= - UTF-8 - B - dMOgaSBsaeG7h3UgaMaw4bubbmcgZOG6q24gc G6o24geHXhuqV0IHPhuqFjaCBoxqFuIG5nw6BuaA== - = hoàn tất sản phẩm kim loại

Mc lc
Mc lc ........................................................................................................................... 1 M u ........................................................................................................................... 5 1 Gii thiu chung ...................................................................................................... 6 1.1 Ngnh hon tt sn phm kim loi ca Vit nam............................................. 6 1.2 M t quy trnh sn xut................................................................................... 7 1.2.1 Chun b b mt v lm sch cc chi tit.................................................. 8 1.2.2 M ............................................................................................................. 8 1.2.3 Hon tt c hc....................................................................................... 15 1.2.4 Khu vc ph tr ...................................................................................... 16 1.3 Cc vn mi trng trong hon tt sn phm kim lo i ............................ 17 1.3.1 Cc vn mi trng trong cng on tin x l................................. 18 1.3.2 Cc vn mi trng trong cng on m in .................................. 19 1.3.3 Cc vn mi trng trong ph phi kim............................................... 21 1.3.4 Cc vn mi trng trong hon tt bng sn .................................... 22 2 Sn xut sch hn Nguyn tc, nhu cu v phng php lun ........................ 24 2.1 Gii thiu v Sn xut sch hn (SXSH)....................................................... 24 2.2 Nhu cu v SXSH .......................................................................................... 25 2.2.1 Cc tc ng n sc khe v mi trng............................................. 26 2.2.2 Bo ton ha cht v cc cht tr .......................................................... 26 2.2.3 Kim sot nhim .................................................................................. 27 2.2.4 Sc p cng lun .................................................................................... 27 2.2.5 Cc yu cu ca th trng xut khu .................................................... 28 2.3 Tim nng Sn xut sch hn ....................................................................... 28 2.4 Phng php lun nh gi sn xut sch hn ............................................ 31 2.5 Cc k thut SXSH......................................................................................... 34 3 Cc c hi SXSH trong hon tt sn phm kim loi ............................................. 38 3.1 Qun l tt ni vi............................................................................................. 38 3.1.1 Ni lm vic sch s ngn np............................................................... 38 3.1.2 Bo dng d phng.............................................................................. 39 3.1.3 Kim k qun l kho................................................................................ 39 3.1.4 Phng nga v kim sot hin tng trn ............................................. 39 3.1.5 o to nhn vin ................................................................................... 40 3.1.6 S quy trnh ....................................................................................... 40 3.1.7 Lp k hoch v lch sn xut................................................................. 40 3.2 Lm sch v tin x l ................................................................................... 42 3.2.1 Trnh cc yu t pht sinh nhu cu lm sch......................................... 43 3.2.2 Cc phng php lm sch vt l .......................................................... 43 3.2.3 Ko di tui th dung dch lm sch ....................................................... 44 3.2.4 Thit b lm sch cc chi tit ................................................................... 45 3.2.5 Cht lm sch sinh hc........................................................................... 45 3.2.6 Lm sch siu m ................................................................................... 45 3.2.7 Nhit phn cho sn tnh in .................................................................. 45 3.3 Kim sot thng s b x l........................................................................... 46 3.3.1 Nng ho cht.................................................................................... 46 3.3.2 Nhit b.............................................................................................. 46 3.3.3 Ngn tht thot nhit v bay hi ............................................................. 46 3.3.4 Chng nhim bn dung dch m ............................................................. 47
Ti liu hng dn Sn xut sch hn trong ngnh hon tt sn phm kim loi 1
3.4 Gim lng dung dch dnh theo vt m........................................................ 47 3.4.1 Thi gian nhc chi tit ra khi thng m v treo ro ............................... 48 3.4.2 nh hng sn phm v cc gi treo.................................................... 48 3.4.3 iu chnh sn phm .............................................................................. 49 3.4.4 Tm thu dch v khay hng..................................................................... 49 3.4.5 Cc cht thm t .................................................................................. 50 3.4.6 Dao kh.................................................................................................... 50 3.4.7 Tr li dung dch dnh theo vt m v b m .......................................... 50 3.5 Ci tin cng ngh ra................................................................................... 50 3.5.1 Khuy trn............................................................................................... 50 3.5.2 Ra xt v phun sng ........................................................................... 51 3.5.3 Ra ng v tnh .................................................................................... 52 3.5.4 Ra ngc dng..................................................................................... 52 3.5.5 Kim sot dng nc.............................................................................. 53 3.5.6 Trnh nhu cu ra .................................................................................. 53 3.6 Cc k thut ti s dng nc ra v thu hi kim loi ................................... 53 3.6.1 Thu hi kim loi bng phng php in phn ...................................... 54 3.6.2 3.6.2 Thm thu ngc .......................................................................... 55 3.6.3 Trao i Ion ............................................................................................. 55 3.6.4 in thm tch ........................................................................................ 55 3.7 Cc quy trnh khc ......................................................................................... 55 3.7.1 H thng m khng xyanua .................................................................... 55 3.7.2 Thay th Crm+6 bng Crm+3 trong quy trnh m Crm ..................... 56 3.7.3 Gia tng tui th b m khng in ........................................................ 57 3.8 Cng ngh mi............................................................................................... 57 3.8.1 Ant ha axt Boric/Sulphuric (SBAA).................................................... 57 3.8.2 Cng ngh in thm tch cho dung dch x l...................................... 58 3.8.3 High Velocity Oxy-Fuel (HVOF) Thermal Spray...................................... 58 3.8.4 Qu trnh kt t hi ion (Ion Vapour Deposition (IVD) ............................ 58 3.8.5 Thu hi bng in phn ti ch xyanua kim loi ................................ 59 3.9 Tng lai ca ngnh cng nghip hon tt kim loi ...................................... 61 4 Phng php lun 6 bc nh gi SXSH .......................................................... 62 4.1 Bc 1: Khi ng......................................................................................... 63 4.1.1 Nhim v 1: Thnh lp nhm .................................................................. 63 4.1.2 Nhim v 2: Cc bc quy trnh & nhn din cc dng thi .................. 67 4.2 Bc 2: Phn tch cc cng on.................................................................. 73 4.2.1 Nhim v 3: Chun b s quy trnh .................................................... 73 4.2.2 Nhim v 4: Cn bng vt liu, nng lng v cu t ........................... 74 4.2.3 Nhim v 5: Xc nh tnh cht ca dng thi......................................... 80 4.2.4 Nhim v 6: nh gi cho cc dng thi................................................. 80 4.2.5 Nhim v 7: Xc nh nguyn nhn ........................................................ 83 4.3 Bc 3: Phn tch cc bc quy trnh ........................................................... 88 4.3.1 Nhim v 8: Xy dng cc gii php SXSH ........................................... 88 4.3.2 Nhim v 9: Sng lc cc c hi SXSH.................................................. 90 4.4 Bc 4: La chn cc gii php SXSH ......................................................... 91 4.4.1 Nhim v 10: Tnh kh thi k thut .......................................................... 91 4.4.2 Nhim v 11: Tnh kh thi kinh t............................................................ 92 4.4.3 Nhim v 12: Tnh kh thi mi trng .................................................... 93 4.4.4 Nhim v 13: La chn gii php thc hin ...................................... 94
Ti liu hng dn Sn xut sch hn trong ngnh hon tt sn phm kim loi
4.5 Bc 5: Thc hin cc gii php SXSH ........................................................ 95 4.5.1 Nhim v 14: Chun b thc hin............................................................ 95 4.5.2 Nhim v 15: Trin khai cc gii php .................................................... 96 4.5.3 Nhim v 16: Quan trc v nh gi kt qu.......................................... 96 4.6 Bc 6: Duy tr hot ng SXSH ................................................................... 97 5 Tr ngi trong vic thc hin SXSH v cch khc phc....................................... 98 5.1 Cc ro cn thi ........................................................................................ 98 5.1.1 Bng quan vi cc vn qun l ni vi v mi trng ......................... 99 5.1.2 Khng mun thay i .............................................................................. 99 5.1.3 Cc bin php khc phc cc ro cn thi ........................................ 99 5.2 Cc ro cn mang tnh h thng .................................................................. 100 5.2.1 Thiu cc k nng qun l chuyn nghip ............................................ 100 5.2.2 Cc h s sn xut s si .................................................................... 101 5.2.3 Cc h thng qun l khng y v km hiu qu .......................... 101 5.2.4 Cc bin php khc phc ro cn mang tnh h thng......................... 101 5.3 Cc ro cn t chc ..................................................................................... 103 5.3.1 Tp trung ho quyn ra quyt nh ....................................................... 103 5.3.2 Qu ch trng vo sn xut .................................................................. 103 5.3.3 Khng c s tham gia ca cng nhn .................................................. 103 5.3.4 Cc bin php khc phc cc ro cn mang tnh t chc .................... 104 5.4 Cc ro cn k thut .................................................................................... 105 5.4.1 Nng lc k thut hn ch .................................................................... 105 5.4.2 Tip cn thng tin k thut cn gp hn ch ........................................ 105 5.4.3 Cc hn ch v cng ngh ................................................................... 105 5.4.4 Cc bin php khc phc ro cn k thut ........................................... 106 5.5 Cc ro cn kinh t ...................................................................................... 107 5.5.1 u tin cho khi lng sn xut hn l chi phi ph sn xut................ 107 5.5.2 Nguyn liu th gi r v d kim......................................................... 107 5.5.3 Chnh sch u t hin hnh................................................................ 107 5.5.4 Cc bin php khc phc cc ro cn kinh t ...................................... 108 5.5.5 Trin khai cc gii php c tnh hp dn v ti chnh ........................... 108 5.5.6 Phn b chi ph hp l v u t c k hoch...................................... 108 5.5.7 Cc chnh sch cng nghip lu di ..................................................... 108 5.5.8 Cc khuyn khch v ti chnh .............................................................. 108 5.6 Cc ro cn t pha chnh ph..................................................................... 109 5.6.1 Cc chnh sch cng nghip................................................................. 109 5.6.2 Cc chnh sch mi trng................................................................... 109 5.6.3 Cc bin php khc phc ro cn chnh ph........................................ 109
M u
Sn xut sch hn c bit n nh mt tip cn 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 hon tt sn phm kim loi c bin son trong khun kh hp tc gia Trung tm Sn xut sch Vit nam, thuc Vin Khoa hc v Cng ngh Mi trng, trng i hc Bch khoa H ni v 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. Mc tiu chnh ca ti liu hng dn ny l nhm tng bc hng dn thc hin nh gi SXSH (CPA) cho ngnh cng nghip hon tt sn phm kim loi ti Vit Nam. i tng ca b ti liu hng dn ny l cc lnh o nh my, cc k thut vin v nhn vin ca cc ban ngnh chnh ph v cc t chc chu trch nhim thc y v iu chnh/quy nh cng tc qun l mi trng ti cc nh my trong ngnh ti Vit Nam. Cc cn b bin son dnh n lc cao nht tng hp thng tin lin quan n hin trng sn xut ca Vit nam, cc vn lin quan n sn xut v mi trng cng nh cc thc hnh tt nht c th p dng c trong iu kin Vit nam. Trung tm Sn xut sch Vit nam v Hp phn Sn xut sch hn trong Cng nghip xin chn thnh cm n s ng gp ca ng Rajiv Garg, cn b Hi ng Nng sut quc gia ca n , cc cn b ca Cng ty C phn T vn EPRO v c bit l Chnh ph Thy s, thng qua T chc Pht trin Cng nghip Lin hp quc UNIDO v 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: Trung tm Sn xut sch Vit nam, email: vncp@vncpc.org hoc Vn Phng Hp phn Sn xut sch hn trong cng nghip, email: cpi-cde@vnn.vn.
H Ni, thng 2 nm 2010 Nhm bin son
Gii thiu chung

Chng ny gii thiu tng quan v tnh hnh cc c s hon tt sn phm kim loi Vit Nam v cung cp cho ngi c thng tin khi qut v khuynh hng th trng v tng lai ca ngnh cng nghip ny. T y, ngi c c th hiu cc loi quy trnh khc nhau v nguyn liu th c s dng trong ngnh hon tt sn phm kim loi. Cui cng, ngi c c th c tnh c v cc loi cht thi v nhim pht sinh t ngnh cng nghip ny Vit Nam.
Nu thiu x l hon tt, cc sn phm kim loi s ch tn ti c trong mt phn khong thi gian vng i ca chng. X l hon tt kim loi s tc ng ln b mt ca sn phm nhm tng cng cc c tnh nh chng n mn, chng mi mn, dn in, in tr, h s phn chiu, m quan, dung sai momen xon, tnh d hn, chng xn, chng ha cht, kh nng gn kt vi cao su (lu ha) v mt lot cc tnh cht c bit khc. Nhng ngnh cng nghip c s dng qu trnh x l hon tt sn phm kim loi bao gm: t in t v tr vin thng kim hon thit b cng nghip gia dng trang sc
C nhiu loi vt liu, quy trnh v sn phm c s dng lm sch, khc axit v bao ph cc b mt kim loi v phi kim. Qu trnh c trng nht y l phn kim loi ca sn phm s tri qua mt hoc nhiu quy trnh x l vt l, ha hc v in ha. Cc quy trnh vt l bao gm m, mi, nh bng, phun ct. Cc quy trnh ha hc bao gm ty du m, lm sch, ty axit, khc mi, nh bng v m khng dng in. Cc quy trnh in ha bao gm: m, nh bng in ha v anod ha.
1.1 Ngnh hon tt sn phm kim loi ca Vit nam

Vit Nam, cc qu trnh hon tt sn phm kim loi thng c xem l mt b phn trong dy chuyn sn xut mt sn phm kim loi no . i b phn cc doanh nghip sn xut cc sn phm kim loi thng t t chc cho mnh mt phn xng m hoc sn hon thin sn phm ca mnh. Chnh v vy, cc n v m in hoc sn thng c quy m nh v nm ri rc trong cc ngnh sn xut nh ngnh kim loi v cc sn phm kim loi, ngnh sn xut v sa cha cc phng tin giao thng vn ti, ngnh ch to my mc v thit b. Ngoi ra, Vit Nam cng c mt s xng m kim loi nhng nng, thng nm trong cc nh my sn xut kt cu thp ca ngnh in hoc ngnh sn xut vt liu xy dng (tm lp kim loi).
Ngoi mt s rt t cc cng ty ln sn xut ni tht xut khu hoc doanh nghip lin doanh vi nc ngoi l c dy chuyn sn xut m, sn tnh in t ng ng b, nhn chung, do c im l cc n v nh l, nn trang thit b phn ln thng t ch to, khng ng b, nng sut thp, tiu hao nhiu ha cht v gy ra tc ng tiu cc ti mi trng. Theo s liu thng k ca VDC, Vit Nam c 203 doanh nghip thuc ngnh kim loi v cc sn phm kim loi trn ton quc tri trn din rng ca 26 tnh v thnh ph. Phn ln cc doanh nghip thng tp trung cc thnh ph ln nh H Ni (45 doanh nghip), Hi Phng (24 doanh nghip), Nam nh (13 doanh nghip) v thnh ph H Ch Minh (64 doanh nghip). Ngnh sn xut my mc v thit b c 304 doanh nghip nm ri rc trn 46 tnh v thnh ph, trong ti H Ni c 85 doanh nghip, thnh ph H Ch Minh c 104 doanh nghip v Hi Phng c 11 doanh nghip. Ngnh sn xut v sa cha cc phng tin giao thng vn ti c 279 doanh nghip phn b ti 36 tnh v thnh ph. Cc doanh nghip ngnh ny tp trung ng nht ti H Ni (68 doanh nghip), thnh ph H Ch Minh (66 doanh nghip), Hi Phng (30 doanh nghip), Nng (12 doanh nghip), Qung Ninh (6 doanh nghip), Nam nh, Khnh Ha v Vnh Phc u c 5 doanh nghip.
1.2 M t quy trnh sn xut

C hai dng doanh nghip trong ngnh hon tt sn phm kim loi: (1) cc nh my hon tt sn phm kim loi c lp, thng c bit n vi nh cc xng gia cng hoc cc cng ty hon tt sn phm kim loi c lp (m v sn); v (2) cc n v hon tt kim loi trc thuc l mt b phn sn xut thc hin cc quy trnh hon tt sn phm kim loi trong mt nh my ln. Cc n v hon tt sn phm kim loi trc thuc c th mang tnh c th nhiu hn trong hot ng sn xut ca mnh v cc qu trnh hon tt kim loi y thng mang tnh hiu qu hn v ch x l mt s lng nht cc chi tit khc nhau. Ni cch khc l h bit c hng ngy sn phm ca h cho ra l g v c nhiu s ch ng iu chnh thit b ca mnh sao cho ph hp vi yu cu sn xut hng ngy. Kt qu l khi mt quy trnh vn hnh ti hiu sut ti u th ph thi s t hn. Sn phm ca cc n v hon tt sn phm kim loi c lp thng c tnh c th t hn so vi cc n v trc thuc v h thng c rt nhiu khch hng vi nhng yu cu v c im v cht lng sn phm khc nhau. Yu cu v tnh linh hot trong vn hnh tha mn yu cu ca cc khch hng khc nhau thng lm gii hn cc u tin la chn v cc quy trnh sn xut thn thin mi trng. Mc d hai dng doanh nghip k trn c s khc nhau trong vn hnh sn xut nhng cc cng ngh hon tt cc sn phm kim loi c p dng th cng ging nhau v kt qu l cc loi tc ng ti mi trng gy ra l tng t.
Sn xut hon tt cc sn phm kim loi l qu trnh s dng nhiu nng lng in, nc v cc loi ha cht, trong c cha nhiu kim loi nng. Cc ngun nng lng chnh l nhin liu (than, du, gas) t l hi, in v du diesel cho my pht in. Cc quy trnh v hot ng chnh trong ngnh hon tt sn phm kim loi cng vi cc loi u vo v cc dng thi s c cp mt cch chi tit ti cc phn tip theo.
1.2.1 Chun b b mt v lm sch cc chi tit

