mi trng) ch l v d
V d: Hin ti cc doanh nghip Vit Nam thng trng s 30, 40, 30 cho tnh kh thi v k
thut, kinh t v mi trng
Trang 51/61
4.5 Bc 5: Thc hin cc gii php SXSH

Mc ch ca bc ny nhm cung cp cng c lp k hoch, trin khai v theo di kt qu ca
vic p dng cc gii php SXSH c xc nh.
Cc gii php c la chn cn a vo thc hin. Song song vi cc

gii php xc nh ny, c mt s cc gii php c chi ph thp hoc khng
cn chi ph, c th c thc hin ngay sau khi c xut (nh trit
y kn cc thng cha sn, m bo thi gian mui , bt r r, kho van khi
khng s dng...). Vi cc gii php cn li, cn c k hoch thc hin mt
cch c h thng.
4.5.1 Nhim v 13: Chun b thc hin

Phiu cng tc s 16 s h tr lp k hoch thc hin. K hoch ny bao
gm c nhn hay mt nhm c trch nhim thc hin, tin thc hin v
thi gian cn phi hon thnh.
Phiu cng tc s 16. K hoch thc hin
Gii php c
chn
Thi gian thc

hin
Ngi chu trch

nhim
Gim st
Phng php
Giai on
Nhn xt:
-
Thi gian thc hin: nn ghi mc thi gian trin khai cng vic ny mt cch c th, v d
thng 1 n thng 5 nm 2009, tng ng ghi giai on gim st kt qu thc hin thng
6-10 nm 2009. Vic trin khai thng xuyn s c cp trong mc tip theo (duy tr
sn xut sch hn).
Ngi chu trch nhim: D l mt nhm ngi, nn c tn ngi chu trch nhim chnh
trin khai.
Cng ty c phn cng ngh cao Sao Xanh cha a ra c k hoch thc hin cc gii
php cng nh ngi chu trch nhim thc hin cc gii php .
4.5.2 Nhim v 14: Thc hin cc gii php

Cc gii php c chn a vo thc hin cn c xc nh cc li ch
thc t do gii php mang li.
Phiu cng tc s 17 c th c s dng ghi li kt qu trong qu trnh
trin khai cc gii php c la chn.
Phiu cng tc s 17. Cc gii php thc hin
Gii php
c chn
Chi ph thc
hin
Li ch kinh t
D kin
Thc t
Li ch mi trng
D kin
Thc t
Trang 52/61
4.5.3 Nhim v 15: Quan trc v nh gi cc kt qu

Cc gii php c thc hin cn c gim st v nh gi. Cc kt qu
thu c cn phi st vi nhng g c c tnh v phc tho trong
nh gi k thut. Nu nh kt qu thc t khng t c nh d tnh th
nn tm hiu nguyn nhn v sao. C th s dng phiu cng tc 17 hoc
tng hp kt qu thu c trong phiu cng tc 18 khi c nhiu gii php
ng thi c trin khai v khng tch bit c li ch thu c.
Phiu cng tc s 18. Kt qu chng trnh nh gi SXSH

Nguyn liu,
nhin liu
n v
Li ch k thut
Trc
SXSH
Li ch kinh t
Sau SXSH
Li ch mi
trng
V d cho Phiu cng tc s 18

ti Cng ty C phn cng ngh cao
Sao Xanh
kg
CO2
Than
kg
CO2
%
Tng cng
SXSH
Sau
SXSH
1308
1300
17,2
10,3
30
50
1120
1100
660,8
649
250
232
510
473,28
0,6%
12.000
ng/kg
14.400.000
40,1%
10.000
ng/kg
10.350.000
1,8%
750
ng/kWh
2.250.000
1770 kg CO2
CO2/kWh
7,2%
1000
ng/kg
2.700.000
5508 kg CO2
CO2/kg than
200
190
20%
15%
5,0%
700.000
ng/kg
1.050.000.000
1.079.700.000
Trang 53/61
4.6 Bc 6: Duy tr SXSH