Chun b b mt, mc sch b mt cc chi tit v cc iu kin mi trng ha cht l cc yu t thit yu qu trnh hon tt sn phm kim loi c thc hin mt cch m bo. Nu b mt khng c lm sch tt, th cc lp che ph k c loi t tin nht cng khng th bm c hoc khng ngn chn c tc ng n mn ca mi trng bn ngoi. Cc k thut chun b b mt gm t k thut mi, nh bng, phun ct n ty bng axit v cc quy trnh lm sch bng ha cht qua nhiu bc phc hp. Cc c im u vo v u ra ca qu trnh ny gm: Cc nguyn liu u vo: cc dung mi, tc nhn nh ha, kim, v a-xt. Cc pht thi kh: cc dung mi bay hi (ch trong trng hp s dng phng php ty bng dung mi v lm sch nh tng) Nc thi: cc cht thi dung mi, kim v a-xt Cht thi rn/nguy hi: cht thi d chy, cht thi dung mi, kim loi, v cc cn lng.
1.2.2 M
M v c bn l to ra lp che ph v c ln b mt ca chi tit cn m nhm em li cc c tnh mong mun nh chng n mn, to cng, chng mi mn, chng rn nt, dn in hoc nhit, hoc trang tr. Nhng quy trnh m phc tp c bit thng ng dng mi quan h in cc (cc m/cc dng) gia vt cn m v b m. Cc dng m ch yu l: M trng quay loi k thut ny dng m mt lc rt nhiu cc chi tit nh. Cc chi tit ny c o vo b m t cc thng hoc cc thng nhng. M xoa lp dung dch m c ph ln b mt vt cn m bng mt vt thm dung dch m ging nh mt cy chi qut, ng vai tr nh cc dng. Chi tit cn m gi vai tr l cc m v qu trnh c thc hin bng mt dng in trc tip. M khng in tch thc hin n gin ch l nhng vt cn m vo b m. M in l mt quy trnh ph bin nht ti cc nh my hon tt kim loi. Trong mt s k thut m in cc ion kim loi trong mi trng dung dch a-xt, kim, hoc trung tnh c gim xung trn vt cn m. Cc ion kim loi trong dung dch thng c b sung bng s tan r kim loi t cc dng kim loi rn c lm t chnh loi kim loi ang m, hoc c th c b sung trc tip dung dch mui kim loi hoc cc loi -xt. Xyanua, thng dng mui hoc kali xyanua, thng
c dng nh mt hot cht tng hp cho m ct-mi v cc kim loi qu, v vi cp t hn, cho cc dung dch khc nh cc b m ng v km. M c kh l mt qu trnh din ra trong thng lng kim loi ln nhiu cht lm nn s dng c hc ch khng dng nng lng in. M trn r - t cc chi tit ln v tr d m nht tip xc vi dng m. M xung in c s dng ph bin m vng v hp kim vng, nickel, bc, chromium, hp kim tr thic, v palladium. M nhng nng l k thut m chi tit kim loi bng mt kim loi khc to ra lp mng bo v bng cch nhng chi tit cn m vo trong mt bn nng chy. M km (km nhng nng) l mt dng m ph bin trong k thut to b mt nhng nng. o Cc nguyn liu u vo a-xt, cc dung dch kim, dung dch c cha kim loi nng, v cc dung dch c cha xyanua nhim kh kh cha ion kim loi v hi a-xt Nc thi t quy trnh a-xt/ kim, xyanua, v cc cht thi kim loi; Cht thi rn/nguy hi kim loi v cc cht thi phn ng (hot ng mnh)
o o o
Trong cc k thut m k trn th m in l ph bin nht, v th cc phn di y s tp trung m t chi tit v k thut m ny. 1.2.2.1 M in M in l mt qu trnh in phn, mt b mt kim loi s c ph mt lp kim loi khc qua qu trnh in phn. Hot ng m in ch yu ng dng vi cc dng m v c cho cc b mt v mc ch chng g, to cng, chng mn, to c tnh chng rn nt, dn in hoc nhit, hoc trang tr. Cc kim loi v hp kim thng c dng trong m in l ng (ng-km), ct-mi, crm, ng , vng, nickel, bc, thic, v km. (OECA, 1995). Hnh 1 biu din mt quy trnh m in c bn. Bc u tin trong quy trnh thng l bc loi b cc cht bn dnh trn b mt chi tit kim loi (du, m, t v.v...). Nhm v thp, hai loi kim loi phi ph bin nht, s dng hai quy trnh ty bn khc nhau. C th nhng thp vo dung dch soda kim nng, cn nhm th phi c lm sch bng a-xt hoc cht ty epoxi v nhm b n mn trong dung dch kim. Ty loi chi tit cn m c th cn phi nh bng s b trc khi m. Kim loi phi thng c nhng vo mt dung dch a-xt ty nh l bc lm sch cui cng. C th dng rt nhiu loi a-xt nhng: A-xt n: a-xt ni-t-rc 50% ti nhit bnh thng A-xt kp: a-xt sulfuric 15% nhng 2 pht nhit 82C, ra qua, v sau nhng vo dung dch a-xt ni-t-rc 50% A-xt hn hp: a-xt ni-t-rc 75% ha vi a-xt hydrofluoric 25%
Cng c th t vo mt thng ty in s dng dng in ngc chiu loi b -xi v du, m hoc bi bn cn st li. Phi kim loi c th c m trc mt lp ng mng (thm qua ng) y l lp chng n mn rt hiu qu v ng thi cng to ra b mt m tt hn cho lp m nickel sau . Sau chi tit c nhng vo mt bn in phn c cha dung dch nickel sulphate v cc dng nickel, v chi tit m s lm cc m. Nickel s to ra lp o khoc bo v khi n mn v l lp hon tt to sng bng cho chi tit. dy ca lp m ph thuc vo mnh yu ca dng in v thi gian nhng chi tit trong bn. Sau khi c ra bng nc, chi tit s c nhng vo bn a-xt chromic m chrome. Hiu sut dng in khi phn r chrome t dung dch chromic l rt km, v v th m m chrome l mt k thut m tiu th nhiu nng lng.
U VO
Nng lng Kim Axit
Chi tit kim loi
U RA
RA
Dch ra dng Dch ty g dng
TY R
KL/mui KL Cht lm bng Nng lng
M Dch i theo vt m RA X L
Dch m dng Nng lng tht thot
Nc
Nc thi
Thnh phm
Bn thi
Hnh 1. Quy trnh m in vi cc u vo v cht thi 1.2.2.2 A-nt ha A-nt ha l mt qu trnh in phn bin b mt kim loi thnh mt lp ph khng ha tan -xt. M a-nt to ra lp bo v chng n mn, cc b mt trang tr, lm nn sn hoc cho cc quy trnh to lp ph b mt khc, ng thi to ra cc c tnh c kh cng nh in c th. Nhm l vt liu thng c dng nhiu nht trong m a-nt. Cc quy trnh a-nt ha nhm gm: a-nt a-xt chromic, a-nt a-xt sulfuric, v ant boric-sulfuric. Sau khi a-nt ha cc chi tit s c ra k v i qua mt qu trnh bt l nng cao tnh chng n mn ca lp ph b mt. Cc cht ph kn ny thng l: a-xt chromic, nickel acetate, nickel-cobalt acetate, v nc nng.
10 Ti liu hng dn Sn xut sch hn trong ngnh hon tt sn phm kim loi
Nguyn liu u vo A-xt, cht ph b mt Pht thi kh kh cha ion kim loi v hi a-xt Nc thi t quy trnh cht thi a-xt Cht thi rn/nguy hi Cc dung dch dng, bn x l nc thi, v cc mt kim loi.
Cc chi tit nhm
CHT THI
Nc Bn
U VO
Kim
Lm sch
Ra
X l Cht thi
A-xt sulphuric/ chromic
Khc mn ty oxit
Ra
Kim A-xt
A-xt Nitric
Ty g
Ra
A-xt Chromic
A-nt ha
Ra
Nhum mu
Ra Thnh phm
Hnh 2: Quy trnh a-nt ha cng vi cc yu t u vo v pht thi 1.2.2.3 M km nhng nng M km l mt quy trnh to lp ph b mt bng km cho thp c chun b khng s dng k thut in phn. Trong tt c cc k thut to b mt ph bin cho thp th m km l phng php to b mt chng g tt nht. Trong quy trnh m km kim loi c nu thnh hp kim vi cht nn. V th lp km m s khng b trc ra nh khi dng sn to ra lp bo v vnh cu cho cht nn. Bc u tin l bc ra sch trong kim nng loi b cc cht bn bm trn b mt chi tit. Sau cc chi tit c t vo mt b ty (a-xt sulfuric hoc hydrochloric) loi b cc vy sc, g kim loi v cc cht bn bm trn b mt khc. Cc chi tit c ra loi b dung dch ty cn dnh trn sn phm. Sau c th chuyn chi tit sang nhng vo mt dung dch to x, thng c 30% km ammonium chloride vi cc cht to m, c duy tr nhit khong 65oC. Dung dch chuyn ng loi b lp mng -xt hnh thnh trn b mt thp hot ng mnh sau qu trnh lm sch bng a-xt, v ngn chn s -xi ha thm 2 gi trc khi m km.
11
Cc chi tit sau khi c chun b sn sng s c nhng vo dung dch km nng chy, duy tr nhit khong 450oC, to ra nhng lp m hp kim km-st ng nht. Cc quy trnh thay th gm mt b m/xc kt hp trong c mt lp km ammonium chloride nng chy ni trn b mt ca km nng chy, v m km in phn cng c s dng rng ri. Quy trnh m km c bit ch ph hp vi quy m cu trc ln v n gin. Cc l nh trn b mt trang tr s c x km lp y. Cc quy trnh m km ly tm trn chuyn s loi b phn km tha lm cho cht lng b mt m ca cc chi tit nh c ci thin ng k. Cng ging nh hin tng n bn km, mt lng sn phm thi ln thot ra t b km do -xt km hnh thnh rt nhanh chng trn b mt b. Lp -xt ny cn phi c ht b trc khi nhc vt phm m ra khi b nhm trnh hin tng xn mu v bm cn tro trn b mt m. y l mt kh khn i vi cc chi tit cn phi nhc ra khi b m mt cch t t v lp -xt kp hnh thnh trong khi nhc v bm vo b mt thnh phm. Nu khng c cnh bo an ton y th hot ng m km c th dn n cc ri ro. Khi nhng cc chi tit vo trong b km 450oC, km s phn ng d di v n bn rt nhiu ra ngoi. Khng kh trong cc l hng nng ln cc k nhanh v c th to ra p sut ln. Nu khng c cc l thng thot kh th chi tit c th b n tan. ng thi Km cng c th lp kn cc u cui ca ng v khi p sut trong ng tng ln th s km bt u c th b bn bt ra ging nh mt khu ca-nng. Nu khng c cc thit b che chn m bo th qu trnh m ny s b tht thot mt lng km rt ln v c th gy nguy him cho ngi cng nhn. Nu cc cng nhn vn hnh phi s tn khi khu vc thc hin quy trnh trong khi nhng c th lm nh hng ln ti nng sut.
Chi tit thp
Kim
Ty du m
bi, cht thi rn

X l A-xt khc dng Cht thi
Nc
Ra
H2SO4/ HCL
Khc n mn Xc s b
Bn
Km 450 C Nng lng
Nhng vo km nng chy
Km bn Nng lng lng ph
Thnh phm
Hnh 3: Quy trnh m km cng vi cc u vo v pht thi
12
1.2.2.4 Sn tnh in Sn tnh in l vic ph mt lp cht do ln b mt cc chi tit cn che ph. C 2 loi cht do ph bin l nha nhit do v nha nhit rn. Cc loi nha nhit do l cc cht hnh thnh mt lp ph m khng cn phi tri qua qu trnh bin i cu trc phn t (nh polyetylen, polypropylene, nylon, polyvinylclorua, v nha nhit do polyeste). Cc loi nha nhit rn xp cho qua nhau to ra mt lp mng vnh cu chu nhit v s khng b tan chy li (epoxy, hybrit, uretan polyeste, acrylic, polyester triglycidyl isoxyanuric (TGIC)). Cc vt liu thch hp sn tnh in l thp, nhm, thp m km, magie, nhm, km v ng thau. Sn tnh in c s dng v mc ch thng mi i vi rt nhiu sn phm kim loi t c nh n c trung bnh, bao gm nhng b g n chiu sng, v thit b, cc thit b ngoi tri, cc k gi, v khung ca s, ... Lp ph c to ra bng cch phun bt c tch in nh phng php tnh in ln b mt ca ca chi tit, v em nung nng, khi bt ph s chy v to thnh lp b mt c lin kt tt. Sn tnh in thng c p dng khi sn 1 lp. Sn tnh in ang ngy cng ph bin v y l mt cng ngh to lp ph b mt to ra pht thi t hn so vi cc cng ngh khc. Xu hng ny xut pht t nguyn nhn chi ph tng ln v thi gian sn xut ko di ca cc cng ngh khc, cng vi cc quy nh lut php v vn mi trng ngy cng kht khe. u th chnh ca phng php sn tnh in l khng dng cc hp cht hu c d bay hi (VOC) v v th m khng cn n cc thit b phn hy VOC tn km nh l thiu hoc cc thit b hp th carbon. Hiu qu ca cc h thng phun bt cao hn nhiu so vi phun dung mi hoc nc. Sau khi phun, lng bt khng bm vo chi tit c th c thu hi v ti s dng. So vi cc k thut phun t, phun tnh in t c bao ph ln hn v bt c th ph ln tt c cc gc cnh v b mt ca chi tit khng trc din vi sng phun. Trc khi phun bt, b mt chi tit cn phi c lm sch, sy kh, v ci thin cht lng b mt. Vic ci thin cht lng b mt c th c thc hin bng cch ra hay sc a-xt. Cc phng php gia cng c bit trc khi sn gm lm sch bng dung mi chuyn dng, bng cc cht mi mn, hay bng ha cht pha long. Vic lm sch b mt c ngha quan trng i vi cng ngh sn tnh in hn nhiu so vi m in v trong quy trnh sn s khng c thm mt bc lm sch no. C rt nhiu loi nha nhit do c dng cho k thut sn tnh in nh polyetylen, polypropylen, nylon, PVC v nha nhit do polyeste. Cc loi nha nhit do ny ch yu c s dng lm cc lp ph bo v v thc hin chc nng nht nh ch khng phi l thay th cho cc sn dung mi. Cc loi nha nhit rn s c nghin thnh bt mn v c to thnh cc mng mng, do b mt ph gn tng t nh sn nc. C 5 h nha nhit rn ch yu l: epoxy, hybrit, uretan polyeste, acrylic, v tri-glycidyl iso-cyanuric (TGIC) polyeste. Cc nguyn liu dng trong sn tnh in c gi cao hn kh nhiu so vi cc nguyn liu sn truyn thng khc cho cng mt th tch. Tuy nhin, c nhiu trng hp chi ph sn xut ra thnh phm li thp hn, c bit l khi cn phi to lp ph dy, v c th b li cho khon chi ph nguyn liu bt cao (EnviroSense, 1994).
Nhng hn ch ln nht khi p dng k thut sn tnh in l cn phi lm nng vt cn sn nhit cao (260oC) lm nng chy bt, v th n ch p dng c cho nhng vt phm bng kim loi, kch c ca chi tit cng cn phi ph hp cho vo trong l v mu sc cc m phi ng nht cng nh phi ph hp mu vi cc loi sn thng dng khc (EnviroSense, 1994).
U VO
Cht kim/a-xt lm sch
Chi tit kim loi
CHT THI
Dung dch ra dng
Lm sch
A-xt
Ci thin cht lng b mt Gia nhit nn
A-xt dng
Nng lng
Nng lng hao ph
Bt nha
Phun sn tnh in
Bt phun tha
ng rn
Thnh phm
Hnh 4: Quy trnh sn tnh in
1.2.2.5 Ph phi kim Crmat ho c dng vi nhiu loi kim loi khc nhau thng qua phng php x l ha cht hoc in ha. Cc dung dch, thng cha crm ha tr 6 v cc hp cht khc, phn ng vi b mt kim loi to mt lp c cha mt hn hp phc tp gm cc hp cht ca crm, cc thnh phn khc v kim loi nn. Pht pht ho c th c to ra bng cch nhng thp, st hoc thp m km vo dung dch mui pht pht long hay a-xt pht pht v cc cht xc tc khc to mi trng b mt cho cng on ch bin tip theo. Nhum mu kim loi bng cch dng ha cht bin b mt kim loi thnh hp cht -xt hoc hp cht kim loi tng t to ra b mt hon tt trang tr nh mu xanh trn ng.
14
Th ng ha l mt quy trnh to lp mng bo v trn kim loi bng cch nhng vo mt dung dch a-xt, thng l a-xt nitric hoc a-xt nitric ln natri icromat. Cc c im ca quy trnh ny bao gm: Nguyn liu u vo: kim loi v a-xt Kh thi: kh mang ion kim loi v hi a-xt Nc thi: cc mui kim loi, a-xt, v cc cht thi t kim loi phi Cht thi rn/nguy hi: dung dch dng ht, bn x l nc thi, v kim loi phi
1.2.3 Hon tt c hc
Hon tt bng phng php thi (blast finishing) gip to ra cc b mt hon tt m hay bng, th hay mn, v li hay loi b nhng yu t khng hon ho khc. Hon tt khi (mass finishing) l mt quy trnh m trong b mt chi tit c hon tt hoc chun b cho cc hot ng khc bng cch khuy mt s lng ln cc chi tit trong hn hp gm cc cht trung gian nh g, nc, v cc hp cht hon tt b mt. nh bng (polishing) l mt hot ng mi mn loi b hoc lm nhn cc li b mt (xc, r, hay du vt khi gia cng) c nh hng xu n ngoi quan hoc chc nng ca sn phm. Cc c im bao gm: Nguyn liu u vo: cc cht trung gian nh bng Kh thi: rt t Nc thi: nc c cha cn nh bng, kim loi v hp cht hon tt b mt Cht thi rn/ nguy hi: kim loi b mt b bong ra, cht nh bng trung gian.
Sn v to lp ph b mt Sn phun l mt quy trnh trong sn c ng trong mt khoang cha b nn v c phun thnh cc tia qua mt vi phun. Trong c 2 phng php ny th nguyn liu lp ph u c phun ln mt v sau ng rn. Cc dy chuyn to lp ph b mt hin i nht c dng c nguyn liu bt v cht lng c th ng rn bng tia cc tm. Lp ph bng nguyn l ngng hi vt l (Physical vapor deposition-PVD) l cc lp ph c bit mng ch khong 2 n 5 micromet. PVD gm mt s qu trnh ngng kt trong cc nguyn t b tch bng phng php vt l t ngun v bm ln sn phm. Nhit nng v phng php bn ph ion chuyn ha cht ph thnh dng hi. Cc c im ca quy trnh ny bao gm:
15
Nguyn liu u vo: cc dung mi v cht ph Kh thi: cc hp cht hu c d bay hi (VOC) v cc cht nhim khng kh nguy hi (HAP) Nc thi: nc cha nhiu dung mi, nc ra Cht thi rn/nguy hi: cc cht cn, x, dung mi sn, sn tha hoc ht hn s dng.
Khc axit Khc to ra cc mu thit k c th hoc hnh thc b mt ca sn phm bng cch ha tan c kim sot s dng cc ha cht phn ng hay cht khc axit. Nguyn liu u vo: axit, cht khc axit, ho cht phn ng. Kh thi: VOCs Cht thi rn/ nguy hi: bn, axit v ho cht phn ng qua s dng.
1.2.4 Khu vc ph tr
Khu vc ph tr bao gm cp nc, cp in, h thng kh nn, v ni hi cng mng phn phi hi nc. Ngnh x l hon tt kim loi s dng rt nhiu nc, c bit ti cc bc ra. Vic cp nc hin c m bo bng cch ly nc t mng cp nc a phng hoc bng cc ging khoan ca cc cng ty. Cht lng nc c bit c tc ng quan trng ti cht lng lp ph v mt nn c phi c x l trc khi s dng vo sn xut. Kh nn c dng cho cc khu xt phun trong qu trnh x l hon tt. Cc my nn thng l yu t gp phn lm gim hiu qu s dng nng lng. H thng l hi v mng phn phi hi trong cc nh my hon tt kim loi cng cn c cn nhc khi nh gi tn hao nng lng. Khi thi t ni hi c thi ra thng qua mt qut gi y vo ng khi. H thng kim sot khi thi nh cyclon a bc, ti lc, v ESP c th c s dng kim sot pht thi ht l lng. Mt s nh my c cc b pht in dng diesel m bo cc yu cu v in nng, phng trng hp mt in t li in quc gia.
16
1.3 Cc vn mi trng trong hon tt sn phm kim loi

Ngnh hon tt kim loi gy ra rt nhiu vn mi trng nh cc cht nhim trong nc thi v kh thi cng nh cc cht c hi trong bn thi. Kt qu l ngnh ny lin tc phi i mt vi ngy cng nhiu cc quy nh lut php v gii hn mi trng. Vn ni cm nht l nc thi, sau l kh thi v cht thi rn. Bng 1 s tng kt li cc dng cht thi ca ngnh hon tt kim loi. Bng 1: Cc dng cht thi trong ngnh hon tt sn phm kim loi Cc nguy c tim tng n mn n mn
Cht thi Kim (hydroxide) Axt (Nit, Lu hunh, axit clohydric, axit flohydric) Cc cht hot ng b mt Du v m Caimi, km, Niken, ng, v cc kim loi khc
Dng thi Nc thi Nc thi
Cng on Lm sch, khc axit Lm sch, khc axit, ngm ty, nhng lm sng Lm sch Lm sch M
c i vi thu sinh c i vi thu sinh c
Nc thi Nc thi, dung mi thi B m, dung dch bm theo ra, nc ra, cc mng lc thi, bn Dung mi thi, (lng hoc bn), kh thi B m, dung dch bm theo ra, nc ra, bn, nc thi khc B m, dung dch bm theo ra, nc ra, bn, nc thi khc v kh m Nc ra, nc bm theo ra, b x l, kh thi (bay hi), nc lm mt, x y l hi
Percloroetylen, Tricloroetylen, cc dung mi khc Xyanua
Bnh h hp v da c
Lm sch
M, lm sch bng tang quay, bc lp m, x l nhit, ty g M, crm ho, khc axit
Cromat
Nc
rt nhiu quy trnh
17
1.3.1 Cc vn mi trng trong cng on tin x l

Cc dung mi, a-xt, v dung dch kim c s dng trong cc cng on tin x l thng dn n cc pht thi kh, nc thi hoc cht thi c hi. Cc ha cht ny c th gy ra cc tc ng mi trng nghim trng nu khng c x l thch hp. Nc thi: nc thi t qu trnh tin x l ch yu l nc thi b nhim t cc b ra v nc v sinh cho quy trnh. Loi nhim cn ph thuc vo ngun gc. Hu ht nhng dung dch m t cc b ty g v t cng on ra kim loi u c tnh a-xt v cha cc dung dch a-xt sulfuric, nitric v clohydric. Nc thi kim t thit b lm sch bng kim v nc ra c cha x phng, cc loi du v cht rn l lng. Dung dch lm sch kim tnh c cha natrihydroxit, cc loi mui pht-pht, silicat, carbonat, mt s cht nh tng hu c v cc cht thm t tng hp. Cc hp cht hu c thi: Thng thng quy trnh sn hon tt l ngun chnh pht thi cc hp cht hu c bay hi (VOC). Khong 40% pht thi dung mi ca cc hot ng cng nghip l t quy trnh ny. trong s bt ngun t ngnh cng nghip sn xut -t. Cc cng ty s dng tricloetylen hoc cc loi dung mi cha clo khc gy ra nhim khng kh nghim trng v 75-90% cc dung mi l bay hi. Tuy nhin, c th s dng cc loi thit b lc than c bit gi li cc dung dch ny. Nn thay th cht ty dung mi cha clo bng cc k thut ty khc chng hn nh ty kim. Pht thi VOC dn n hin tng to ozone v gy khi m ti tng i lu. Qu trnh ny rt c hi cho sc khe con ngi v lm gim sn lng ma mng t 10 15%. Tc ng mi trng ch yu t cc quy trnh tin x l c lit k trong Bng 2. Bng 2: Cc vn mi trng t nhng hot ng tin x l Quy trnh X l c hc Tiu hao / Cht thi Tiu hao nng lng Cc phn t kim loi nng v bi ca mi cht nh bng Cc vn mi trng Cn kit ti nguyn v nhim khng kh. c bit l gp phn gy ra hin tng m ln ton cu. Mi trng lm vic khng bo m v nhim ting n. Cc hp cht hu c bay hi t cc dung mi l rt c hi v gy ra hin tng khi quang ho lm kch ng ng h hp v dn ti cc bnh v phi. Mt s dung mi cha clo l nhng cht ph hy tng ozon, v cn c loi b theo Ngh nh th Montreal
Ty du m bng dung mi
Cc hp cht hu c bay hi Cht thi nguy hi
18
Quy trnh Ty du m bng kim
Tiu hao / Cht thi Hi v nc thi t cc b x l kim c cha du, ion kim loi v cc ha cht khc Tiu hao nng lng
Cc vn mi trng C nguy c gy nhim c cho thy sinh nu nh nc thi ny thot ra mi trng
Ty du m bng phng php in phn
Sn kh v cc dch x l s Sn kh c th nh hng xu ti dng c cha du, ion kim loi mi trng lm vic. Cc dch x l v cc ha cht dng c th gy nhim c cho thy sinh Cn kin ti nguyn, nhim Tiu th in khng kh v gp phn vo hin tng m ln ton cu Hi axit Nguy c ph hng cc cng trnh nh xng
Ty r bng axit
Cc dch x l bng a-xt s Nguy c nhim c cho thy sinh dng cn cha du, ion kim nu x nc thi ny ra mi trng loi, ha cht M lt Tiu th nng lng v nc Tiu th nng lng dn n suy thi ra c cha ion kim loi, cc gim ti nguyn khng ti sinh ha cht (nh du m), pht thi kh v hin tng m ln ton cu Nc thi: nh trn Tiu hao nc Tiu th nc c th dn n cn kit ngun nc sch trong khu vc Nc thi c cha du, ion kim Nc thi c kh nng gy nhim c cho thy sinh loi v ha cht t b trc
Ra
Nm 1995 tng lng pht thi VOC hng nm ca Lin minh Chu u c tnh mc 8 triu tn trong 8% bt ngun t cc hot ng sn cng nghip. cc nc cng nghip pht trin th t l ny cng c d on mc tng t.
1.3.2 Cc vn mi trng trong cng on m in

Cc cht thi ca cng on m in ch yu l cc dung dch c cha kim loi. Cc loi kim loi v hp kim thng c m in l ng thau (ng-km), caimi, crm, ng, vng, nickel, bc, thic v km. Tnh cht v nhim ca cc cht thi trong m in rt khc nhau v ty thuc vo cc yu cu m, phng php ra v s lng cng on tin x l thc hin ti nh my. Kh thi: cc hot ng m lm pht sinh pht thi v sn kh. Cc sn kh thot ra t cc dung dch m in v cc kh trong quy trnh l ngun pht thi kh v c th cha cc kim loi nng hoc cc cht khc c trong b m. Cc sn kh v hi dung dch nh hng xu n mi trng lm vic ti khu vc sn xut.
19
Tiu th nc: Cc quy trnh m in tiu th nc rt khc nhau ty thuc vo din tch b mt c m. Mc tiu th nc ti cng on m in trong thc hnh tt c th t mc 10-20 lt/m2 b mt . Bng 3: Tnh hnh tiu th nc tnh theo din tch b mt m Loi m in M km quay M km treo M nicken quay M nicken treo M crm cng M thic quay Lng nc tiu th/m2 10 - 210 l/m2 10 - 600 l/m2 20 - 50 l/m2 40 - 50 l/m2 20 l/m2 50 l/m2
Nc thi: Nc thi t cng on m in ch yu l nc ra v cht nhim bao gm cc ion kim loi, i khi l xyanua ty thuc vo thnh phn ca b m. Nc thi thng c x l ti ch bng phng php kt ta hydroxit truyn thng. Nc thi c cha Cr6+ phi c x l s b kh Cr6+ thnh Cr3+. Nc thi c cha xyanua phi c -xy ho ring. Vic x l nc thi s to ra bn. Hm lng kim loi nng trong nc thi nh m gim xung v chuyn thnh pha c c gm cc hydroxit kim loi. Bn sau khi to ra cn phi c lm lng. Xyanua: Xyanua, ch yu l natri hoc kali xyanua, thng c dng lm tc nhn to phc cho m ct-mi v, cc kim loi qu, v dng cho cc dung dch khc nh dung dch m ng v km. Cc mui xyanua thng c a dng v chng l cc dung mi tt, v trong m km th n cho ra sn phm sng hn v t r hn. Xyanua rt c hi i vi c, cc loi thu sinh khc, cng nh con ngi. Ch cn trong nc c nhim mt lng nh xyanua l rt nguy him v cn phi trnh. Cc loi cht thi khc: Cc cht thi khc pht sinh t m in gm cc dung dch qua s dng b nhim bn trong qu trnh s dng v v th lm gim bt hiu sut x l. Cc dung dch qua s dng c th c x b nh k. Bng 4 trnh by cc vn mi trng t cc bc x l trong cng on m in.
20
Bng 4: Cc vn cn quan tm trong qu trnh m in Quy trnh M Nickel Tiu hao/cht thi Tiu hao nng lng Cc vn mi trng Tiu hao nng lng c th dn n suy gim cc ngun ti nguyn khng ti to (vd: du m) v pht thi kh, c bit l gp phn gy ra hin tng nng ln ton cu v pht thi carbon dioxide (CO2) Nu thi cc dung dch s dng ra mi trng th n c th gy ra cc tc ng c hi cho thy sinh. Ngoi ra cn c nguy c gy nhim t Cc kh thi v sn kh khin cho mi trng lm vic tr ln c hi Nh trn Nguy c ph hu nh xng
S dng cc b dung dch c cha cc ion kim loi v ho cht
t pht thi kh v sn kh
M km axt
Tiu th nng lng Hi axt
Cc dung dch a-xt qua s Nh trn dng c cha cc ion kim loi v ho cht Ra Tiu hao nc Tiu hao nc c th dn n cn kit ngun nc sch trong vng
Nc thi c cha ion kim loi Nc thi c th gy tc ng v cc ho cht t b trc c hi ti mi trng thy sinh do n c cha kim loi nng
1.3.3 Cc vn mi trng trong ph phi kim

Cc vn mi trng trong ph phi kim cng tng t nh trong cc quy trnh m in. Trong crmt ha mu vng, c crm ho tr 6 v ho tr 3 u xut hin trong nc thi t cc b ra. V crm ho tr 6 rt c nn cn phi trnh s dng loi ny v nn ch dng crm mu xanh c cha duy nht crm ho tr 3.
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Bng 5: Cc vn mi trng cn quan tm trong qu trnh ph phi kim Quy trnh Pht pht ho Tiu hao/cht thi Tiu hao nng lng Cc vn mi trng Tiu hao nng lng c th dn n cn kit cc ngun ti nguyn khng ti to (v d: du m) v pht thi kh, c bit l gp phn gy ra hin tng m ln ton cu. Cc dung dch s dng nu x mi trng th s gy ra cc tc ng c hi cho thy sinh. Ngoi ra cn c nguy c gy nhim t. Cc pht thi kh v sn kh c th khin cho mi trng lm vic tr ln c hi Nh trn Nc thi c cha crm ho tr 6 rt c hi Nh trn Tiu hao nc c th dn n cn kit ngun nc sch trong vng
Cc b dung dch s dng c cha cc ion kim loi v ho cht
Lng nh pht thi kh v sn kh Crm-mt ho Tiu hao nng lng Cc b dung dch a-xt s dng c cha cc ion kim loi v ho cht Lng nh pht thi kh v sn kh Ra Tiu hao nc
Nc thi c cha ion kim loi Nc thi c th gy tc ng v cc ho cht t b trc c hi ti mi trng nc do n c cha kim loi nng
1.3.4 Cc vn mi trng trong hon tt bng sn

Cc vn mi trng lin quan ti hon tt s dng sn rt phc tp v cc phn tch thc hin SXSH cn phi cn c vo ci nhn tng qut. Bng 6 trnh by cc quy trnh c chn v nu ra cc ngun gy nhim tng cng on. Mt s vn mi trng lin quan n cng on hon tt s dng sn l: Pht thi cha cc ht l lng; Cc dung mi thi (cc hp cht hu c d bay hi) Mi Ti lng thy lc, nc thi; v Pht sinh cht thi c v nguy hi.
22
Bng 6: Cc vn mi trng cn quan tm trong qu trnh sn Quy trnh To lp sn lt Tiu hao/cht thi Cc cht mu c hi Cht thi rn, bung phun Cht thi lng, cn sn Cc vn mi trng c hi vi con ngi v mi trng C th gy ra mi ti bi rc Tc ng v mt m quan ti nc thi, v c nguy c gy c Cc hp cht hu c bay hi l cc cht c v to ra khi m quang ha gy kch ng ng h hp v gy ra cc bnh v phi C th gy ra cc bnh v phi Gy kh chu cho ngi dn khu vc xung quanh
Dung mi thi
Cc ht l lng trong kh thi Mi
Cc cht nhim siu nh Sc khe an ton lao ng (cht mu l lng trong khng khng c m bo kh) ng rn nhit Dung mi thi Cc ht l lng trong kh thi Mi Cc cht nhim siu nh Tiu hao nng lng Nh trn Nh trn Nh trn Nh trn Tiu hao nng lng c th dn n cn kit cc ngun ti nguyn khng ti sinh (v d: du m), kh thi v hin tng m ln ton cu Ging nh quy trnh to lp sn lt
Sn lp ngoi
Ging nh quy trnh to lp sn lt
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Sn xut sch hn Nguyn tc, nhu cu v phng php lun

Chng ny gii thiu cc nguyn tc v SXSH, cc yu cu ca tip cn ny v tim nng thc hin i vi ngnh hon tt sn phm kim loi Vit Nam. Chng ny s gii thiu tng quan phng php lun v SXSH v cc bc khc nhau trong phng php lun ny. Ngi c cng s c gii thiu nhiu k thut khc nhau xc nh cc la chn SXSH trong sn xut hon tt sn phm kim loi. Chi tit hng dn s dng phng php lun ny v cch tip cn tng bc s c cung cp c th hn trong Chng 4.
2.1 Gii thiu v Sn xut sch hn (SXSH)

Qu trnh cng nghip ha nhanh v rng l mt trong nhng yu t ng gp quan trng vo s pht trin ca nn kinh t Vit Nam. Tuy nhin, i km vi s bng n tng trng cng nghip thng l cc vn v mi trng. Mt trong cc cch thc tip cn gii quyt vn ny l phng php tip cn cui ng ng (EOP), tc l x l pht thi/cht thi ch sau khi chng pht sinh. V thc tin, iu ny ng ngha vi xy dng v vn hnh cc c s x l nc thi, cc thit b km sot nhim khng kh v cc bi chn lp an ton - y l nhng cng vic rt tn km. Xt n quy trnh cng nghip cn phi hiu rng bt c quy trnh hoc hot ng no cng khng bao gi t c hiu sut 100%. Lun c tn hao no vo mi trng v khng th chuyn thnh dng sn phm hu ch. Tn hao ny l s lng ph hay s nhim lun gn lin vi sn xut cng nghip. Yu t ny thng c nhc n nh c hi b mt i trong qu trnh sn xut. T l pht sinh cht thi thng rt cao v c mt thc t l rt t nh sn xut cng nghip nhn ra iu ny. Hin nay tip cn x l cui ng ng vn ang c p dng ph bin trong cc c s cng nghip, nhng kh nng tip nhn nhim ca mi trng ang gn nh cn kit v cc n v sn xut cng nghip dn nhn thc c s cn thit phi xem xt li cc cng on sn xut ca mnh. iu ny dn n s xut hin khi nim v mt tip cn mang tnh ch ng gim cht thi ti ngun trong qun l cht thi. Tip cn ch ng ny c gi l Sn xut sch hn (SXSH). SXSH c nh ngha l s p dng lin tc chin lc mi trng tng hp mang tnh phng nga trong cc quy trnh, sn phm, v dch v nhm nng cao hiu sut v gim thiu ri ro cho con ngi v mi trng. Vi cc quy trnh sn xut, SXSH bao gm vic bo tn cc nguyn liu th v nng lng, loi b cc nguyn liu th c hi, v gim lng v c tnh ca tt c cc dng cht thi; Vi cc sn phm, SXSH bao gm vic gim thiu cc tc ng tiu cc trong vng i sn phm, t khi khai thc nguyn liu th cho ti khi thi b cui cng; v Vi cc dch v, SXSH l s tch hp cc mi quan tm v mi trng trong qu trnh thit k v cung ng dch v.
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S khc bit cn bn gia EOP hay cn gi l kim sot nhim v SXSH l vn thi im hnh ng. Kim sot nhim l phng php tip cn sau khi vn pht sinh, phn ng v x l; trong khi , SXSH li mang tnh ch ng, theo "trit l d on v phng nga". Phng nga, c tha nhn rng ri, lun lun tt hn x l, ging nh cu ni phng bnh hn cha bnh. Khi gim thiu cht thi v nhim thng qua SXSH th ng thi s gim tiu th nguyn liu v nng lng. SXSH l c gng a hiu sut s dng u vo ti st 100% trong gii hn v kh thi kinh t. Mt im quan trng cn nhn mnh rng, SXSH khng ch n thun l thay i thit b m SXSH cp ti thay i thi quan im, p dng cc b quyt v ci tin quy trnh sn xut cng nh ci tin sn phm. Cc khi nhim khc tng t nh SXSH l: Gim thiu cht thi; Phng nga nhim; v Nng sut xanh.
Nhng khi nim ny v cn bn l tng t nh SXSH, vi tng nn tng l lm cho cc cng ty tr ln hiu qu hn v t nhim hn.
2.2 Nhu cu v SXSH

Cc nguyn liu c s dng trong cng ngh hon tt kim loi v cc loi cht thi nu khng c qun l tt u tim n kh nng gy nguy hi cho sc khe con ngi v mi trng. iu ny c bit ng i vi cc quy trnh to lp ph b mt v m in. Cc quan ngi v vn an ton v sc khe, tc ng ti mi trng, chi ph x l cht thi, cc yu cu v tun th quy nh lut php v mi trng, trch nhim php l tim n v vn tiu th nng lng v nc l mt s trong rt nhiu l do v sao cn phi nghin cu cc cng ngh hon tt kim loi mi hn v t nhim hn. Gn y, SXSH ni ln nh mt gi hp dn i ph vi cc vn mi trng pht sinh t s cng nghip ha nhanh chng v tip cn ny ang c chp nhn ngy cng rng ri trn khp th gii. Ngoi vic gim thiu nhim, SXSH cn nng cao hiu sut ca qu trnh sn xut, t gim chi ph sn xut. Ngnh hon tt kim loi c c im l tiu th ti nguyn nh nc, nhin liu, v ha cht mc cao, ng thi cng l ngnh c hiu sut thp dn ti s lng ph ti nguyn rt ln. Trong bi cnh , SXSH chnh l mt tip cn c bit ph hp cho ngnh. Do xut hin nhng thch thc ln t qu trnh ton cu ha thng mi v t do ha nhp khu, s cnh tranh trong ngnh hon tt kim loi ang tr ln cng thng hn tng ngy. Hin nay, s tng trng v tn ti ca nhiu doanh nghip ngnh ny ph thuc kh nhiu vo vn h c th vn hnh sn xut mc chi ph thp nht c th hay khng. Do chi ph ha cht v nng lng chim n hn 75% tng chi ph sn xut trong ngnh nn vic gim thiu tiu th hai loi ti nguyn ny mang tnh quyt nh. Bn cnh , nu lm c vic ny th yu cu xy dng cc trm x l tn km v phc tp c th p ng c cc tiu chun ca lut php cng s c gim i do gim c lng cht thi pht sinh.
Ngoi cc im chnh nu trn, SXSH cn gip tm ra cc gii php hiu qu cho cc kha cnh khc lin quan ti hot ng ca doanh nghip nh c phn tch di y:
2.2.1 Cc tc ng n sc khe v mi trng

Nhiu quy trnh hon tt kim loi lm pht sinh cc cht nhim c hoc nguy hi trc tip tc ng ti ngi cng nhn hoc ti mi trng khng kh, t v nc. Vic thi b cc cht thi ca cc quy trnh hon tt kim loi m khng qua x l hoc ch x l mt phn s c th gy hng thit b x l cht thi tp trung v nh vy cht thi khng c x l s thot ra v gy nhim tng nc mt. S tiu th nng lng v nc trong hon tt kim loi cng l l do dn n nhng tc ng mi trng. Chun b b mt v lm sch cc chi tit: Cc cht lm sch gc dung mi c cha VOC v cc cht nhim khng kh nguy hi (HAP) cn kim sot do chng c tc ng xu ti sc khe v mi trng. Bi t qu trnh thi v lm sch bng c kh c th gy ra cc vn v ng h hp. M: Cc kim loi nng v xyanua l nhng cht c bit nguy him v l nhng cht thi ph bin trong ngnh m. Crm v m crm cng c th to ra lp m b mt c c tnh chng n mn tuyt vi, nhng cromat li l cht gy ung th cho ngi c khng nh v crm ha tr 6 l cht gy ung th phi tim tng. Cc m mm b nhim ch c th gy tn thng cho gan, thn, no, v c, cn tr em th c bit nhy cm khi tip xc vi ch (cc hp kim cha ch c sinh ra t cc ant ch cng nh cc hp kim cha ch s dng trong m). Caimi c th gy hi cho thn v phi, thm ch l ung th. Cc kim loi khc dng trong ngnh m gm nickel, km, bc, v ng cng vi cc hp cht ca chng l nhng cht c nguy c gy hi cho mi trng v sc khe. Xyanua, s dng trong cc b m, l mt cht c hot ng cc nhanh gy cn tr qu trnh hp th -xy ca cc t bo. S phn hy xyanua thnh cc dng phc cng s gy hi cho i sng thy sinh. A-nt ha, Khc a-xt, v ph phi kim: Ty thuc vo cc ha cht c dng trong cc quy trnh ny, cc cht hot tnh mnh, cc a-xt cha kim loi, cc hp cht cha pht-pht v crm l nhng cht nguy hi cn c kim sot. Nh ni trn, Cr+6 trong qu trnh a-nt ha crm l mt cht gy ung th phi tim tng. To lp ph b mt: Sn dung mi v cc loi cht ph dng lng cng nh cc cht lm sch v pha long bng dung mi, cc bn cn v cc cht lng, u c cha VOC v HAP c hi.
2.2.2 Bo ton ha cht v cc cht tr

Ngnh hon tt sn phm kim loi s dng rt nhiu loi ha cht v cht tr vi khi lng ln. Lng ha cht s dng ph thuc vo thnh phm, loi quy trnh v yu cu v cht lng b mt hon tt. Hin khng c bt c ch s r rng no v lng ha cht ti u, bi iu ny ph thuc vo c tnh sn phm m cc khch hng khc nhau yu cu. Nhng nhn chung c th tit kim c ha cht trc tip hoc gin tip thng qua thu hi v ti ch.
2.2.3 Kim sot nhim

Bn cnh vic tiu th nng lng v nc ln, ngnh hon tt kim loi cn s dng rt nhiu loi ha cht nh a-xt, cc dung mi hu c cha kim, v cc ha cht c hi, v.v Mt lng ln cc ha cht ny xut hin trong dng thi nhiu cng on x l. Cht thi ny nu thi loi ra mi trng m khng qua x l c th gy ra nhng thm ha ln cho mi trng. Cc pht thi pht sinh t qu trnh t nhin liu gy nhim khng kh. Vic x l nc thi t cc nh my hon tt kim loi c th dn n hai vn ln: Lng dng thi ln nn cn phi c cc h thng x l ln v tn km. y c bit l vn i vi cc doanh nghip va v nh, bi h phi i mt vi nhng kh khn v khng gian v ti chnh. Tnh cht kh x l khin cho vic x l tr ln phc tp v mt k thut v rt d gay nn ch. Do vy, bc u tin trong vic i ph vi cc vn v mi trng nm ch gim thiu lng cht thi pht sinh. Tip n l nhng n lc gim thiu pht thi ha cht v cc cht ph tr gim c hi cng nh gim phc tp trong x l. p dng SXSH c th gip gi quyt c hai vn ny, thc y qu trnh x l cht thi vi mc chi ph thp hn ng thi m bo p ng cc yu cu v mt lut php. Pht thi v cc cht pht sinh t ngnh cng nghip hon tt kim loi c qun l theo php lut, do vy cc doanh nghip phi chu nhng gnh nng v vic bo co ti chnh, xin giy php. Gim vic s dung nhng nguyn liu th chu s qun l ca php lut c th gim bt cho doanh nghip nhng gnh nng trn ng thi gim nhng tc ng xu ti an ton v sc khe ngh nghip.
2.2.4 Sc p cng lun

Ngnh cng nghip Vit Nam ang phi i mt vi mt tnh th ht sc kh khn khi ngy cng nhiu cc doanh nghip nh nc chuyn sang hnh thc hp tc t nhnnh nc, nhn thc ca cng ng v vn bo v mi trng c nng ln ng k. C mt s t chc phi chnh ph v bo v mi trng xut hin, khng ch nhm nng cao nhn thc v vn ny m cn hot ng nh nhng t chc gim st cc nh my. Cc cht thi pht sinh t cc n v hon tt kim loi rt c hi c bit l cc kim loi nng v xyanua c ln trong nc thi, v v vy thu ht nhiu ch ca cng chng. iu ny to ra nhiu p lc hn i vi ngnh cng nghip ny khin h quan tm hn n vic qun l pht thi ca mnh ngay c khi cc pht thi ch vi khi lng nh. Ngnh cng nghip hon tt kim loi cng khng th tch mnh ra khi p lc v phi thc hin cc bc tch cc gim thiu nhim mi trng.
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2.2.5 Cc yu cu ca th trng xut khu