Mc ch ca bc ny nhm h tr duy tr thc hin chng trnh cng nh pht huy cc
thnh cng t c.
Vic t c mt s kt qu ban u v ti chnh v mi trng t chng

trnh SXSH cha c ngha l khai thc ht cc c hi ci tin ti doanh
nghip. Do vy, thng xuyn ci thin hiu qu sn xut, tip tc tit kim
v nguyn nhin liu cng nh ci tin hin trng mi trng, vic duy tr thc
hin chng trnh cp cao hn v thng xuyn hn l thc s cn thit.
4.6.1 Nhim v 16: Duy tr SXSH

Nhng c hi mi ci thin hiu qu sn xut l lun lun c. Nhm nh
gi SXSH cn xy dng mt khung hot ng nhm tch hp hot ng sn
xut sch hn vo cng vic hot ng hng ngy ca doanh nghip. Khung
hot ng ny bao gm nhng ni dung sau:
-
B nhim mt nhm lm vic lu di v nh gi SXSH, trong c i

din ca lnh o ca nh my lm trng nhm;
a tip cn SXSH vo k hoch pht trin chung ca nh my;
Ph bin cc k hoch SXSH ti cc phng ban ca nh my;
Khuyn khch nhn vin c nhng sng kin mi v nhng xut cho c
hi SXSH;
T chc cc tp hun cho cn b v cc lnh o nh my.
Ngay sau khi trin khai thc hin cc gii php SXSH, nhm SXSH nn bt
u thc hin t bc 2: Phn tch cng ngh, xc nh v chn la cng
on lng ph nht trong nh my. Tip tc trin khai tng bc nh c
m t trn.
duy tr c vic p dng thnh cng chng trnh SXSH, cha kha cho
thnh cng lu di l phi thu ht s tham gia ca cng nhiu nhn vin cng
tt, cng nh c mt ch khen thng cho nhng ngi c bit xut sc,
lm cho SXSH tr thnh mt hot ng lin tc, c thc hin thng
xuyn.
4.7 Cc yu t bt li cho vic thc hin SXSH

Hu ht cc nh gi SXSH u dn n gim chi ph sn xut, gim tc
ng xu ti mi trng v c cc sn phm tt hn. Tuy nhin, nhng c
gng SXSH c th b gim dn hoc bin mt sau giai on hng khi ban
u.
Cn xc nh ra nhng yu t gy tc ng xu cho chng trnh SXSH, bao
gm:
-
Cc tr ngi v ti chnh trong vic thc hin mt s cc phng n mong
Trang 54/61
mun;
-
C thay i trong phn cng trch nhim ca cc thnh vin ca nhm

dn ti vic gin on v mai mt kin thc ca nhm SXSH;
Cc thnh vin ca nhm chng trnh SXSH i lc sang cc Cng

vic khc m h cho l khn cp hn;
Tham vng qu nhiu dn ti vic rt nhiu phng n cng c thc

hin mt lc, lm mt mi nhm SXSH;
Kh khn trong vic phn tch chi ph v li ch ca cc phng n SXSH.
4.8 Cc yu t thnh cng ca chng trnh SXSH

C rt nhiu yu t ng gp cho s thnh cng ca chng trnh sn xut
sch hn. Mt trong cc yu t l:
-
S hiu bit y v cam kt ca lnh o doanh nghip trong vic thc

hin SXSH;
Trao i gia tt c cc cp ca doanh nghip v nhng mc tiu v li

ch ca SXSH;
Chnh sch r rng v u tin v u t cho SXSH v kim sot mi

trng;
H thng gim st, nh gi cng bng;
C ch thng pht cng bng i vi n lc thc hin.
Trang 55/61
5. X l mi trng
Mc ch ca chng ny nhm cung cp thng tin tm tt cc nguyn tc x l vn mi
trng c bn ca ngnh c kim loi. l x l kh thi, nc thi v cht thi rn.
SXSH h tr doanh nghip ci thin hin trng mi trng thng qua gim ti
lng pht thi ra mi trng, nng cao hiu sut s dng nguyn nhin liu.
Tuy nhin, c th p ng c tiu chun thi, trong nhiu trng hp
cn c thm cc gii php x l cui ng ng, c m t di y.
5.1 X l kh thi
Kh thi
v kh c hi.
t qua cc khe t di sn xng.
5.1.1 X l bi trong kh thi l nu luyn