Do ngnh hon tt kim loi c ng gp kh ng k vo nn cng nghip xut khu ca quc gia nn cc yu t kch thch th trng xut khu phi c xem xt k lng. Ngnh cng nghip ch bin kim loi s dng rt nhiu loi ha cht v a-xt, rt nhiu trong s c tnh cht c hi. Mt s cc quc gia Chu u, ngoi vic a ra cc quy nh cm sn xut v s dng cc ha cht c hi trn t nc mnh cn cm nhp khu cc vt phm s dng cc yu t ny trong quy trnh sn xut. Rt nhiu cc quc gia khc cng ang chun b p dng cc cm vn ny. Do , tn ti trong cc th trng xut khu ny th vic trnh s dng cc ha cht c hi l mt iu kin bt buc. p dng SXSH c th gip ngnh ny tm ra cc cht thn thin vi mi trng thay th cho cc ha cht c hi ny. Do cc khch hng cc nc pht trin ngy cng quan tm n mi trng, nn ngnh cn phi c mt h thng qun l mi trng y . Trong bi cnh , vic p dng cc h thng qun l theo tiu chun quc t ISO 14001 l mt ng thi ng n i vi cc n v xut khu. SXSH c th rt hu dng v n gip ngnh ny to ra cc s liu, ci tin vn bn h s v xy dng h thng qun l mi trng, p ng c nhng iu kin tin quyt t c chng ch ISO 14001. SXSH c th c s dng nh l mt b cng c ci tin hnh nh ca cng ty trc cng chng bng vic nhn mnh cc bc cng ty thc hin bo v mi trng. Mt khi SXSH tr thnh mt phn khng th thiu trong quy trnh sn xut ca cng ty, cc tuyn ngn nh Ch bin trong Mi trng Xanh hoc Sn phm xanh/thn thin mi trng c th c s dng nng cao th phn v s chp nhn sn phm.
2.3 Tim nng Sn xut sch hn

Tim nng SXSH Vit Nam c th thy t nhng li ch t c ti 5 nh my hon tt kim loi tham gia chng trnh trnh din p dng SXSH do Trung tm Sn xut sch Vit Nam trin khai (2003 2004). Cc cng ty tham gia chng trnh SXSH xy dng c 122 c hi SXSH, trong s c 103 gii php c thc hin trong thi gian din ra chng trnh. Phn nhm cc gii php c biu th trong hnh 5 di y.
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Hnh 5:Implemented CP measures by categories Phn nhm cc gii php SXSH c thc hin
Material Vt liu 1% 5% Technology 13% Thay i cng ngh Recycle Tun hon 5%
13%
Chnh sa thit b 9% Equipment

9%
Qun l Good HK ni vi 50% 50%
Kim sot quy trnh Process Control 22%

22%
Thc hin cc gii php SXSH xut, cc cng ty tham gia chng trnh thu c nhng kt qu tch cc c v k thut/ mi trng v kinh t thng qua vic gim nh mc tiu hao u vo ti tt c cc cng ty. Hnh 6 cho bit cc li ch k thut thu c ti cc cng ty.
Technical ch k thut Hnh 6: Li benefits

70% 60% 50% 40% 30% 20% 10% 0%
Nc w ater in electricity Du FO fuel oil
max min
gas
Ha cht chemical
Do vic gim tiu hao cc loi nguyn nhin liu u vo cc cng ty thu c li ch kinh t nh sau: Ti thiu (ng) Tng u t Tit kim d tnh mi nm 25.000.000 72.775.000 Ti a (ng) 212.000.000 2.589.690.000
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Mt khc, SXSH khng ch gip gim c chi ph sn xut m cn c th gp phn bo v mi trng. Qua qu trnh trin khai chng trnh SXSH ti cc cng ty, tiu th ti nguyn mi nm d tnh gim: Nc thi: Ha cht: in: Du FO: DO: Kh t ha lng (LPG): Pht thi CO2: 129.000 m3 36 tn 1.000 MWh 3.100 lt 58.000 lt 66.000 lt 1.118 tn
Bn cnh cc li ch v mt s lng, cc cng ty tham gia cn nng cao c cht lng sn phm (theo phn hi t pha khc hng). Chng trnh khng ch tit kim c ngn qu cho cng ty, gp phn bo v mi trng m cn lm thay i thi ca ngi cng nhn trong sn xut. Tm li, hot ng hon tt sn phm kim loi ti Vit Nam c tim nng ng k trong ct gim tiu hao cc loi u vo v gim cc dng pht thi. Bng 7 tm tt tim nng SXSH trong chng trnh. Bng 7. Tim nng SXSH trong ngnh hon tt sn phm kim loi Vit Nam.
Cc thng s T l x l li [%] Tiu th nc gim [%] Tiu th ha cht gim [%] Tiu th nhin liu gim [%] Tiu th in gim [%] Gim lng nc thi [%] Ti lng nhim COD [%] Gim ti lng cht rn l lng [%] Gim ti lng kim loi nng trong nc thi [%]
Mc ct gim T 0, 3 5 cn n 0,15 2 15 30 5 50 2 15 5 30 10 25 5 20 5 10 10 30
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2.4 Phng php lun nh gi sn xut sch hn

Phn tch dng nguyn liu v nng lng vo v ra ca mt quy trnh l yu t trng tm ca nh gi SXSH. Vic thc hin mt nh gi SXSH phi c thc hin theo tip cn c phng php lun v logic gip nhn din c cc c hi SXSH, gii quyt cc vn v cht thi v pht thi ngay ti ngun, v m bo tnh lin tc ca cc hot ng SXSH ti nh my. Tip cn nh gi phn tch ny c tng quan nh m t trn Hnh 7. Chng 4 s gii thiu chi tit tng bc thc hin nh gi SXSH theo tip cn ny. Mc d theo nh ngha th nh gi SXSH bao gm c cc vn v nguyn liu v nng lng, nhng trong thc t cc vn nng lng i vi cc quy trnh t khi c xem xt mt cch chi tit tr cc vn v bo n, r r, thu hi nc ngng, v.v ngha l ch i vi cc dng hu hnh. y l iu ng tic v SXSH v nng cao hiu qu nng lng thng c tnh b tr cho nhau rt cao v s tch hp gia hai hot ng ny c th to ra sc mnh m rng phm vi ng dng v em li cc kt qu c hiu qu cao hn c v mi trng v kinh t. Ti liu ny s cp n c nguyn liu v nng lng trong ngnh hon tt sn phm kim loi.
Hnh 7: Phng php lun v nh gi SXSH
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Do SXSH thng c p dng i vi nhng lng ph ti nguyn hu hnh (v d nguyn liu), nn hin tng lng ph ngu nhin s l rt t. Nhn chung, c th tnh ton truy tm c vt liu u vo cho mt cng on no thng qua cc sn phm u ra nh tnh v nh lng c. iu ny khng phi lc no cng ng khi xem xt cc dng nng lng. Trong khi cng p dng quy lut cn bn cho cc dng nng lng u vo (v cn bn, nng lng vo phi bng nng lng ra), th vn gp phi y l cc dng nng lng u ra thng kh nhn bit hn so vi dng vt liu. V th, vic xc nh v nh gi cc dng nng lng lng ph dng n v s dng thiu hiu qu thng gp nhiu kh khn. iu ny c bit ng vi cc thit b chy in nh my bm, qut, my nn kh, v.v khi nng lng u vo di dng in nng c th d dng o lng c, nhng mc chuyn i hiu qu sang u ra hu ch (v.d: nc c bm, kh c nn, v.v) th li khng th nh lng trc tip c. Cc mu thun c th ny sinh SXSH v nng cao hiu qu s dng nng lng (HQSDNL) c tnh b tr cho nhau rt cao. Tuy nhin, trong mt s tnh hung, cc kt qu c li thu c ca mt phng php lun (chng hn SXSH) li c th c hiu l i lp vi phng php cn li (HQSDNL). Di y l mt s v d minh chng cho iu ny: Tun hon l mt k thut SXSH rt c li, nhng tun hon du v cht bi trn, ti s dng cc m qua sa cha hoc qun li cc ng c b chy (c bit l trng hp vic sa cha hoc qun li c thc hin khng hon chnh) thng dn n tiu hao nng lng mc cao hn. Lm lnh bng cng ngh hp th hi l mt gii php SXSH chuyn nghip v thn thin sinh thi khi so snh vi cc my nn hi ang thnh hnh. Tuy nhin, khi xt v mt s dng nng lng th cc h thng hp th hi li c hiu qu thp hn. Cc bng n hunh quang tup gy c hiu qu nng lng hn loi bng si t, nhng v mt mi trng (SXSH) th vic ph thy ngn lm cho loi bng ny t thn thin sinh thi hn.
Cc bc thc hin phng php lun SXSH 6 bc c m t trong Hnh 8. Chng 4 s trnh by chi tit hn tng bc thc hin SXSH.
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BC 1: KHI NG
Nhim v 1: Thnh lp nhm SXSH Nhim v 2: Lit k cc bc quy trnh v nhn din cc dng thi
BC 2 : PHN TCH CC BC QUY TRNH

Nhim v 3: Chun b lu ca quy trnh sn xut Nhim v 4: Cn bng vt liu, nng lng v cu t Nhim v 5: Xc nh c tnh dng thi Nhim v 6: Xc nh chi ph cho cc dng thi Nhim v 7: Xem xt li quy trnh xc nh ra cc nguyn nhn
BC 3: XUT CC GII PHP SXSH

Nhim v 8: Xy dng cc gii php SXSH Nhim v 9: Sng lc cc gii php SXSH c th thc hin c
BC 4: LA CHN CC GiI PHP SXSH

Nhim v 10: Tnh kh thi k thut Nhim v 11: Tnh kh thi kinh t Nhim v 12: Tnh kh thi mi trng Nhim v 13: La chn cc gii php thc hin
BC 5: THC HIN CC GII PHP SXSH

Nhim v 14: Chun b thc hin Nhim v 15: Thc hin Nhim v 16: Gim st v nh gi kt qu
BC 6: DUY TR SXSH
Nhim v 17: Tr v bc 1
Hnh 8: Cc bc thc hin phng php lun SXSH
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2.5 Cc k thut SXSH

Sn xut sch hn l phng php tip cn mi v sng to gim mc s dng ti nguyn trong qu trnh sn xut da vo mt lot cc k thut. Cc k thut ny c th c phn thnh 3 nhm nh sau: Gim thiu ti ngun Qun l tt ni vi: y l loi gii php SXSH n gin nht. Qun l tt ni vi khng i hi phi u t hoc ch u t vi thi gian hon vn rt ngn v c th trin khai ngay khi xc nh c gii php. y bao gm cc k thut phng nga cc ch r r, chy trn thng qua bo dng Mt cng ty u t 5 triu ng thc hin cng tc phng nga v kim tra thit b qun l ni vi tt nh o to, lu tr nguyn liu tt hn thng xuyn, cng nh kim sot trnh n mn vt cn m v a ra c ch thng vic thc hin ng hng dn pht cho cng nhn. Cng ty tit kim c 100 triu ng mi nm t gii php ny. cng vic hin c. Mc d qun l Mt cng ty khc u t 100 triu ng pht sinh vo ni vi l mt cng tc khng phc qun l nhn cng, nhng thit b kim tra v bo tr, lp tp nhng i hi c s tp trung t ng h ga, nc v in, cng nh phn thng nghim tc ca ban lnh o, c cho cng nhn. Sau chin dch, cng ty thu c khon tit kim 348 triu ng tin in, 336 triu ng s o to nhn vin v gim st tin nc, 20 triu tin gas, v 20 triu tin ha cht. ph hp. Nhn thc c v c hi t tn km v thm ch l khng cn chi ph thuc loi ny, 5 cng ty tham gia vo chng trnh SXSH ni trn ngay lp tc trin khai cc bin php qun l ni vi tt gm lp t cc thit b o (nc, in, nhit , etc.) theo di tnh hnh tiu th; cc ng ng hi nc cch nhit, sa cha cc ch r r v cc ng ng c, v.v... Nhm gii php ny khng cn nhiu u t, nhng cn c s quan tm v thc xy dng cao. Thng th cc khon tit kim thu c t nhm gii php ny l rt kh nh lng, nhng li c ng gp rt ln vo kt qu chung.
Mt cng ty lun phi i mt vi cc s c lp m bm km, v phi tn rt nhiu tin x l li. Trong khi tin hnh bo dng th pht hin ra nguyn nhn l ng ng khut dng cho x l pht pht b tc v v th quy trnh ny khng din ra mt cch hon ton. H thng ng ng ngay lp tc c lm sch v sa cha. K t cng ty khng h gp phi vn g v cht lng ca dy chuyn sn xut. Mt cng ty m in bt u thc hin cng tc qun l ni vi tt ngay t u chng trnh SXSH: tp hun, cung cp nhng hng dn r rng v m in nh nhc vt ra ngay lp tc nu n v tnh b rt vo trong b m, sy kh vt hon ton trc khi m, gc nhng, thi gian nhng..., qua gim ng k lng km b cng trong b m. Mt cng ty c kh Vit Nam sn xut l nng BBQ tham gia chng trnh SXSH. H xc nh quyn hn v trch nhim cho tng gim st vin v cung cp cc khay phn loi cho cc my dp. Gii php ny gip gim lng sn phm li v 2% lng l thp, tng ng 400 triu ng/nm. Ngoi ra, cc ph kin c x l cng c bo v tt hn v t b n mn hn. iu ny cng lm gim lng a-xt tiu th trong bc ty tip theo.
Bo dng: Thiu bo dng thng xuyn c th dn n h hi thit b. Thc t ph bin l cc thit b trong dy chuyn sn xut ch c xem xt bo dng khi chng khng cn hot ng c. R r t ng ng hay cc thng cha, b cha l hu qu ca vic thiu bo dng. iu ny khng ch gy ra tn km do tht thot nguyn liu, m cn thi loi ra mi trng nhng cht gy nhim.
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Thay i quy trnh: k thut ny bao gm: Thay i nguyn liu u vo: Dng nguyn liu u c cht lng cao hn c c hiu sut cao hn. Thng th c mt mi quan h trc tip gia cht lng ca nguyn liu th v s lng cng nh cht lng sn phm u ra. Xa hn na l s tm kim v thay th cc nguyn liu ang dng vi cc nguyn liu c tnh thn thin vi mi trng. Nhm gii php ny c pht hin ra bi cc cng ty tham gia sau khi nhn ra rng rt nhiu nh cung cp khuyn co s dng ha cht cht lng cao hoc nng cao v l do an ton (ch s an ton). Ngoi tr cc cht ph b mt, th cc ha cht khc khng cn st li trn sn phm, m b thi ra trong cc bc sn xut tip theo. Vic s dng qu nhiu ha cht s khng ch lm tn tht nguyn liu ca cng ty m cn lm tn thm chi ph loi b v lm Mt cng ty c mt dy chuyn m Nisch. Tuy nhin, y l mt thi quen ti rt Cr thay i s dng nc my sang nhiu nh my v ng dng SXSH l mt c nc sch do thnh ph cp ra. Vic lm ny gim c t l sn hi h nhn li nhng la chn c sn trn phm li t 5% xung 2%, tit kim th trng v la chn cc nguyn liu khc 280 triu ng/nm, trong khi chi thay th hiu qu hn v thn thin hn vi ph u t l 5 triu ng/nm mi trng. Cc kt qu cho thy hin nay rt nhiu cng ty ang tm kim nhng nguyn liu ph tr hiu qu hn (chng g, cc cht dn, v.v...) c th gim c khi lng v thi gian ch bin. S dng t ha cht hn cng ng ngha vi vic gim chi ph x l. Kim sot quy trnh tt hn: l nhm m bo cc iu kin ca quy trnh trng thi ti u v mt tiu th ti nguyn, sn xut v pht thi. Cc thng s quy trnh nh nhit , thi gian, p sut, pH, tc ch bin, v.v cn phi c gim st cn thn v duy tr cng gn trng thi ti u cng tt. Cng vi vic qun l ni vi tt, kim sot quy trnh tt hn i hi phi ci tin c cng tc gim st v c s ch trng ca ban ngnh lnh o.
Mt cng ty s dng my sy ga sy kh cc sn phm sn tnh in. Trong khi thc hin chng trnh SXSH, cng ty ny cch nhit cho my sy ny v iu chnh v tr ca b cm ng nhit kim sot nhit tt hn. Ngoi ra cng ty ny cn thay i quy m ca m sy. Hai bin php ny cng li tit kim c 20% lng ga tiu th gim 3 tn CO2/nm. Chi ph cng ty u t l 500.000 ng, v thi gian hon vn ch c cha y 2 thng. Mt cng ty c dy chuyn m Cr-Ni t ng u t 23 triu ng lp t h thng ti ch nc lm mt. 3 Cng ty tit kim c 400m nc/thng, tng ng vi 45 triu ng/nm. Thi gian hon vn ca gii php ny l 7 thng. Mt cng ty iu chnh t l kh/du ca l hi (4 l hi 0,75 tn/h/chic) v gim c 8% chi ph DO, tng ng vi 80 triu ng/nm. Gii php ny cng ty khng phi u t cht kinh ph no.
Ci tin thit b: l bin php ci tin cc thit b hin c gim thiu lng ph nguyn liu. iu chnh thit b c th l iu chnh tc ng c, ti u ha kch c thng cha, cch nhit cc b mt nng v lnh, hoc ci tin thit k cho mt b phn quan trng trong thit b. Trang b thm hoc ci tin nh cho thit b trong cng ty c th gip cng ty tm ra cc gii php sn xut hu hiu hn, ch yu bng vic tiu th t
nng lng hn. i khi cc chi ph thay th hoc sa i ci tin c v nh kh cao nhng thi gian hon vn trn thc t li rt ngn.
Mt cng ty c dy chuyn m Cr-Ni s dng cc gi cch nhit km treo sn phm v th cng ty tht thot rt nhiu kim loi (Cr, Ni) trn gi. Trong khi thc hin chng trnh, cng ty u t 2 triu ng sn cho gi . Gii php ny tit kim cho cng ty 28 triu ng mi nm. Mt cng ty ti s dng sn dung mi cho sn tnh in. Trong khi tham gia chng trnh SXSH, cng ty ct ngn chiu di ca bng truyn v tng s lng chp trn gi. Gii php ny gip cng ti tng cng sut ln 2,5 ln. Khon u t ca cng ty tr gi 53,5 triu ng tit kim c cho cng ty 111,6 triu ng mi nm, thi gian hon vn ch c 4,8 thng. Gii php ny cng gim 60 tn pht thi CO2/nm. Mt cng ty thay th my sy t l gch sang l kim loi c hiu sut cao hn. Bin php ny gim 60% lng in tiu th v tit kim 60 triu ng mi nm. Khon u t ban u l 25 triu ng, do cng ty ch mt 4 thng thu hi khon vn u t. Mt nh sn xut l nng BBQ thay ti lc xoy sang h thng lc t ng cho phng sn tnh in. Bin php ny tit kim cho cng ty hn 30 triu ng mi nm nh thu hi bt sn, v ng thi ci thin mi trng lm vic. Gii php ny ch cn u t 5 triu ng. Mt cng ty s dng h thng sy ga t ng cho sn phm sn tnh in. Trong khi thc hin chng trnh SXSH cng ty pht hin ra mt lng nhit ln b tht thot do thit k khng tt v ca bung sy h. Cng ty ny tin hnh mt s sa i cho my sy vi chi ph 11 triu ng. Sau khi lm xong tit kim c 3% lng ga tiu th, tng ng vi 30 triu ng mi nm, v nh vy thi gian hon vn ch mt 5 thng. Ngoi o o ra nhit mi trng lm vic gim t 35-37 C xung di 32 C v mi nm gim 14 tn pht thi kh CO2.
Thay i cng ngh: l vic lp t thit b mi hin i c hiu sut cao hn, nh l hi hiu sut cao hay my nhum phun c t l nc thp. Cng ngh ch bin mi yu cu u t ln hn cc gii php Mt cng ty m in thay i bin php ra SXSH khc v th cn phi c chy trn sang chy ngc cho dy chuyn m 3 nghin cu cn thn. Tuy nhin vic km. Gii php ny tit kim 7500m nc mi nm tng ng 30 triu ng/nm. Cng ty ch tit kim v ci tin cht lng cn u t 700.000 ng, v th ch mt 0,5 thng thng gip cho doanh nghip b li thu hi vn u t. khon u t rt nhanh.
Tun hon, ti s dng ti ch Thu hi v ti s dng ti ch: l vic thu thp ph thi v ti s dng chng ngay ti ch hoc ti mt b phn khc trong dy chuyn sn xut. Mt v d n gin l ti s dng nc ra t mt cng on ny sang mt cng on ra khc.
Mt cng ty lp t mt h thng tun hon nc lm mt t my nn vi chi ph u t 20 triu ng. Bin 3 php ny tit kim cho cng ty 20.000m nc/nm, tng ng vi 82 triu ng, nh vy ch cn cha ti 3 thng hon vn. Mt cng ty khc u t 3 triu ng xy dng mt h thng thu hi crm t b ra. Bin php ny gim c 64 kg kim loi nng thi ra mi trng. Gii php ny khng ch tit kim cho cng ty 2 triu ng/nm t khon tht thot nguyn liu, m cn c khon tit kim khng tnh c t h thng x l v ph mi trng. Tng t nh vy, mt nh my tham gia chng trnh SXSH u t 7,2 triu ng vo h thng lng crm. Vi chi ph vn hnh 24 triu ng/nm, h thng ny thu hi c 360 kg crm/nm tng ng vi 30 triu ng. Thi gian hon vn l 13 thng.
Sn xut cc sn phm ph hu ch: l vic thu thp v (x l) cc dng thi bn cho khch hng hoc cc cng ty khc.
Ci tin sn phm Ci tin sn phm chng tr nn t nhim hn cng l mt tng ch o trong SXSH. Thay i sn phm ngha l suy ngh li v sn phm v cc yu cu i vi sn phm . Ci tin thit k sn phm c th giptit kim mt lng nguyn liu ln v s dng t cc cht ha hc c hi hn. Thay i cch thc ng gi cng c ngha quan trng. Quan trng nht l phi gim bt c lng bao b m vn m bo kh nng bo v cho sn phm. Bng 8 di y s trnh by v d v cc k thut SXSH khc nhau c ng dng cho ngnh hon tt kim loi ti Vit Nam. Bng 9: V d v k thut SXSH cho ngnh hon tt sn phm kim loi
Sa cha cc ch r r Kha cc vi nc khi khng s dng S dng cc khay hng dung dch theo ra cng vt m Thng xuyn kim ra tt c cc by hi, ti hi Thay i vt liu u vo Kim sot quy trnh Ci tin thit b Thay i cng ngh Thay cht ty dung mi bng cht ty enzyme Thay nc thng bng nc mm khi ra iu chnh cc b gim xc trong l hi Duy tr nhit , p sut v thi gian tt trong m in S dng p sut kh nn ti u Lp sung phun p lc ra Dng t b nng h s cng sut Lp t thit b dng v n cho h thng lc lin tc trc tuyn S dng phng php ra ngc M khng c xyanua Ra siu m ty du Thu hi cc ha cht nh Ni, Cr, v.v... s dng phng php trao i ion, RO Thu hi v tun hon nc ngng Thu hi dung mi t nc thi ca qu trnh lm h bng dung mi Thu hi v tun hon ha cht thu c cc khay hng dch ra khi b x l cng vt m ng pht in QUN L TT NI VI TO RA SN PHM PH HU CH THU HI V TI S DNG TI CH THAY I QUY TRNH
TUN HON V TI S DNG
GIM THI TI NGUN
CI TIN SN PHM
Dng sn phm sn tnh in ti ni c lng kim loi (metal deposition)
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Cc c hi SXSH trong hon tt sn phm kim loi