C nhiu phng php x l bi trong kh thi, di y trnh by mt s
phng php ph bin
5.1.1.1 Bung lng bi
Nguyn tc tc
90%.
Trang 56/61
Kh thi sau
lm sch
Kh thi vo
Kh thi sau
lm sch
Kh thi
vo
Hnh 3. Cc loi bung lng bi
5.1.1.2 Lc bi Cyclon
Kh thi sau
lm sch
Kh thi
vo
B lc bi Cyclon c s dng tng i ph

bin v thng c khuyn khch p dng ti
cc c s c c cng sut nh hay sn xut th
cng.
u im: cu to n gin, hiu sut lc bi cao,
gi thnh thit b thp, tn t khng gian lp t.
Nguyn l lm vic ca thit b lc bi kiu
Cyclon l li dng lc ly tm khi dng kh thi
Hnh 4 Cyclon lc bi
chuyn ng xoy trong cyclon tch bi. B
98%.
n ngi ta c lp thm van x
bi vo thng cha. Van x 5 l van x kp 2 ca 5a v 5b khng m ng
thi nhm m bo lun cch ly bn trong Cyclon vi thng cha bi, khng
cho kh thi lt ra ngoi.
5.1.1.3 Lc bi ti vi
Thit b lc bi kiu ti vi c
-95%.
trn b mt vi lc lm tng tr lc v nng sut lc.
Trang 57/61
Thit b lc bi kiu ti vi c nng sut lc khong 150 - 180m3/h trn 1m2

din tch b mt vi lc. Khi nng bi
trong khng kh cao trn 5000 mg/m3 th
Kh ra
cn lc s b bng thit b lc khc trc
khi a sang b lc ti vi.
5.1.1.4 Lc bi kiu si bt
Thit b lc bi kiu si bt c th c lp
t sau thp ra kh to thnh h thng
x l bi. i vi cc c s c kim loi c
iu kin v kinh ph th nn p dng h
thng ny thay v lc bi cyclon.
, tng kh nng hp th kh
thi c hi v bi. Thit b lc bi nhiu
Hnh 5. Lc bi ti vi
tng bt cho hiu qu lc bi kh cao, t
99,7%, nng bi trong khng kh cn li kh thp, di 12 mg/m 3
5.1.1.5 Lc bi tnh in
Thit b lc bi tnh in nn p dng ti cc doanh nghip c cng nghip,
sn lng ln. Thi b lc tnh in s dng lc ht gia cc ht nh np in
m. Cc ht bi bn trong thit b lc bi ht nhau v kt li thnh khi c kch
thc ln cc tm thu gp. Thit b lc bi kiu tnh in rt hiu qu i vi
cc loi bi kch c t 0,5 n 8m. Khi cc ht bi c kch c khong 10m
v ln hn th hiu qu gim. Cn lu vn an ton v in th s dng
rt cao v nguy him n tnh mng con ngi.
B lc th
kiu trc quay
Dy ion ha
Ni t
Kh thi sau x
l
Kh thi + bi
Vng ion ha
Vng thu gp
Hnh 6. Lc bi kiu tnh in
Trang 58/61
5.1.2 X l kh c hi trong kh thi

i trong kh thi
phng php thp th v hp ph.
5.1.2.1 Hp th
Thit b hp th c chc nng to ra b mt tip xc cng ln cng tt gia
hai pha kh v lng. C rt nhiu kiu khc nhau ca thit b hp th, nhng
c th phn chia thnh bn loi chnh sau:
-
Bung phun, thp phun: trong cht lng c phun thnh git nh
trong th tch rng ca thit b v cho dng kh i qua.
cht lng. Qu trnh phn tn kh c th thc hin bng cch cho kh i

qua tm xp, tm c l hoc bng cch khuy c hc.
-
Thit b hp th kiu si bt: kh i qua tm c l bn trn c cha lp

nc mng.
Thit b hp th c lp m bng vt liu rng: cht lng c ti trn

lp m rng v chy xung di to b m t ca lp m dng kh
tip xc khi i qua.
Nc l loi cht hp th sn c, r tin v thun thin nht. Tuy nhin, nc

ch hp th c mt s t loi kh c hi, hn na mc hp th vt l ca
nc cng hn ch. Do trong nhiu trng hp ta phi s dng cc loi
dung dch ha cht khc nhau nh: dung dch Na 2CO3, NaOH, Ca(OH)2,
CaCO3,
5.1.2.2 Hp ph
Trong thit b hp ph, vt liu hp ph c thnh lp m c b dy
nht nh v cho dng kh cn x l i q
ng tng t hoc lin tc, c hon nguyn hoc khng hon nguyn
Vt liu hp ph c th c chia thnh 3 nhm chnh:
-
Vt liu khng c cc: hp ph vt l.
Vt liu c cc: hp ph ha hc nhng khng lm thay i cu trc ca

phn t kh.
Vt liu m trn b mt ca chng xy ra qu trnh hp ph ha hc v

qu trnh lm thay i cu trc ca phn t kh.
Vt liu ph bin nht thuc nhm 1 l than hot tnh. Ngoi ra, mt s vt
liu hp ph khc nh silicagel, alumogel
Trang 59/61
5.2 X l nc thi
cc thit b cng ngh trong
thng
luyn
ti s dng
V
r trng hp lm ngui kh thi bng

phng php t, nc thi cn c x l ring bit. C th s dng dn
ma nc lm mt nhanh chng t c nhit gn bng nhit mi
trng
5.3 X l cht thi rn

Cht thi rn pht sinh trong nh my c
ct thi
c chc nng
Trang 60/61
6. Ti liu tham kho

-
GS.TSKH Nguyn Vn Thi, M.TECH Chu c Khi: Bo co tng kt

ti Nghin cu xut m hnh pht trin ngnh c Vit Nam, p ng
yu cu CNH-HH t nc, 2009;
M.Tech. Chu c Khi: Ti liu hng dn p dng K thut tt nht

hin c (BAT) v Kinh nghim mi trng tt nht (BEP) nhm gim pht
thi cc cht nhim hu c kh phn hu trong sn xut thp bng cng
ngh l in h quang (EAF)
Nguyn Hu Dng: Cc phng php c c bit, Nh xut bn Khoa

hc v K thut, 2006;
L Vn Minh: Thit b c, Nh xut bn Khoa hc v K thut, 2006;
S Khoa hc, cng ngh v mi trng thnh ph H Ch Minh: S tay

hng dn x l nhim mi trng trong sn xut tiu th cng nghip
- Tp 5. X l nhim mi trng ngnh nu c kim loi, 1998.
P L Jain Principles of Foundry Technology, Fourth Edition Tata Mc

Graw-Hill, 2006;
Asia invest Technical Assistance Cleaner Production in the Foundry

industry of the People republic of China Text book Part 7, 2005;
Technologies for Sustainable Development European IPPC Bureau Reference Document on Best Available Techniques in the Smitheries and
Foundries Industry 2004;
Cleaner Production Manual for the Queensland Foundry Industry, 1999;
UNEP industrial Sector guide cleaner production asessment in foundries,

1999;
Bundit Funtamasan Energy utilization and cost-saving potentials in an

iron foundry Faculty of Engineering King Mongkuts Institute of
Technology North Bangkok, Thailand;
http://oce.nrcan.gc.ca/cipec/newscentre/foundry/5/5_2.cfm
http://www.custompartnet.com
www.meslab.org: Trang v vt liu, c kh, t ng ha
http://www.airbooster.com/
Trang 61/61