Chng ny cung cp thng tin tng quan v c hi SXSH c th ng dng ti cc nh my hon tt sn phm kim loi Vit Nam. Cc c hi SXSH ny c c th trin khai ti c s sn xut quy m nh in hnh. Tnh kinh t ca cc gii php ph thuc rt nhiu yu t nh quy m vn hnh, thnh phm, yu cu t pha khch hng v cht lng sn phm, v th trong chng ny khng cp ti ch ph s b cho gii php.
Vic nghin cu SXSH ti cc nh my hon tt kim loi cho thy cc tim nng SXSH nh m t trong Chng 2 l hon ton c th t c bng nhiu gii php SXSH khc nhau. Quan trng hn c l cc gii php ny, ngoi vic gip tng kh nng sinh li cho cc doanh nghip, cn gip lm gim pht sinh mt lng rt ln nc thi, hm lng nhim v cc cht c hi. Trong chng ny, cc c hi SXSH c m t c th c thc hin ti cc n v tng t khc vi mt s iu chnh nh. Chi tit hn, cc c hi SXSH cp trong chng ny s c chia thnh nhiu phn khc nhau, mi phn sau s c bn lun chi tit. Trong ngnh cng nghip hon tt kim loi, rt kh t c cc gi tr trung bnh v nhng yu t tit kim cng nh ngun vn s dng bi tnh cht khc nhau ca cc quy trnh p dng, loi hon tt, v.v. Nhiu trong s cc bin php lit k di y ph bin hu ht tt c cc doanh nghip va v nh ti Vit Nam, v c th c p dng vi mt s iu chnh khng ng k. Mt s bin php tit kim ngun nc hin ti c v nh khng c tnh kh thi v mt kinh t nhng ng trc tnh trng cn kit ngun ti nguyn nc v gi c leo thang, trong tng lai gn c th s l u tin s mt ca cc doanh nghip.
3.1 Qun l tt ni vi
Cc ci tin trong qun l ni vi chnh l cch n gin nht gim nhim mi trng vi chi ph thp v khng cn phi u t thm thit b. Cc ci tin trong qun l ni vi c cp n trong phn ny bao gm bo dng phng nga, kim k qun l kho, chng trn, chng nhim bn cho dung dch trong b, phn loi cht thi v o to cng nhn vin.
3.1.1 Ni lm vic sch s ngn np

Mt gii php chnh ca cng tc qun l ni vi tt n gin ch l gi cho ni lm vic sch s, ngn np. Cng tc ny c th lm gim ng k cc nguy c xy ra tai nn v h hi i vi hng trong kho hoc thit b v c th gip lm cho cng vic c thun li hn. V d, lu tr hng ha trong cc khu vc kho c thit k sn c th lm gim nguy c v tnh xe nng ph hng hng ha. i vi cc sn phm nguy hi, vic ny c th ngn chn hin tng nc trn ra cc khu vc cha c che chn.
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Gi cho lung cng vic thun li c th lm tng hiu qu hot ng rt ln. Vic ln k hoch sp xp v tr nguyn vt liu c bo qun v s dng, s rt tin li khi cn. Cht thi do cng c th d dng c tch lc hn.
3.1.2 Bo dng d phng

R r ng ng v thit b c th dn n nhng hao ph rt ln v ngun lc, bng sau y a ra mt v d v mc tht thot nc do ng ng b r r: Bng 9: Hao ph nc t l r r (ti p sut 4,5 bar) Kch thc l r (mm) 0,5 1 2 4 6 Kilolit/ngy 0,39 1,2 3,7 18 47 Kilolit/nm 140 430 1.300 6.400 17.000
Bo dng d phng s hn ch cc ch r r, hin tng trn v cc nguy c tht thot ngun lc khc. Lch v sinh v bo dng nh k c ghi chp, theo di cc hot ng sa cha cng l mt cng c qun l tt. Cc khu vc chnh cn bo dng v kim tra l my bm, mp bch, b lc, cc dng, cc m, ng h o, in tr, b cm bin, thng cha v lp lt thng cha. Khi pht hin ra li phi lp tc sa cha khc phc ngay.
3.1.3 Kim k qun l kho

gim khi lng nguyn vt liu nguy hi lc no cng cn phi lu tr ti hin trng, hy cn nhc h thng mua ng lc. Mt h thng ng lc thng s hiu qu nu nh cung cp c th cp hng ng tin , nu khng bn s cn phi c mt h thng ghi chp thng k cc chi tit trong kho. kim sot vic phn phi cc cht ph gia ho hc nguy him v t tin, cn phi xem xt vic kho cc kho hng mt cch cn thn v p dng phng php mt i mt ngha l ngi cng nhn ch c th c sn phm mi khi c v hay thng cha ca sn phm s dng ri i. Vic ny s gip trnh khng phi tch kho qu nhiu hoc s dng nhm, ngoi ra cn thun li cho vic hon tr cc thng cha.
3.1.4 Phng nga v kim sot hin tng trn

Cch tt nht hn ch hin tng trn l o to cho nhn vin cch qun l nguyn vt liu ng. Cn phi c cc quy trnh c th r rng cho vic pha ha cht, v trch nhim pha ha cht ch nn giao cho mt s t cc cng nhn qua o to thao tc quy trnh. Ngoi vic hn ch hin tng trn, iu ny cn c tc dng ci thin ng u ca cc cng thc pha ch.
Bng vic s dng cc mng hng v chn bn trn b cha, ha cht nh xung t cc chi tit s c thu hi v b v b ngn khng cho rt xung sn. Cung cp y cc phn ni trong b cha cng c th hn ch ng k hin tng trn. Cng on gy tht thot nhiu nht trong cc xng m km l khi nhng chi tit vo b m, do dung dch km phn ng gy n bn. Nhiu ni dng cc np y hn ch s tht thot ny.
3.1.5 o to nhn vin

Nhng k hoch phng chng nhim ca cng ty thng hay b qua khu o to nhn vin. o to khng ch gip ngn chn hoc hn ch tai nn m cn to thm nng lc cho cng nhn v lm cho h cm thy c cng ty trn trng hn. Cc doanh nghip nn cn nhc vic o to v cc yu cu qun l ni vi chung v cc bin php khc phc hin tng trn.
3.1.6 S quy trnh

Ci thin s quy trnh c th nh hng rt ln ti s pht sinh rc thi, c bit l trong m in. Nhiu xng m in nh thng ch c mt b bn ra phc v cho ton b qu trnh m. iu ny c ngha l cc cng nhn vn hnh phi di chuyn rt nhiu ln gia cc b m v bn ra. iu ny khng nhng gy lng ph thi gian cho cng nhn sn xut, lm tng lng tht thot cc dung dch xung sn m cn lm tng nguy c cng nhn c th b tip xc vi dung dch. Bng cch hp l ho cng on x l v b sung thm mt b bn ra ngay cnh mi bn m, cng nhn vn hnh c th di chuyn trong sut qu trnh lm cho lung cng vic thun li hn. iu ny cng c ngha l dung dch b dnh v theo ra khi bn m cng vi vt m c th c hng v quay tr li bn m, trnh hao ph. Cc gi treo khng ch cho php tng nng sut m, m cn cho php kim sot tt hn s ln thi b v s vng ra. Nh s c cp trong phn 1.5.2 sau y, vic kim sot cc yu t ny c th lm gim pht thi ng k. Cc gi treo t ng thm ch cn mang li nhiu li ch hn na, v k thut ny nn c cn nhc cho quy m sn xut ln do lng sn phm m nhiu.
3.1.7 Lp k hoch v lch sn xut

Kim tra cc chi tit cn thn trc khi sn c th gip trnh c vic phi x l cc chi tit c nhiu kh nng b loi. Cn c hng dn r rng v cht lng cho cng nhn chu trch nhim treo cc chi tit vo gi h c th nhn ra cc sn phm c kh nng b li trc khi chng c x l. Lp k hoch v tinh chnh lch sn xut cng c th c nh hng n vn pht thi, c bit i vi cng nhn sn tnh in. Chng hn vic cng lc sn tt c cc sn phm cng mu s lm gim yu cu lm sch thit b gia cc m sn. Nu cc m sn c b tr ln lt mu nht chuyn sang mu m th phn d ca cc m nht hn c th c tn dng trong cc m c mu m hn. Nh vy yu cu lm sch thit b cng s gim i. Qu trnh ny c gii thch trong bng di y nh mt v d in hnh v mt quy trnh m catmi ti mt trong cc nh my ca c.
S gc
Dung dch dnh theo vt m M Xyanua ctmi
Ra phun (Khng s dng)
M Xyanua catmi (Khng s dng)
B ng
B ty g caimi
Ra
M crm vng
Ra
Ty crm
Ra ln cui (Nc t)
S ci tin
M Xyanua caimi
M trng quay ctmi
Ra phun
Dung dch dnh theo vt m
Ra chy ngc
Ty crm
Ra chy ngc
M crm vng
Phun nc ra
Ra ngc dng
Ra ln cui (Nc t)
Cc thay i ny gip gim dung dch dnh theo vt m xyanua caimi 490 lt/ nm, dung dch dnh theo vt m ph crm 3.300 lt/nm v nc ra 870 lt/nm. Nhu cu bnh lc dng trong h thng x l nc thi cng gim 1.090 kg/ nm.
Vn u t cho cc thay i ny l 4.520 USD bao gm thm hai b ra mi, hai b phun mi v nhn cng. Tuy nhin, cc thay i ny mang li tit kim hng nm l 2.620 USD v thi gian hon vn l 1,7 nm. Cc thay i ny cn gip gim s bc chn ca cng nhn trong qu trnh m t 58 xung cn 21.
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3.2 Lm sch v tin x l

Cc chi tit kim loi cn phi c lm sch loi b v s cc cht nhim bn b mt trc khi sn m. Cc cht bn c th tm thy trn b mt chi tit kim loi l: Cc hp cht v kim loi dng hoc cha nhum mu pigment Cc hp cht nh bng M, x phng dng cho kim loi, cht mi mn, sp Dung dch ct v nghin G (xt kim loi) s xi ho v vy ng trn b mt Cc mui kim loi nng Cht tr dung, chng g, bi trn v dung dch thu lc Mt kim loi, bi, cn cc-bon Sn v mc Cc hp cht c-l-phan v nha thng Cht tr dung
Hu ht cc quy trnh hon tt kim loi u cn c cc c ch lm sch rt trit v cc cht nhim bn b mt nh hng rt ln n cht lng ca thnh phm. Quy trnh lm sch cng c th c xem l hot ng tin x l b mt kim loi nhm mc ch to bm cao hn khi m ph trn b mt kim loi. Trong cc quy trnh m in, cng on lm sch thng c tin hnh trong cc b dung dch kim hoc axt. Thp v ng c nhng vo dung dch lm sch kim tnh c cha nh tng hoc cht c hot tnh b mt loi b v ho tan du v cht rn bm trn b mt. Bn lm sch cng c th dng mt dng in hoc ngun nhit nh mt phn ca qu trnh lm sch. Cc b mt nhm c lm sch bng dung mi a xt v dung dch kim c tnh n mn mnh i vi nhm. Nha thng c lm sch bng cch khc axt, b mt c lm sch ny c th dng lm phi nh kim loi. Trong m km, g v vy g c loi b bng cch ngm vo a-xt sulfuric hoc a-xt clohydric. Vt m lc s c ngm trong dung dch tr dung thng c cha 30% km amoni clorua v cc cht lm t, c duy tr ti nhit 65oC. Dung dch tr dung loi b mng xt hnh thnh trn b mt st thp c tnh phn ng cao sau khi lm sch bng a-xt, v ngn qu trnh xi ho trc khi m km. Trong a-nt ha, vic lm sch thng c tin hnh vi dung dch kim khng cha a-xt. Sau vt m s c ngm trong mt dung dch kh -xt c cha a-xt sulfuric v a-xt crm-mc khong 2-5 pht loi b mng xt v qu trnh a-nt ha c din ra ng nht.
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Hin nay vic s dng dung mi lm sch gp kh nhiu hn ch. Nguyn nhn chnh l do c cc yu cu v mi trng v v sinh an ton lao ng quy nh vic hn ch v loi b s dng sn phm c qua ch bin bng dung mi. Do , trong ngnh hon tt kim loi, cc dung dch kim v a-xt l cc cht chnh c dng lm sch v tin x l. Cc dung dch ny c thi gian s dng hn ch v thng s b thi b sau mt thi gian nht nh, t mt n su thng tu vo lng nguyn vt liu a vo quy trnh. Do vy cht thi a xt v kim l lng thi lng ca ngnh, v chi ph thi b thng l mt khon ng k trong chi ph sn xut ca hu ht cc doanh nghip. B quyt SXSH cho cc n v hon tt kim loi: Ti a ha thi gian s dng ca cc ho cht x l. Gi cho cc ho cht x l lun ni ca chng - trong cc bn. Thu hi ti a dung dch dnh theo vt m ra ngoi cho tr li b quy trnh. B quyt SHXH cho cc xng sn phun Hn ch vic phun qu nhiu sn Ti u ho hiu qu vn chuyn Pha sn mt cch chnh xc y l cc cch ng xem xt c th ko di thi gian s dng ca dung dch lm sch nhm gim lng thi pht sinh t cng on ny ca qu trnh x l.
3.2.1 Trnh cc yu t pht sinh nhu cu lm sch

Cc cch sau y mc no c th gip trnh c mt s cng on lm sch: Cung cp ng lc gim vic s dng cht chng g. Yu cu cc nh cung cp cung ng cc chi tit d lm sch hn. Trnh ty du m nh k cho ton b cc chi tit, ch ty cc chi tit khi thc s cn. Trnh s dng nhiu loi cht lm sch khc nhau bng cch la chn cc cht c di ng dng rng.
3.2.2 Cc phng php lm sch vt l

Nhiu hot ng hon tt b mt ang chuyn dn sang cc phng php lm sch vt l nh cc k tht co, c sch hoc phun hn ch vic s dng cc dung dch lm sch. Cc phng php lm sch vt l gm: S dng d lau sch du tha Thi hi
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Cc h thng bn ht nha bc sn Cc h thng bn vi ht (natri ccbont hoc cacbonic cng) Thit b rung phng tin mi mn (v d ht thu tinh, bi thp dng cho ng; la v cc ming carbua cho cc chi tit m kn; chi quay v bt cho ng) Gia nhit/ t/ nhit phn
Cc dy chuyn bc lp sn c trang b cc h thng thi c cc thit b thu gom c th loi b ti 99% lng bn so vi vic s dng k thut ty dung mi ho cht truyn thng. My rung vi phng tin mi mn (v d ht thu tinh, bi thp dng cho ng; la v cc ming cacbua cho cc chi tit m kn; chi quay v bt cho ng) c thay th cho cc quy trnh ty. Lm sch tin ch bng cc phng tin c kh kt hp vi vic lm sch bng ho cht c th ko di thi gian s dng ca cc dung dch lm sch.
3.2.3 Ko di tui th dung dch lm sch

Hn ch yu cu lm sch v s dng cc phng php lm sch vt l c th lm gim pht thi t cng on lm sch mt chng mc no ; nhng phn ln cc doanh nghip tip tc da vo cch s dng cc bn lm sch ha Phn ng gia dung dch lm sch v b mt chi tit kim loi to ra cn ng li trong cc bn lm sch. i vi cc bn lm sch kim, cht kim phn ng vi cht bn du m v to ra bn cn ging nh x phng. Cn bn thi dn tch t trong bn cho ti khi n qu bo ho v lm bn mt tc dng th n c loi b v thay th. Thi gian s dng ca dung dch trong bn c th c tng ln ng k bng cch lc dung dch loi b cc cht rn l lng. b p cho phn mt i ca cht lm sch v nh tng th b ra cn phi c b sung mt lng tng ng. Cc h thng lc hin c trn th trng nh cc thit b t trong bn hay thit b t ngoi bn hay cc thit b nh hn rt thch hp cho cc doanh nghip c quy m nh. cc n v sn xut ln th cc thit b lc c th phi chy lin tc, tuy nhin i vi cc n v nh hn th chng ch cn chy mt vi gi mi ngy. Hin nay cng c thit b lc lu ng n c th lc tt c cc dung dch lm sch, d l loi kim hay axit. Cc h thng lc ngoi khng cn ph bin nh trc y do gp phi cc vn nh n mn, r r, tc, v.v... Nhng vn ny c th c gii quyt vi nhng h thng lc c t trong b. Vic thay th cc cht lc dn n pht sinh thm pht thi rn v lm gia tng chi ph vn hnh. Mt s b lc s dng vt liu lc c th lm sch v ti s dng c, v vy nn xem xt k chn la h thng lc ph hp nht.
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3.2.4 Thit b lm sch cc chi tit

Thit b lm sch c dng loi b cc cht bn, du m bng vic s dng kt hp nc v cht ty ra. Cc thit b lm sch c dung tch t 300 ti 1500 lt v phn ln c h thng ti ch/ lm sch ti s dng dung dch ty ra hoc dung mi. My lm sch dng nc c th thay th cc h thng lm sch s dng cc cht lm sch c hi khc; v dung dch ty ra s dng trong nhng h thng ny c bit c kh nng phn hy sinh hc v c th thi trc tip ra trm x l nc thi. Quy trnh hin ti l lm th no cc thit b lm sch cng c khp kn v t phi bo dng cng tt. Cng c loi thit b lm sch s dng dung dch khng mang nc nh cc dung mi ho tan hoc du khong; tuy nhin t cch nhn ca sn xut sch hn th nn trnh vic s dng nhng loi dung mi ny. Nu s dng dung mi th cc thit b lm sch phi gim c s bay hi ca dung mi, hn ch tip xc gia ngi cng nhn v cc ha cht c hi v ng thi cho php ti s dng nhm lm gim tiu th cht lm sch.
3.2.5 Cht lm sch sinh hc

Cc h thng lm sch sinh hc hay rp lm sch ang c pht trin Thu in nh l mt gii php thay th cho lm sch bng cht ho hc. Phng php ny mi c pht trin giai on u v s rt ha hn cc doanh nghip m c quy m ln. Phng php ny yu cu ni nu phi ln v qu trnh lm sch cn phi din ra tht t t. Khi pht trin xa hn, ng dng ca phng php ny c th rng hn.
3.2.6 Lm sch siu m

Phng php lm sch siu m c th t c sch cao cho b mt kim loi v c th loi b c cc ht vt cht nh b. Phng php ny c th loi b cht bn trn chi tit c hnh th phc tp nhanh hn phng php ngm ra. Cc thit b ny thng c dung tch kh nh, t 20 - 140 lt. Mt im hn ch na l chi ph cho cc thit b ny rt tn km, tuy nhin cc nh khoa hc k vng rng phng php lm sch siu m s c th c ng dng rng hn trong tng lai.
3.2.7 Nhit phn cho sn tnh in

i vi nghnh sn tnh in, vic bc sn bng dung mi nh metylen clorua c th c thay th bng phng php nhit phn. Nhit phn l qu trnh chy c kim sot din ra trong l c nhit khong 400oC. Sau cc sn phm in phn c dn ti bung t ph trc khi g b.
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3.3 Kim sot thng s b x l

Theo di v kim sot thng s b mc ti u s gip ti u ho hiu qu, gim s lng ph vt liu v nng lng, v gim dung dch dnh theo vt m. C th s dng cc b cm bin kim sot nhit , m, pH, dng nc v mc nhim bn; v cng ngh cm bin hin nay c th kt hp vi my tnh nh gi cc iu kin. S ci tin cng ngh cng vi gi thnh ngy mt h khin cc b cm bin phn tch, cc giao din my tnh, v cc h thng kim sot x l ngy cng c quan tm hn. Nhng phn sau y s m t cc thng s chnh trong vic kim sot iu kin ca b.
3.3.1 Nng ho cht

Nn duy tr cc b vi t l nng ho cht ti thiu t c cht lng sn phm cn thit. Cc doanh nghip cng nn theo di theo kinh nghim thc t ch khng nn da vo khuyn co ca cc nh cung cp ho cht v mt s nh cung cp c th a ra cc yu cu cao hn cn thit. Bng vic h thp nng ha cht xung mc ch trn im gy li, cc chi ph v ho cht v cc chi ph khc lin quan n vic thi loi v x l s gim xung. Khi nng ho cht gim th lng dung dch dnh theo vt m cng s gim theo.
3.3.2 Nhit b
Nhit ca mt b c th tc ng n hiu qu ca qu trnh m, v lng dung dch dnh theo vt m. nhit cao hn, st (nht) ca b thp hn, v v th dung dch dnh theo vt m gim i. Mt khc, nu nhit vn hnh cao hn cng c ngha l chi ph nng lng cao hn, v c th lm hng cc cht lm sng. Doanh nghip cn phi cn nhc v vn ny xem nu thay i nhit b, hoc ln hoc xung c th thc s gip gim chi ph hay khng.
3.3.3 Ngn tht thot nhit v bay hi

Cc cch gim tht thot nhit v bay hi t cc b cha: Cn cch nhit cho cc b c nung nng gim thiu tht thot nhit. Dng np y trong khi cc b khng hot ng. Thng thng, bng v cp ni c s dng gim thiu tht thot nhit v hi nc, v c th ch cn vi thng l hon vn. Cht ngn hi ho cht cng c th c dng trong mt s ng dng ngn nga tht thot do bay hi.
Mt nghin cu c tin hnh bi Vin Cng ngh cng nghp (1997), Australia, ch ra rng: Bng cch s dng cht chng bay hi, nng crm trong lp khng kh pha trn b m c th gim xung ch cn 0,9% so vi khi khng s dng. Tng t nh vy, ng dng ca bng poly (bng nha polypropylene c 1-3/8 inch) c th lm gim 13% nng kim loi trong khng kh so vi khi khng dng bng. Nghin cu
cng ch ra rng vic p dng ng thi c cht ngn bay hi v bng khng mang li li ch hn nhiu so vi vic p dng mt phng php n l.
3.3.4 Chng nhim bn dung dch m

S tch t cc cht nhim bn dn dn lm gim hiu qu ca cc dung dch m, v dn ti vic phi thi loi cc dung dch ny. S tch t cc cht nhim bn, nh b xyanua b nhim cacbonat, cng lm tng 50% lng dung dch dnh theo vt m v n lm tng snh ca dung dch. Hin c mt s cng ngh hiu chnh n gin c th ko di tui th ca dung dch cc b bng cch loi b cc cht nhim bn. Lc: Hin c cc h thng lc gn trong hoc ngoi cc thng cha, v cc thit b nh hn thch hp vi cc doanh nghip quy m nh. Chit xut kim loi t dung dch bng quy trnh in ho: Vic chit xut kim loi t cc dung dch bng cc quy trnh in ho cho php loi b cc cht bn kim loi khng mong mun v ch cn li cc kim loi mong mun trong dung dch m, c th thy r nht ng dng ca phng php ny trong vic loi b ng khi cc b m km v nickel. Khi hm lng ng qu cao, mt thanh kim loi c t trong b v cho mt dng in nh chy qua. in p thp, ng s bm vo b mt kim loi, cn phn ln cc cht ph gia trong b khng nh hng. Mc d mt s kim loi m (km, nickel) b loi b, nhng khon tit kim t vic ko di tui th ca b s b p li nhng hao ht ny. S dng nc chng ct hoc nc kh ion ho: Vic s dng nc chng ct hoc nc kh ion ho thay v nc my b cho lng mt i ca cc b m kim loi s lm gim s tch t cc cht gy nhim bn cc dung dch, gim lng bn cn v gim lng dung dch dnh theo vt m ra ngoi. Nc my cha cc cht gy nhim bn nh canxi, st, magie, mangan, clo, cacbon, v photpho, do vic s dng nc chng ct hay nc kh ion ho s loi b s xm nhp ca cc cht gy nhim bn ny. Khuy trn c hc thay cho sc kh: Bin php sc kh c khuynh hng lm tng cht nhim bn nh du t my nn v cacbonic vo cc b v v th khuy trn c hc c l thch hp hn. Tuy nhin, nu s dng khng kh, cn phi m bo khng kh c lc loi b cc cht gy nhim.
3.4 Gim lng dung dch dnh theo vt m

Dung dch dnh theo vt m, l lng dung dch theo ra t b x l ti b ra, v l ngun gy nhim nc ra trong quy trnh hon tt kim loi. Gim lng dung dch dnh theo vt m c th gp phn: Gim s nhim bn v v vy, lm tng tui th ca nc ra; Ko di tui th cc b x l; Gim nhu cu cp nc v ho cht mi; v Gim chi ph x l loi b cc cht nhim c hi hoc trong phm vi qun l ca lut php trc khi nc c ti s dng hoc thi b.
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Nhiu doanh nghip m kim loi lo ngi rng vic thay i lm gim lng dung dch dnh theo vt m, nh tng thi gian treo ro trn b, s nh hng ti nng sut sn phm. Tuy nhin, nguyn nhn dn n cc cuc tranh lun ny l do cc doanh nghip cha xem xt n s lng ph ca vic tiu hao dung dch x l v khon chi ph dnh cho vic x l. Phn ny a ra cc kin nhm lm gim lng dung dch dnh theo vt m.
3.4.1 Thi gian nhc chi tit ra khi thng m v treo ro

Khi nhc cc chi tit ra khi b cng nhanh th lp dung dch bm trn chi tit cng dy v lng dung dch theo ra cng vt m cng ln hn. Tng t nh vy, thi gian treo ro cng nhanh th cng c nhiu dung dch theo ra cng vt m sang b ra. Vic nhc chi tit ra khi thng m c ngha rt ln, chnh v th trong hu ht cc trng hp ngi ta dng cc gi treo nhc vt m ra khi b v n nh thi gian cn thit treo trn b lm ro. Mt s nghin cu chng minh rng khi tng thi gian treo ro sau khi nhc cc chi tit ra khi b m th lng dung dch dnh theo vt m c th gim i ng k. Mt th nghim M ch ra rng khong thi gian treo ro t nht 10 giy c th gim hn 40% lng dung dch dnh theo vt m, nu so snh vi cng ngh x l treo ro 3 giy thng thng. Mt th nghim Hng Kng cho thy thi gian thot nc di hn 15 n 20 giy c th gim gim 75% lng dung dch dnh theo vt m m khng h nh hng n cht lng v s lng sn phm (Phng cng nghip Hng Kng, 1995).
Bin php ny khi p dng s khng gy nh hng g n tin sn xut bi quy trnh lm sch khng phi l nhn t mang ngha quyt nh i vi c quy trnh. Bng cch phn tch ton b quy trnh v xc nh yu t no l quan trng, th c th gim thi gian hot ng ca cc quy trnh khc ti a ha thi gian treo ro.
3.4.2 nh hng sn phm v cc gi treo

C th lm tng thi gian lm ro vt m m khng cn phi tng thi gian lm vic ca cng nhn bng cch s dng cc gi treo v cc quy trnh ra sch t ng. Nhng h thng ny c th lm tng nng sut lao ng v v th cc xng m c th m ng khi lng cng vic ln hn. Cc chi tit khi c treo ln gi s t ro. Cc chi tit nn c xp sao cho cht lng c th thot nhanh nht tr li b m, hn ch ti a lng ko theo sang b khc. Xp nghing cc chi tit s gip trnh hin tng to cc ti ng ho cht v khng nn xp cc chi tit ny ngay trn chi tit kia. Nu c th c th khi nhc cc chi tit ra khi b m, quay trn cc chi tit gim lng dung dch bm qu nhiu trn b mt.
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3.4.3 iu chnh sn phm

Nhng thay i nh trn sn phm c th lm gim lng dung dch dnh theo vt m. Thng thng ngi ta gia cng thm cc l ln cc chi tit thun tin cho vic treo chng ln gi. Nhng l ny cn phi v tr thun li cho vic thot dung dch m khng lm nh hng n cu trc tng th ca cc chi tit. Ta cng c th to ra cc l loi b cc h trn b mt m dung dch thng hay ng li. Cc bin php ny c th gip cho thi gian lm ro dung dch ngn hn. C rt nhiu yu t lin quan n cu trc ca vt m lm tng kh nng dung dch b dnh theo, nh cc mi hn ni/gp. Chng to thnh cc khe, l nh v dung dch b ht vo do lc mao dn. Khi gim s lng cc chi tit lp rp v dng cc mi hn ni 2 u th c th lm gim nh hng ny.
3.4.4 Tm thu dch v khay hng

Tm thu dch (xem hnh) c s dng rng ri trong nghnh cng nghip hon tt kim loi thu hi dung dch m. Nhng tm ny c treo gia cc b x l v c lm bng nha, hoc thp phng hay m teflon. Dung dch nh xung tm ny v quay tr li cc b x l tng ng. t mt tm bn trn ming ca 2 thng lin k hng dung dch dnh theo vt m. Nghing tm bn ny v pha thng th nht (vic ny gip cho dung dch khng b ri ra sn v ng cng). Vt m
Vt m
Tm thu dch
B x l
B x l
Hnh 9: Tm thu dch
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3.4.5 Cc cht thm t

Cc cht hot ng b mt v cc cht thm t khc c th lm gim 50% lng dung dch dnh theo vt m, bng cch lm gim sc cng b mt ca dung dch (Cng ty t vn Hagler Bailey). Tuy nhin, cc cht thm t c th to ra bt v c th khng ph hp vi cc h thng x l nc thi. Do , cn phi lm th nghim xc nh cc cht thm t no l thch hp nht.
3.4.6
Dao kh
Thi kh vo b mt ca chi tit khi chng c nhc ra khi b m hoc b lm sch, y cht lng tr li b. Trong mt s ng dng, phng php lm kh nhanh ny c th nh hng n cht lng sn phm.
3.4.7 Tr li dung dch dnh theo vt m v b m

Trc tip tr li dung dch dnh theo vt m v cc b m l dng thu hi kim loi n gin nht v c thc hin rng ri trong ngnh cng nghip. Thng u tin sau thng m l thng hng dung dch dnh theo vt m hoc ra tnh v thng ny hng phn ln lng dung dch tha bm theo vt m. Lng dung dch c hng li ny s dng b sung cho b m b li cho phn tht thot do bay hi. Ging nh vn tch t cht bn c ni phn trc, lng dung dch thu hi c thng nhiu hn lng dung dch cn b p cho tht thot do bay hi trong thng m, v v th cn phi thng m hot ng nhit cao hn iu tit tt c cc dung dch dnh theo vt m. Hoc cng c th dng cc bin php kch thch bay hi hn ch vn ny.
3.5 Ci tin cng ngh ra

H thng ra tt nht l h thng va t c hiu sut cao nht va s dng t nc nht. Trc nay ngnh ny vn s dng nc mt cch thoi mi nhm t c hiu qu ra tt. Tuy nhin, c nhiu cch ra tt m li s dng t nc hn rt nhiu. Bng cch gim thiu lng nc ra, bn c th tit kim 2 kha cnh. Th nht l tit kim tin mua nc, v th hai bn tit kim c chi ph trong khu x l v thi b. Phn ny m t cc cch s dng nc t hn trong khu ra nhng vn c th duy tr c hiu qu ra tt.
3.5.1 Khuy trn

V a phn cc nh my s dng gi treo vn hnh bng tay, v th c th khuy trn bng cch di chuyn cc gi treo ny bng tay. Vic ra sch s hiu qu hn nu cc vt m c nng v h xung hn l khuy khi chng ang c ngm. Nhng 2 ln trong cng mt b c th gim lng dung dch ko theo vt m hiu qu hn gp 16 ln so vi nhng 1 ln.
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Vic sc kh nn thng khng phi l mt cch lm hiu qu, v thng ty ht khng kh c trong dung dch. My khuy Vortex bng s tun hon khp kn ca dng bn t thng ra thng rt hiu qu, nhng hiu qu khuy cao nht ch c th t c khi s dng cc my khuy chuyn bit.
3.5.2 Ra xt v phun sng

Vic ra sch bng cch phun xt s s dng mt vi phun phun nc ra ln vt m khi chng va c mang ra t b x l. y l cch thch hp nht ra cc tm phng, tuy nhin c th s dng kt hp vi vic ra ngm i vi cc vt c hnh dng c bit. i vi cc b c gia nhit, c th sp xp cc vi phun theo c v t l dng nc c iu chnh nh nc phun s lm cn bng lng tht thot bay hi. Cc b sng v phun sng l mt bin i trong cch ra bng cch phun, kt hp s phun nc vi p sut kh to ra lp sng m ca nc. Lp sng m thu ho cht v dn chng quay li bn x l. Cc b phun hoc b sng thng c s dng trong nhng trng hp m nc sng c th lml ong dung dch x l ngoi mong mun. V hiu qu ra, ra phun ch c hiu qu bng mt na so vi ra nhng, nhng li ch tiu tn khong t 1/8 n 1/4 lng nc so vi phng php ny.
Vt m
Vt m
B sng
Phun sng
B x l
B x l
Hnh 10: B sng v phun sng
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3.5.3 Ra ng v tnh
Mt s nh my nh ch s dng mt s lng t cc bn ra nh tnh (nc t) c th t c hiu qu ra tng i. Tuy nhin, i vi cc nh my c s lng vt liu sn xut cao hn, th s dng cch sc ra ng thng ph bin hn; mt lng nc c nh thng xuyn c cung cp ti thng ra h thp nng cht bn. Nu ch s dng mt b ra ng th cn mt lng nc ln t c hiu qu ra cao. C th gim vic s dng nc bng cch lp t mt hoc vi b ra tnh trc b ra ng. C th tham kho hnh di.
Vt m
Vt m
B x l
B cha dung dch dnh theo vt m tnh Dng nc
B ra ng
Dng nc
Hnh 11: Lm sch ng v tnh
3.5.4 Ra ngc dng

Ra ngc dng c th lm gim nhu cu nc sch bng cch chuyn dung dch bm vo vt v li b x l. Nc sch c cho vo thng ra cui cng v chy trn tr li qua cc thng sc ra ang hot ng cho ti khi ti thng ra c t ngay sau thng m. Thng th dng nc trn t thng ra u tin s c thi ra h thng x l hay h thng thot nc. Tuy nhin, nu thng x l hot ng nhit cao cho vic bay hi, th dng nc trn c th i vo thng x l, bng cch c th ti s dng c nhiu dung dch dnh trn vt m. Vic chy trn vo thng x l ch c ch khi qu trnh ra c s dng nc kh oxi ho. Mt h thng lm sch ngc dng nhiu giai on s dng t hn ti 90% nc ra so vi mt h thng lm sch thng thng (m t nh hnh 12)
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Vt m
Vt m
B x l
B ra 1
B ra 2
B ra 3
Nc thi
Nc ra thi
Hnh 12: Ra ngc dng
3.5.5 Kim sot dng nc

Cch d nht v n gin nht kim sot dng nc l kho nc chy n cc b ra khi khng s dng chng. Tuy nhin, vic ny c th hi phc tp, v th tt nht l trang b mt h thng khng da trn hot ng ca con ngi. Cc b hn ch dng chy ni tip (in-line flow restrictors) n gin c th gii hn ch t l dng chy, v c gi rt r (khong US$10.-). Tuy nhin, v khng th iu chnh c b hn ch nn chng c th khng thch hp cho mt s xng m ni m cc sn phm cn m rt a dng v u c nhng yu cu khc nhau v t l dng chy. Nhng quy trnh yu cu dng bin thin, c th s dng cc h thng o lng t ng kim sot dng chy vi chnh xc hp l. Vic ny c th hot ng hoc da trn dng t trc i vi cc hot ng chi tit hoc kim sot dng chy s dng cc b cm bin dn in. Cc b cm bin dn in o nng cht bn trong nc ra v iu chnh dng ph hp; dn in cng cao th dng chy cng cao.
3.5.6 Trnh nhu cu ra

C th b qua bc ra gia b ra ngm v b ra in phn nu c hai b tng thch.
3.6 Cc k thut ti s dng nc ra v thu hi kim loi

Khi nim v mt h thng khng dng thi ang ngy cng tr thnh mt la chn kh thi i vi ngnh cng nghip. iu ny c c da trn l thuyt rng nc v kim loi cha trong nc thi c th c khi phc v ti s dng trong qu trnh. V chi ph cho vic x l v thi b cht thi ngy cng t , nn chc chn s n lc vic x l v ti s dng nc thi s tit kim hn l x l v loi b chng.
Nc thi c x l c th c ti s dng cho cc qu trnh ph tr nh ra, lm sch, b ty g hay v sinh sn xng. n 90% lng nc s dng trong m in u s dng cho cc hot ng ra, v th li ch t vic ti s dng ngun ti nguyn ny l rt r rng. Mt s k thut c ch ra trong phn ny cng cho php kim loi c ti ch t dng thi. Tuy nhin, vic ti ch kim loi c th mu thun vi cc n lc gim ngun nguyn liu. Th nht, mc ch ca vic gim ngun l lm gim nng dung dch dnh li trn vt m, tuy nhin nhiu cng ngh thu hi kim loi hot ng tt nht khi nng dung dch cao. Th hai, cng ngh ti ch kim loi li sinh ra cc cht thi khc nh cc b lc, mng, catot v nha thng qua s dng. Do , cc doanh nghip nn xem xt cn thn tnh kh thi k thut, cc tc ng mi trng v cht lng trc khi u t vo h thng ti ch. Chng c th ch tng thch vi cc lung rc thi m cn chi ph cao loi b hay thay th. Vic x l v ti ch cht thi thu hi nc hoc kim loi thng yu cu vn u t trong h thng x l nh nhng g c ch ra trong phn ny. Cc dng cng ngh ti ch ang c s dng M cho mc ch ny c ch ra trong bng sau: Bng 11: Cng ngh ti ch c s dng M Cng ngh ti ch Trao i Ion Thit b bay hi trong khng kh Khai thc in Thit b bay hi chn khng Thm thu ngc in thm tch % doanh nghip s dng
3.6.1 Thu hi kim loi bng phng php in phn

Thu hi kim loi bng phng php in phn gi kim loi trong dung dch bng cch m chng trn mt tm kim loi mng lm bng loi kim loi s c khi phc hoc mt khong trng thp khng g, ng vai tr nh mt catt trong thng. Sn phm ca qu trnh ny l mt tm kim loi cng, n c th c khi phc v ti s dng nh mt ant trong thng m. K thut ny yu cu s phn lung nc thi ca cc bc ra ngn s nhim bn ca ant vi cc kim loi khc nhau.
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3.6.2 Thm thu ngc

S thm thu ngc l vic cho dng cht lng s dng i qua mt mng ngn khng thm phn ln mui ho tan, s dng p sut cao. Cc li ch ca n bao gm kh nng x l cc dung dch long, nc thi thch hp cho vic ti s dng trong khi nhu cu s dng nng lng li thp hn cc h thng bay hi. Nc c lm sch c th c s dng li cc qu trnh ra v mui kim loi c ti ch b sung vo cc b m. Thng thng, phng php ny c s dng tinh ch nc thi ra t cc b axit nickel. Phng php ny khng thch hp cho cc dung dch c tnh oxi ho cao, nh axit crm, v nu cha cc cht hu c hin hu th dch s phi c i qua b lc than hot tnh. Chi ph vn trung bnh khong 30.000 la v chi ph hot ng hng nm khong 1/3 chi ph vn.
3.6.3 Trao i Ion

S trao i Ion loi b c kim loi in tch m v dng cng nh ion ho cht ra khi dung dch bng cch a nc thi ra qua cc lp nha. Khi cc lp nha ny bo ha, cc kim loi s c thu hi trong dung dch c v nha thng c hon nguyn ti s dng. S bt li khi s dng cng ngh ny l: y l qu trnh phc tp yu cu hot ng v bo dng cn thn, nc thi phi c phn lung thu hi kim loi, v pht sinh thm lng nc thi b sung t qu trnh hon nguyn v ra. Chi ph vn c th t 5.000 la n 500.000 la v chi ph hot ng hng nm khong t 25% n 50% chi ph vn.
3.6.4 in thm tch

in thm tch l mt qu trnh x l mng, trong , nc thi i xuyn qua h thng mng chn lc ion, h thng ny s loi b c ion m v dng. in thm tch c th t c nng cao hn bin php thm thu ngc hoc trao i ion, tuy nhin phng php ny li khi phc c cc tp cht v khng th khi phc mt vi cht quan trng khc c trong dch x l nh cc tc nhn lm sng v cht ph gia. Chi ph vn c th t 10.000 la n 50.000 la vi chi ph hot ng t 15% n 30% vn u t.
3.7 Cc quy trnh khc