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Ti liu hng dn

C quan bin son

1. Gii thiu chung

1.1 M t ngnh c kim loi

Dy chuyn lm khun t ng DISAMATIC ca Cng ty C kh ng

Mt s my c p lc hin i cng c nhp v s dng, mang li

V quy m cng sut, cc doanh nghip

chia thnh 3 nhm:

Doanh nghip quy m ln (sn lng > 5000

/nm tp trung H Ni,

Doanh nghip quy m nh v va (sn lng 1000 n 4000

Trong 3 nhm trn, cc d

Ngnh c Vit Nam ang

Bng 2. D tnh sn lng vt c ca Vit Nam giai on 2011-2020

c bnh qun (kg/ngi)

nhiu nhin liu,

1.2 Quy trnh c kim loi

khi qut bao gm

Chun b khun, rut, mu (khun ct, khun mu t chy, khun kim

(c lng, bn lng km theo p, c ly tm v.v...);

Hnh 1. S dy chuyn c kim loi

1.2.1 Chun b khun, rut (thao), mu

n chic hoc chi tit phc tp

Khun ct ti: vt liu lm khun l ct st

Khun ct nc thu tinh ng rn bng kh ccbonc: nc thu tinh

ton quc. Khun c nc thu tinh sau khi c nn c ti ch nhm

Khun Furan: ct s c trn vi nha Furan v axit

Lng khun c to nn bi vt liu d chy. Do , vic ly mu ra khi

Vt c c chnh xc cao nh lng khun khng phi lp rp theo mt

nhn b mt m bo do b mt lng khun nhn, khng c hin

Hp kim c c th l loi vt liu kh nng chy, nhit rt cao.

Nhc im ca phng php c khun mu chy l:

c khun mu chy ch ph hp vi vt c l kim loi qu, cn c mc

t c bng v chnh xc cao;

Khng cn h thng rt ln nh i vi khun ct, gim c hao ph kim

Khun truyn nhit km nn vt c khng b bin trng;

Qu trnh d khun, lm sch vt c n gin;

Chu trnh lm khun di, gi thnh khun cao, ch ph hp vi sn xut

Khun mu chy/mu t thiu:

Gi thnh ch to mu r, khng dng n g ch to mu, nng sut

Ch to mu bng phng php rt chn khng, gim nh sc lao ng,

Sn phm c c chnh xc, bng cao, lng d gia cng cc thp.

Trng lng vt c t nh n trung bnh, c th ph hp vi sn xut

Nhc im ca phng php c trong khun mu chy l:

Cn c h thng thu ht khi bi tt trnh khi bi c hi do

Khi cn c cc vt c ln gp kh khn trong khu lm khun (thit b

Khun kim loi

Tc kt tinh ca hp kim nhanh nh kh nng trao i nhit ca hp

bng b mt, chnh xc ca lng khun cao to nn cht lng vt

Tui th khun kim loi cao;

Do tit kim c thi gian lm khun, to nng sut cao, h gi thnh

Mt s nhc im ca phng php c trong khun kim loi l:

Khun kim loi khng c c cc vt c c hnh dng qu phc tp,

Khun kim loi khng c tnh ln v khng c kh nng thot kh. iu ny

Gi thnh ch to khun cao.

Mu c lm t cc vt liu to hnh nh g, thch cao, xi mng,

hi ti s dng nhit tha ca kh thi sy liu, gi nng v c c trang

1.2.3 c kim loi

khun quay, kim loi s phn b ng u trn thnh khun v ng c ti

khun v lm sch th cng.

2. S dng ti nguyn, tc ng n mi trng v

Phn ny m t cc hot ng c tiu th ti nguyn v pht thi ca cc c

Hnh 2. Nguyn liu u vo v pht thi trong qu trnh c kim loi