Phn ny s cung cp mt s v d v cc k thut khc - l phng php ty chn cho cc quy trnh hon tt kim loi v c th gim ng k chi ph x l cht thi.
3.7.1 H thng m khng xyanua

Xyanua c s dng rng ri trong ngnh cng nghip m nhng do hm lng c cao nn nc thi c cha xyanua cn phi c x l thm mt khu oxi ha xyanua.V vy, chuyn i sang h thng khng xyanua c th tit kim c chi ph khong 10% nh tit kim c khu x l nc thi.
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M thic l phng php thnh cng nht trong vic thay th xyanua thng qua vic s dng dung dch km clorua v h thng kim km. B (axt) km clorua ngy cng c a chung trong ngnh cng nghip. Ngoi li ch tit kim chi ph x l nc thi th dung dch ny cn c u im l hiu qu hot ng cao hn, c b ngoi p v sng bng, tit kim nng lng ng k thng qua vic tng nng sut v t gin hydro hn. chu c trong iu kin axt, cc b thp truyn thng cn c thay th, tuy nhin chi ph ph thm s c b nh cc khon tit kim t vic gim chi ph x l cht thi v ri ro v an ton lao ng. H thng kim km l h thng r nht trong cc b m km, c th c s dng trong cc b thp truyn thng v cng c th to ra sng bng tt. H thng ny khng chu c s thay i trong cc iu kin vn hnh v nu vn hnh bn ngoi nhng tiu chun ca hot ng th hiu sut v cht lng c th s b nh hng. Tuy nhin, h thng kim km chng t tnh kh thi hn trong hai h thng khng xyanua bi n c th c p dng ngay trn cc b c trc . Cc cng ngh thay th cc h thng xyanua khc nh ng , ng thau, vng v bc nhng khng hiu qu bng vic dng xyanua km. Thay th gii php xyanua bng gii php khng xyanua yu cu cc k thut lm sch, ty sch du m do cc gii php khng xyanua i hi b mt lau sch k lng t c cht lng m cao. Tuy nhin, h thng khng xyanua dn c chp nhn ngay sau khi c gii thiu ln u tin.
3.7.2 Thay th Crm+6 bng Crm+3 trong quy trnh m Crm

S dng Crm+3 thay cho Crm+6 mang li mt s thun li sau: Gim s c hi i vi sc khe khi tip xc vi Crm+6. t lng cn trong cc b m Gim bc chuyn ha Crm+6 sang Crm+3 trong qu trnh x l nc thi. Gim lng dung dch dnh theo ra v dung dch t dnh hn so vi Crm+6 v nng dung dch thp hn, v Crm+3 s dng cng nhng thit b vi Crm+6 nn rt d thay th.
dy ti a ca lp m Crm+3 l 0,003 mm; nu m dy hn s d lm xut hin vt nt v gim cht lng sn phm. V vy, k thut ny thng khng ph hp vi m Crm cng c yu cu v dy t 0,508 mm tr ln. M, qu trnh thay Crm+3 bng crm ha tr ba rt chm do cht lng m c cho l km hn so vi s dng Crm+6. Cc cng ty sn xut t i hi lp gia cng bng, cht lng cao m ch c Crm+6 c th p ng. Tuy nhin trong nhng ng dng khng i hi qu cao v cht lng, c th s dng crm+3 thay th.
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Tng mu ca lp m Crm+3 s khc so vi Crm+6. Tuy nhin, c th s dng mt vi cht ph gia thm vo dung dch Crm+6 iu chnh c tng mu theo yu cu.
3.7.3 Gia tng tui th b m khng in

M khng s dng in l mt dng m m khng trc tip s dng dng in m kim loi, thay vo l s dng chnh lch in th ca kim loi. Vn ln nht ca qu trnh ny l dung dch trong b s b nhim bn do cc sn phm ph ca phn ng ha hc. Sn phm ph pht sinh trong qu trnh m s lm gim hiu sut dung dch. Khi dung dch khng cn hiu qu thng th s c loi b i v thay th bng dung dch mi. Di gc ca SXSH, hnh thc m ny khng phi l gii php thay th hng u v tui th ca b khng cao v cc dung dch qua s dng cn phi c x l. Tuy nhin, trong mt vi trng hp, qu trnh ny c th c ci thin bng cch tng tui th dung dch nh thm cht ha hc, thng thng l cc cht kh nh hypophotphat. Cc cht kh s lm cho b dao ng, khin cht bn pht sinh s c bn ra, thng th trn bng thp. Qu trnh ny s lm tng tui th ca b gp mi ln v gim lng cht thi to ra ti 90%.
3.8 Cng ngh mi

Phn ny s cung cp nhng thng tin v cc cng ngh sch c tm thy trong cc ti liu, ch yu t M. Mc d nhng cng ngh ny cha xut hin trong i sng thc tin nhng chng mang nhng c im c tnh kh thi v v vy ng c xem xt n. Cng ngh sch l cc quy trnh hay cng ngh sn xut m gim thiu c s nhim hay cht thi, tiu hao nng lng hay s dng ngun nguyn liu khi so snh vi cc cng ngh khc.
3.8.1 Ant ha axt Boric/Sulphuric (SBAA)

Quy trnh SBAA l phng php thay th trc tip cho qu trnh Ant ha axt Crm s dng trn nhng quy trnh sn xut nhm. Qu trnh SBAA cn c b Ant ha axt Boric v b cht hn crm cc chi tit s c nhng vo sau qu trnh SBAA. Nc ra vn cn cha kim loi v axt cn phi c tin x l nhng khi lng crm cn x l th thp hn nhiu so vi cc phng php thng thng. Do vy, SBAA gip gim ng k qu trnh x l axit crm cng nh gim kh c thi ra t lp m. Chi ph hot ng SBAA bng vi chi ph hot ng m crm. M, vic gim mc crm cho php c hy vng s lm cho SBAA tr thnh s thay th hng u i vi qu trnh oxit ha ant thng thng trong vng 5-15 nm ti (USAEP).
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3.8.2 Cng ngh in thm tch cho dung dch x l

in thm tch l mt qu trnh duy tr nng ion kim loi thp trong dung dch b ant ha bng vic vn chuyn ion kim loi bng dng in v ht chng khi chng thnh lp bn c. V d khi ant ha nhm th dung dch b phi c thay v thi b khi nng nhm t mc 80-100 gram/lt. Cng ngh thm tch bng in c th gip tng rt nhiu tui th ca dung dch b oxit ha ant v cho php thu hi v ti s dng kim loi. Ngoi ra, iu chnh nng ion kim loi trong dung dch ant ha s ci thin cht lng sn phm. Lp cn s c ly b ra v catt s c thay i da trn nguyn l c bn m bo qu trnh tch b kim loi t hiu qu. Ti M, cha c nhiu cng ty s dng cng ngh ny do chi ph vn qu cao, ng thi vic tm ra c mt cng ty thu hi v ti s dng kim loi t cn x l rt kh. Khi chi ph x l tng th bin php thm tch bng in s chng t tnh kh thi v mt kinh t (USAEP).
3.8.3 High Velocity Oxy-Fuel (HVOF) Thermal Spray

Cng ngh phun nhit oxy-nhin liu tc ln (HVOF) l qu trnh sy kh nhm to ra lp m kim loi c. Cng ngh ny s dng hn hp nhin liu/oxy trong khoang t, y bt kim loi s c nu chy v c np vo sng phun s dng kh ga lun chuyn v c y i vi tc cao ti thit b c m. Bt kim loi l hp cht bao gm nickel, cacbua crm, cacbua vnfram. dy lp m c th t c ln n 0,25 inch. Qu trnh ny to ra mt lp m kim loi dy m c tnh k thut tng ng hoc vt qu c c tnh ca lp m c m bng phng php crm cng s dng crm ha tr su. Dng nc thi duy nht c to ra l sn phun li, v hin nay vn ny c th c khc phc bng cch s dng h thng lc mn ngn nc hoc my lc khng kh chuyn bit. Do sn phun li ch cha hp kim hoc kim loi nguyn cht nn c th ti ch cc loi kim loi v hp kim ny thnh nguyn liu th. M, HVOF ang dn c chp nhn v thi gian thu hi vn t 2 n 4 nm, ty thuc vo quy m hot ng (USAEP).
3.8.4 Qu trnh kt t hi ion (Ion Vapour Deposition (IVD)

IVD l mt qu trnh bay hi dn dn to nn mt lp mng mng trn b mt kim loi, v c th thay th qu trnh m in. Phng php ny rt ph hp cho vic to lp ph trang tr hoc cho cc dng c.
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Li ch chnh ca cng ngh ny khi thay th quy trnh m in l n gn nh khng cn n nc ra. Tuy nhin c mt hn ch l lp m khng thc s tt cho cc b phn cn bi trn. V do phng php ny khng phi l s la chn tt cho cc g kp hay nh v. Ngoi ra, nhng ng dng lin quan n m cc vt th c hnh vnh khn cng rt hn ch. Mc d c nhiu hn ch nh vy nhng cng ngh IVD vn c mong i l s tip tc thay th cc quy trnh m nc M (USAEP).
3.8.5 Thu hi bng in phn ti ch xyanua kim loi

Nc thi to ra t qu trnh ra cc b phn m xyanua c cha cc kim loi v hp cht c xyanua. Cc dng nc thi ny yu cu cn phi c qu trnh tin x l trc khi thi ra ngoi c bit l khi c cha cc ha cht c hi nh axit, kim, cc ha cht c cha clo. Cng ngh khi phc in phn s dng dng in m kim loi v oxy ha cht xyanua trong nc ra. Kim loi s c thu hi t bnh phc hi in phn v l kim loi c th quay tr li b xyanua nh l ngun ant v ch mt phn xyanua c oxy ha thnh xyanit. Cc h thng ny c th thu hi c hn 90% ion kim loi v oxy ha khong 50% lng xianua. Do cc h thng ny hot ng theo ch cch t v t i hi phi thay i quy trnh v giai on thu hi vn c tnh l khong 2 nm nu nh quy trnh hot ng to ra 1.000 kilo lit mt nm. Qu trnh thu hi in phn ch c th thc hin c i vi cc loi nc thi c hm lng kim loi cao, v hiu qu kh s gim khi hm lng gim. in hnh l cng ngh ny khng c s dng rng ri trong cng nghip M nhng li rt c a chung trong vic thu hi cc kim loi c gi tr (bc v vng). Bng 13 di cho thy tng v Cng ngh sch hn hin c cho ngnh gia cng tinh kim loi trn khp th gii.
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Bng 13: Li ch do cc cng ngh sch mang li Li ch M ng khng xyanua V mt phng nga nhim: Thay th xyanua Thay th kim loi c hi Loi tr/gim nc thi Loi tr cht hu c c hi V mt vn hnh: Gim s bc quy trnh C kh nng t ng ha V mt kinh t: Chi ph vn tng i thp Chi ph vn hnh tng i thp Yu cu v mc k nng vn hnh tng i thp Bc lp m khng xyanua Cng ngh sch hn hin c M in km/ hp kim km Cng ngh Blackhole Kt t hi ion Kt t hi vt l X l b mt nhm khng crm Ph bng phun kim loi Cng ngh sch hn ang pht trin Cacbua NickelWolframSilicon NickelWolframBo M In-mold
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3.9 Tng lai ca ngnh cng nghip hon tt kim loi

Cng ging nh cc nc pht trin, Vit Nam s tip tc c nhng bin php qun l mi trng cht ch hn. Vic pht trin v ng dng nhng cng ngh sch mi v mang tnh i mi l mt iu tin quyt m bo nn cng nghip s khng to nn nhng p lc qu cho php i vi mi trng. Ti M, vn v mi trng lun l yu t c u tin hng u khi tin hnh nghin cu v pht trin cng nghip. Cc nh cung cp nguyn liu ang hng ti nhng cng ngh thay th mi. Cc cht thay th cho xyanua, caimi, v crm+6 ang thu ht rt nhiu s ch t cc doanh nghip. Cc ti liu M cng on nh c trc nhng khuynh hng pht trin mi ca cng ngh snh trong tng lai gn v c tng lai xa. Khuynh hng trong tng lai gn: S pht trin ca sn tnh in Trong nhng nm sp ti, sn tnh in s tr thnh mt cng ngh ph bin trong ngnh hon tt kim loi. Cng ngh ny ang ngy cng ln sn th trng sn nc v cng dn chim c th trng sn trang tr. Nhng ci tin ca sn tnh in v h thng phn phi m ra nhng ng dng mi. S a chung ca sn tnh in l do nhng u im v vic hn ch pht thi v cc hp cht hu c d bay hi VOC cng vi hiu sut s dng nguyn liu vt tri. Khuynh hng trung hn: S bng n cng ngh kt t hi ha hc v vt l Cng ngh kt t hi l quy trnh hon tt kh trong m kim loi. C nhng cng ngh chuyn ha cc kim loi sang dng hi t c lp m kim loi cng cho mt vi chi tit quan trng trong quy trnh. Nhng cng ngh ny hin ti ch th c p dng trong nhng ng dng cng ngh cao, chuyn bit. Tuy nhin, s pht trin trong tng lai v nhng yu cu v sn phm cht lng cao hn chc chn s mang li tim nng cho nhng cng ngh to ra v cng t dng thi ny. Khuynh hng di hn: Cng ngh th h tip theo Nhng ci tin trong ngnh cng ngh vt liu mt ngy no s a n mt nn cng nghip hon tt kim loi hon ton mi, hoc lm gim nhu cu v ngnh ny do ng dng ca nhng vt liu thay th. Bn cng ngh ni bt cho khuynh hng di hn l: Cc b dung dch khng cha nc (v d nh cn) Lin kt vt l, trong cc kim loi c kt t bng cc phng php vt l, ch khng phi cc phng php c in Cng ngh nano s dng cng ngh laser nh v kim loi trn b mt Cc vt liu thay th nh gm hay nha, hn ch c nhng nhu cu v hon tt kim loi.
Ti liu hng dn Sn xut sch hn ngnh hon tt sn phm kim loi
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Phng php lun 6 bc nh gi SXSH

Chng ny gii thiu chi tit cch thc tip cn tng bc tin hnh nh gi sn xut sch hn ti mt nh my hon tt sn phm kim loi. Cc phiu cng tc s c cung cp ti cui mi nhim v nhm h tr cho vic thu thp, phn tch v bin son d liu. Mc d cc phiu cng tc ny c thit k ring cho cc nh my hon tt sn phm kim loi, nhng vn cha th st vi tng iu kin ca tng doanh nghip c th, v v th tu thuc vo quy trnh v sn phm khc nhau cn iu chnh cho ph hp. Bn cnh cc phiu cng tc, chng ny cn cung cp v d c th v mt nh my x l hon tt sn phm kim loi. V d ny c xy dng da trn nghin cu nh gi SXSH c thc hin ti cc nh my khc nhau Vit Nam. Km theo nhng v d, chng ny cng a ra nhng nhn xt v s tho ng ca cc d liu v phn tch tin hnh. Cc nhn xt ny s gip ch cho c gi khi thu thp v phn tch d liu cho cc nh gi SXSH tng lai.
L thuyt c bn sau mi nh gi SXSH (CPA) l bt k vt cht no i vo mt nh my th s i ra di dng ny hoc dng khc; Tuy nhin, gi nh cn bn c a ra l nguyn liu c d tr s khng tri qua bt c s thay i no v dng v v cht. Thc hin CPA gip pht hin ra ngun pht thi trong quy trnh t c th hn ch cc nguyn nhn v ng thi cht lng sn phm c th cng c nng cao. SXSH ti mt nh my hon tt sn phm kim loi cn c s tham gia ca tt c cc khu vc sn xut nh lit k Chng 1, v bt k khu vc no cng c tim nng gim thiu pht thi. Ngoi ra, cc gii php SXSH ca mi khu vc s c hiu ng lin i v tng h vi cc b phn khc. V th, iu quan trng l phi p dng phng php tip cn tng bc phi hp tt c cc b phn vi nhau v m bo thc hin SXSH. Phng php tip cn cn phi c s linh hot cn thit thch ng vi nhng tnh hung bt ng. Phng php tip cn ny cng m bo vic khai thc ti a nhng c hi SXSH. Chng ny s lun bn v mt tip cn c trng c th nghim v kim chng nhiu ngnh cng nghip ti Vit Nam.
X nghip C kh Bnh Minh, trc thuc y ban Nhn dn thnh ph Thi Bnh, thc hin cc nghin cu SXSH nm 2004. Sn xut n nh vi cc dng sn phm m chnh l cc ai chi sn, khung con ln sn, ng lt v kha mc xut khu v cc ph tng xe my cho Honda Vit Nam. X nghip c 200 cn b cng nhn vin hot ng vi 2 phn xng c kh v m.
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4.1 Bc 1: Khi ng
4.1.1 Nhim v 1: Thnh lp nhm
CPA s t c hiu qu cao nht khi c thc hin theo nhm. V th vic thnh lp nhm l mt phn quan trng khi ln k hoch trin khai CPA. Nhm s gm cc thnh vin l nhn vin ca doanh nghip, v c s h tr thm t trung tm sn xut sch hoc chuyn gia t vn trong nc khi cn. Cn phi ch to mi quan h cht ch gia cc thnh vin thng qua cc cuc hp nh k. Chn la thnh phn ca nhm l mt cng vic ht sc quan trng v nu lm khng tt th nhm c th gp phi nhng tr ngi t ni b v c t bn ngoi (v d t pha cc nhn vin v cng nhn ca doanh nghip).
Vi cc doanh nghip ln, mt nhm c th bao gm trong mt i nng ct (gm i din ca cc phng ban khc nhau) v mt s thnh phn cho tng nhim v c th. Vi cc doanh nghip va v nh, nhm c th ch gm ch doanh nghip v mt qun c - ngi gim st cc hot ng hng ngy. Nhm ny nn khi xng, iu phi v gim st cc hot ng CPA. cc nh my hon tt sn phm kim loi quy m ln, mt nhm c th gm 8-10 thnh vin, cn vi cc nh my nh th nhm c th ch cn t 4-6 thnh vin.
thc hin c hiu qu, v c bn, nhm phi c kin thc phn tch v r sot thc hnh sn xut hin ti ca doanh nghip. H cn phi c c sng to pht hin, xy dng v nh gi nhng ci tin trong thc hnh sn xut. Cui cng, h phi c nng lc trin khai nhng can thip kh thi v kinh t. mt nh my hon tt sn phm kim loi, nhm ny cn phi gm nhn s ca cc b phn: lnh o, k ton/cung ng, cc dy chuyn tin x l v m, cc khu vc ph tr, v bo dng. Ty vo nhu cu c th, nh my c th mi cc chuyn gia bn ngoi tham gia vo thnh phn ca nhm. Nhm SXSH trc ht cn phi ln k hoch cng vic v cc vn v t chc cn thit m bo s c cc d liu hoc cc thng tin cn thit trong nhiu giai on nh gi. n cui qu trnh nh gi, nhm cn phi thu thp c cc thng tin chung v nh my. Phiu cng tc 1 s h tr vic thu thp v tng hp thng tin.
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PHIU CNG TC 1: Thng tin chung

PHIU CNG TC 1
Tn v a ch cng ty NHM SXSH 1 2 3 4 5 6 7 8 Cc quy trnh chnh M in: Nickel Crm Thic Khc Ant ha Pht pht ha M nhng nng Sn tnh in Sn nc Khc Cc u vo s dng
3
Tn
Chc v
B phn
Thng tin c bn v cng ty v c im sn xut C/Khng Din tch m, m / nm

2
Lng Axit sunfuric Dung mi ty du m Mui Niken Mui Crm Km HCl Axit photphoric Sn Mui xyanua Khc
tn/nm
TI NGUYN N C V NNG L NG
Nc mua m /nm 3 Nc ging khoan m /nm in mua kwh/nm in pht kwh/nm t/nm Than t/nm Du t cho l hi t/nm Du t pht in
T H I T B PH TR
Cng sut danh nh Ni hi My nn Thit b sinh kh nng
64
HA CHT
PHIU CNG TC 1 (V d xuyn sut) Tn v a ch cng ty NHM SXSH 1 2 3 4 5 6 7 8 9 10 Quy trnh chnh M in Niken Crm Km-amon Khc Ant ha Photphat ha M nhng nng Sn tnh Sn nc Khc C/Khng C C C Din tch m, m 2 /nm Khng p dng (xem bng di) Sn phm ai chi sn Khung con ln sn tng Ph tng xe my Cn s xe my H v Tn
Th Ng o Duy Tng on Ngc Hng Ng Duy Chc Bi K Ln H Vn Hin Phm Cng Ng Phm Vn Phi H Vn Hin V B Du
X nghip C kh Bnh Minh, phng Tin Phong, th x Thi bnh, tnh Thi Bnh Chc v
Ph Gim c K thut Trng phng k hoch Ph phng ti v Trng phng k thut Qun c phn xng m Qun c phn xng c kh KT Ca m Ni-Cr KT Ca m Ni-Cr KT ca m Km-Amn Th in
Vai tr
i trng Thnh vin Thnh vin Thnh vin Thnh vin Thnh vin Thnh vin Thnh vin Thnh vin Thnh vin
Thng tin c bn v cng ty v sn xut (1999)
Khng Khng Khng Khng Khng Khng Cc u vo s dng

m3/nm m3/nm kwh/nm kwh/nm t/nm t/nm t/nm
NC V NNG LNG
CC THIT B PH TR
Cng sut danh nh Ni hi My nn Thit b sinh kh nng
Bng s liu tiu th u vo thp v ha cht Tiu th 6 thng u nm 2003 0,299 0.0027 0.0057 Tiu thu thng 8/2003 0,3 0.003 0.0052
STT 1 2
u vo Thp Ha cht - A-xt Sulphuric - Nickel sulphate ...
n v SP kg/sn phm kg/sn phm kg/sn phm
Tiu th nm 2002 0.3 0.0018 0.0049
NHN XT: Nhm c thnh lp cng ln th vic tng hp s liu v s phi hp gia cc thnh vin trong nhm nhng giai on tip theo s ngy cng kh khn. Hn th na vic tp hp y cc thnh vin trong cc cuc hp cng gp nhng kh khn nht nh.
HA CHT
Nc mua Nc gingkhoan in mua in pht Than Du t l hi Du pht in
S lng 2,385,000 khng p dng 8,735,500 khng p dng 8,211 1,065 khng p dng
Tn/nm Axit sunfuric Dung mi ty du m Mui Niken Mui Crm Km HCL Axit photphoric Sn Mui xyanua Khc
65
Do h thng h s ca nh my, s liu v sn phm ch c dng s sn phm tng loi m cha quy v din tch m/nm. Nn khi lp s liu nn v sut tiu hao u vo, i s phi bc tch s liu cho tng chng loi sn phm.
Mt s d liu ca nh my khng sn c, v th cc thnh vin ca nhm cn thu thp v in vo cc thng tin cn thiu. Mt nh gi SXSH s yu cu phi c mt lng ti liu v thng tin nht nh. Nu cha c nhng yu t ny th s phi xy dng v cp nht. Phiu cng tc 2 s gip nh gi mc sn c ca thng tin. PHIU CNG TC 2: Tnh sn c ca thng tin
THNG TIN S nh my Phiu theo di sn xut Phiu theo di s dng nguyn liu Phiu theo di s dng ti nguyn S m t quy trnh Cn bng vt liu Cn bng nng lng Cn bng nc H s ph phm v cht lng Phiu theo di bo dng Phn tch cht thi Cc thng tin khc Cn bng Niken Cn bng Crm Cn bng Km Cc kt qu kim tra hiu sut ni hi Kim tra r r kh nn Kho st cch nhit ng ng hi Hiu sut trm x l dng thi TNH SN C NGUN V CCH TIP CN GHI CH
66
Phiu cng tc 2: Tnh sn c ca thng tin (V d xuyn sut)

THNG TIN S nh my Phiu theo di sn xut Phiu theo di s dng C C C Khng c Khng c Khng c Khng c C Khng c nguyn liu Phiu theo di s dng ti nguyn S m t quy trnh Cn bng vt liu Cn bng nng lng Cn bng nc H s ph phm v cht lng Phiu theo di bo dng Phn tch cht thi TNH SN C Khng c C NGUN V TIP CN GHI CH C th v c
S thu thp t nhiu b phn khc nhau S thu thp t nhiu b phn khc nhau
Kh tng hp Kh tng hp
Nhn xt: D liu sn c rt khng khp nhau v v th hu ht d liu cn phi c thu thp. D liu cha c cn phi c cc thnh vin ca nhm tng hp.
4.1.2 Nhim v 2: Cc bc quy trnh & nhn din cc dng thi

Khi c thng tin chung v nh my, nhm SXSH phi lit k tt c cc bc chnh trong quy trnh chnh (v d m niken, m crm, sn tnh in, ...) v cc khu vc ph tr. Nhm SXSH cn phi tin hnh mt cuc kho st thc a. Kho st thc a l mt k thut n l hiu qu nht c c thng tin ban u v hot ng sn xut trong mt thi gian ngn. Nhm SXSH khng nn tin hnh kho st thc a khi ang dng sn xut (nh vo cui tun hay trong chu k sn xut t, hoc trong cc ca m). Nhm nn bt u kho st t khu vc tip nhn nguyn liu v kt thc b phn c lin quan n thnh phm. Kho st thc a cng cn phi tin hnh c cc khu vc ph tr nh ni hi, my pht in, b cha nhin liu, trm bm, cc trm lm lnh, trm x l nc th, trm x l nc thi, v.v Kho st thc a khng phi nhm mc ch tm ra li m l hiu thu o cc dng nguyn liu v nng lng, v pht kin cc tng nng cao hiu qu, tng li nhun v ci tin mi trng tng th. Tin hnh kho st thc a cng l mt c hi kt bn nhm c thm cc mi lin h v xy dng quan h hp tc tim nng trong tng lai. V vy, ngi thc hin khng c ph phn m phi t thi xy dng v a ra cc gi ci tin.
67
Nhm SXSH khi nghin cu ln u tin ti khu vc sn xut cn phi xc nh c u vo v u ra ca cc bc quy trnh. Cc khu vc pht thi ch yu v r rng cn phi c ghi chp li nh gi trong phiu cng tc 3. Vic ghi ch cc dng thi theo trng thi vt l ca chng (rn, lng, kh) s gip ch trong bc nh lng pht thi tip sau. Nu c th th nhm nn xc nh v ghi chp li nhng nguyn nhn pht sinh cht thi. Trong mt nh my x l hon tt kim loi, vic qun l ni vi km l mt trong nhng yu t chnh dn n pht thi mc cao. Tuy nhin, rt nhiu nh my, vn ny hu nh b lng qun. Ngoi ra, y cng chnh l bc khi u n gin v hp dn nht i vi SXSH. Trong khi tin hnh nghin cu ln u tin ti khu vc sn xut, nhm SXSH nn ht sc ch cc khu vc thc hin khng hu hiu cng tc qun l ni vi. Phiu cng tc 4 c th dng ghi chp li tnh trng qun l ni vi ca tng b phn. Mt s vn thng gp trong vn qun l ni vi cc nh my x l hon tt kim loi c th hin trong phiu cng tc ny. Tuy nhin ni dung ca phiu vn cha th coi l y v cn ph thuc vo tnh trng ca tng nh my v nhm SXSH cn phi da vo m xy dng thm m bo yu cu cng vic. Sau khi ghi chp li thc trng qun l ni vi, cc s liu v chi ph c bn cn phi c ghi chp li vo phiu cng tc 5. bc ny, ch cn thu thp thng tin v chi ph nguyn liu u vo l . y l nhng thng tin ny c th d dng thu c t cc kho hoc phng mua vt t.
68
PHIU CNG TC 3: Cc bc quy trnh chnh
Chi tit KL
in ...
Ct
kim loi vn bi
Nc
Ra
Nc thi
Vt liu mi in, ...
Mi
kim loi vn bi bi, khi mi
Xt, Nc
Trung ha
dch x l dng
Que hn in, ...
Hn
Nc
Ra
Nc thi
in Pht, ...
Lm bng c hc
bi, cht thi rn
in
Sy
Gi lau X phng, ...
Lau mn
bi, cht thi rn
Thnh phm
Ha cht, in, Nc, ... Nc
Ty du m
dch x l dng
Ra
Nc thi
Nc Axit
Ty r
dch x l dng
Nc
Ra
Nc thi
Niken, Nc Ha cht, in, ... Niken, Nc Ha cht, in, ...
M Niken bn bng
dch x l dng
M Niken bng
dch x l dng
Nc
Ra
Nc thi
DD CrO3, Nc Ha cht, in, ...
M Crm
dch x l dng
69
Phiu cng tc 3: Cc bc quy trnh vi dng thi (v d xuyn sut)

S dy chuyn m cn s xe my (Ni-Ni-Cr)
Chi tit KL
in Pht, ...
Lm bng
bi, cht thi rn
Nc
Ra 3
Nc thi
Gi lau X phng
Lau mn
bi, cht thi rn
Nc
Ra 4
Nc thi
Xt, Nc Ha cht, in, Nc Nc
B ch
Nc thi
DD CrO3, Nc Ha cht, in, ...
M Crm
Ty du m
dch x l dng
Nc
Ra thu hi 5
m dung dch, dch m dng, ri vi dch cha crm tun hon
Ra 1
Nc thi
Nc
Ra 6
Nc thi
Nc H2SO4
Ty nh
dch x l dng
Xt, Nc
Trung ha
dch x l dng
Nc
Ra 2
Nc thi Nc
Ra 7
Nc thi
Niken KL, Nc Ha cht, in Niken, Nc Ha cht, in, ...
M Niken bn bng
dung dch m dng, ri vi dung dch m dng, ri vi
Nc
Ra 8
Nc thi
M Niken bng
in
Sy
Thnh phm
Nhn xt: Trong thc t, ti giai on ny, nhm SXSH xc nh rng dy chuyn m cn s xe my s l trong tm nh gi ti thi im do c y l dng sn phm c gi tr cao, tiu th nguyn vt liu t tin, c cc loi cht thi c hi. V th, t bc ny tr i, nhm SXSH ch tin hnh cc nh gi SXSH i vi dy chuyn m Ni-N-Cr cho sn phm cn s xe my. Tuy nhin, vn qun l ni vi c xc nh cho ton nh my. y cng chnh l s dng trong v d xuyn sut cho nhim v 3 (phn 4.2.1).
70
PHIU CNG TC 4: Hin trng qun l ni vi

Khu vc Phn xng m Cc quan st lin quan n qun l ni vi B tr cc b x l khng hp l Cc vi nc chy khi khng cn thit Trn b Thi gian ch ro dung dch khi di chuyn chi tit kim loi t b ny sang b khc cha Cht lng khu lm sch cha bo m Cc vn khc R kh nn t bnh cha kh nn V tr ca van gi trong ng ng khi l hi cha ph hp cc on khy, mt bch v ng ng thu hi nc ngng cha c bo n Cc vn khc
Khu vc ph tr
C rt nhiu gii php khng cn phi tri qua phn tch k lng c th nhn din c. Thng vic duy nht cn lm l kho st ton nh my, v chun b sn cc cu hi ti sao trc mt s thc hnh sn xut no hoc ti sao mt s tnh trng no li tn ti. Vic mi mt chuyn gia bn ngoi ti kho st lun c mt ngha tch cc v ngi ny c th a ra c mt cch nhn mi v hot ng hin ti ca nh my. Mt trong nhng bi hc kinh nghim t trng hp ny l ng b qua nhng s vic tng nh hin nhin. Rt nhiu cc gii php SXSH c tm ra mt cch d dng, v vic trin khai cc gii php ny ngay giai on u to ng lc mnh m cho nh gi sau ny.
Phiu cng tc 4: Tnh trng qun l ni vi (V d xuyn sut)
Khu vc Dy chuyn m cn s xe my Cc quan st lin quan n qun l ni vi B tr cc b x l khng hp l Cc vi nc chy khi khng cn thit Trn b Thi gian ch ro dung dch khi di chuyn chi tit kim loi t b ny sang b khc cha Cht lng khu lm sch cha bo m R kh nn t bnh cha kh nn V tr ca van gi trong ng ng khi l hi cha ph hp cc on khy, mt bch v ng ng thu hi nc ngng cha c bo n
Khu vc ph tr
71
PHIU CNG TC 5: Chi ph nguyn liu u vo

B phn/ ha cht u vo Ha cht A-xt Sulphuric Nickel sulphate Nickel clorua A-xt Boric Soda kim Chromic Saccharine Tubos Crom Bat I Crom Bat II P1060 Cht to bt Khc Khu vc ph tr Nc mua Nc ging khoang Than FO cho l hi FO cho b pht Diesel Hi to ra in mua in pht Ha cht lm mm nc Khc Chi ph/ Tn Tiu th hng nm Tiu th/n v sn phm Chi ph/ n v sn phm
Phiu cng tc 5: Chi ph nguyn nhin liu (V d xuyn sut) TT 1 2 u vo Thp Ha cht - Sulphuric Acid - Nickel sulphate - Nickel chloride - Boric Acid - Caustic soda - Chromic - Saccharine - Tubos - Crom Bat I - Crom Bat II - P1060 - Foaming in cc Niken in n v kg kg kg kg kg kg kg kg kg lt lt lt kg kg kg KWh Tiu hao nm 2002 54.200 326,4 900 475 375 426 350 50 145 150 7,5 639,2 19.185 n v kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kg/SP kWh/SP Sut tiu hao nm 2002 0,3 0,0018 0,0049 0,0026 0,002 0,0023 0,0019 0,00027 0,0008 0,0008 0,00004 0,0035 0,106
3 4 5
Nc
m3
1.560
m3/SP
0,0086
Nhn xt: i SXSH khng th thu thp c s liu mt cch chi tit hn trong nh gi SXSH ny. S liu v chi ph khng tp hp c,v th s kh khn khi phn tch chi ph mt cch chnh xc.
72
4.2 Bc 2: Phn tch cc cng on

4.2.1 Nhim v 3: Chun b s quy trnh
Vic chun b s quy trnh l bc quan trng trong nh gi SXSH. xy dng c mt s quy trnh c hiu qu nht, nhm SXSH nn bt u t vic ln danh sch cc cng on vn hnh quan trng, t khu tip nhn nguyn liu th ti cng on lu kho/ bn giao thnh phm. Tip theo, mi cng on ny c th biu din bng mt s khi cho bit cc bc chi tit vi nhng u vo v u ra tng ng. Bng vic kt ni cc biu khi ca cc cng on vn hnh n l ny th s xy dng c mt lu m t quy trnh sn xut. i khi, cch tt nht xy dng v cng c mt lu quy trnh l thc hin mt s cc cuc kho st thc a. Khi chun b lu quy trnh th nhm SXSH cn ch mt s im sau: S dng cc hnh hp th hin cng on vn hnh. Vi mi khi, vit tn ca cng on v tt c cc iu kin vn hnh c bit cn phi ch ; v.d: vi cng on nu, c th cn ghi r nhit 180 C v p sut 1,2 at. Th hin tt c cc u vo v u ra tng khi, ch r cc nguyn liu th chnh, sn phm trung gian v thnh phm, nc v hi (nu c th), nc thi, pht thi kh v cht thi rn. Lu quy trnh cn phi s dng nhiu loi biu tng khc nhau thm thng tin v quy trnh. V d, nu r vn hnh theo m hay lin tc. ng thi c th s dng cc vch lin hoc vch t th hin s pht thi thuc loi lin tc hay khng lin tc. Cn phi ht sc ch quan st cc hot ng lin quan n khi ng, tt my v bo dng; cc thay i lin quan n sn phm hoc sn xut thi v, v.v... iu ny c th c thc hin mt cch hiu qu nht khi chun b ring mt lu th hin mt quy trnh hoc cng on c vn hnh theo mt iu kin c bit.
Mt lu th hin quy trnh cn phi lit k v, nu c th, phi nu c cc c im ca dng vo v dng ra. Cn phi c bit quan tm n cc dng tun hon. Mc d c th xy dng cc lu quy trnh cho ton b nh my, nhng bc ny ta cha cn lm iu m ch cn phn tch nhng cng on hoc b phn lng ph nht - tc l c nhiu tim nng SXSH nht. Hay ni cch khc, t hiu qu cao nht, ta nn xc nh khu vc trng tm cn c vo thng tin thu thp c v kho st thc a c thc hin.
73
4.2.2 Nhim v 4: Cn bng vt liu, nng lng v cu t

Sau khi lp s quy trnh cng ngh, bc quan trng nht l tin hnh cn bng vt liu cho cng on c chn. Cn bng vt liu v nng lng (M&E) l mt cng c kim k cn bn cho php theo di nh lng u vo v u ra v vt liu v nng lng. Nn tng ca cn bng vt liu l s quy trnh cng ngh. Mt hot ng quan trng trong cn bng M&E l kim tra rng ci g i vo u s phi i ra ni no . V vy tt c cc u vo u c nhng u ra tng ng. Cn bng vt liu v nng lng c ngha quan trng i vi cc nh gi SXSH v s gip cho vic xc nh v nh lng nhng tht thot v pht thi m trc khng pht hin c. Cc php cn bng ny cng hu dng cho vic gim st cc tin b t c t chng trnh SXSH v nh gi chi ph cng nh li ch ca chng trnh ny. Mc d ta khng th t ra nhng hng dn y xy dng cn bng vt liu v nng lng, nhng mt s ch s vn c th c ch. Cn bng vt liu: Di y l cc thnh t c bit ca php cn bng vt liu: Trc tin, thit lp bng cn bng vt liu i vi tt c cc cng on chnh trong trong nh my; v d nh x l b mt, ra, m, ... Tip n, tinh chnh li bng cn bng nguyn liu cho cc bc quy trnh trong dy chuyn c chn lm trng tm nh gi SXSH; Trong ngnh x l hon tt kim loi, cn ch n nc, mt s loi ha cht quan trng
Phiu cng tc 6 c th gip thc hin cn trng vt liu. PHIU CNG TC 6: Cn bng nguyn liu
Quy trnh Nguyn liu u vo Tn S lng Nc Ha cht Hi nc Cc ha cht khc Nc Hi nc Nc Hi nc NaOH Ha cht khc Nc Hi nc Nc Hi nc H2O2 Cc ha cht khc Nc Ha cht Nc Nc S lng nguyn liu u ra Dng thi Dng thi Rn
Ty du
Ra Ty g
Ra M
Ra Trung ha Ra
74
Phiu cng tc 6: Cn bng nguyn liu (V d xuyn sut)

Nguyn liu u vo STT 1 Hot ng Lau mn Tn - Cn s bn thnh phm - Gi lau - Cn s bn thnh phm - Soda - Nc - Cn s bn thnh phm - Ha cht - Nc - Cn s bn thnh phm - Nc - Cn s bn thnh phm - H2SO4 - Nc - Cn s bn thnh phm - nc - Cn s bn thnh phm - Ha cht: + NiSO4 (250g/l) + NiCl2 (60 g/l) + H3BO3(40 g/l) - kim loi Nickel - Nc - Cn s bn thnh phm - Cc ha cht: + NiSO4 (300g/l) + NiCl2 (60 g/l) + H3BO3(40 g/l) - Nickel - Nc Nguyn liu ra Khi lng 1000 chic Tn - Gi bn - Bn Dng thi Khi lng 0,15 kg Khi Tn lng 1000 Cn s chic bn 0,15 kg thnh phm 1000 Cn s chic bn 0,15 kg thnh phm 1,5 lt 1000 Cn s chic bn 0,96 kg thnh phm 16 lt 1000 chic Cn s bn thnh phm Cn s bn thnh phm
Ty g V= 450l
1000 chic
10% dung dch soda
1,5 lt
Ty m bng in ha V= 450l
1000 chic
Dung dch ty in ha
17 lt
Ra 1
1000 chic
Nc thi c cha ha cht
Lm sch trung tnh
1000 chic 1 lt 19 lt 1000 chic
1000 chic
Ra 2
Cn s bn thnh phm
1000 chic
5% dung dch lm sch trung tnh c cha ha cht v cc kim loi nng Nc thi c cha a-xt
20 lt
Chy trn, khng nh lng c 1 lt 0,25 kg 0,06 kg 0,04 kg
M Nickel bn bng Bn dung tch: V=2000
1000 chic
Cc trc li hp cn m Ni NiSO4 NiCl2 2,6 kg H3BO3 1,15 kg kim loi Nickel Nc 1 kg
1000 chic 2,37 kg 1,1 kg 0,9 kg
Dung dch m b n bn ra ngoi NiSO4 NiCl2 H3BO3
M Ni bng B dung tch: V=1800
1000 chic
Cc trc ly 1000 hp cn chic m NiSO4 2,02 kg NiCl2 2,6 kg 1,04 kg H3BO3 0,86kg Nickel 1,15 kg Nc 1 kg
Hi nc
2 lt 0,5 kg 0,12 kg 0,08 kg 20 lt
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Ra 3 V=280l
- Cn s bn thnh phm - Nc - Cn s bn thnh phm - Nc - Cn s bn thnh phm - Cc ha cht: + CrO3 (300g/l) - Nc - Cn s bn thnh phm - Nc - Cn s bn thnh phm - Nc - Cn s bn thnh phm - Nc - Soda - Cn s bn thnh phm - Nc - Cn s bn thnh phm - Nc - Cn s cn m - in - nhit
1000 chic
Cn s bn thnh phm Cn s bn thnh phm Cn s bn thnh phm
1000 chic
Nc thi c cha Ni2+ (30 mg/l), Cr6+ (420 mg/l) Nc thi c cha Ni2+ (4,5mg/l), Cr6+ (5,5 mg/l) + Dung dch m n bn c cha: : CrO3 +Hi nc c cha ha cht
Khng xc nh c
10
Ra 4 V=30l
1000 chic
1000 chic
Khng xc nh c
11
M C-rm V=900l
1000 chic 2 kg
1000 chic
4 lt
1,2kg 1,6 lt
12
Ra 5
1000 chic
Cn s bn thnh phm Cn s bn thnh phm Chic bn thnh phm
1000 chic
Dung dch n bn
1,5 lt
13
Ra 6 V=280l
1000 chic
1000 chic
Nc thi c 2+ cha Ni (30 6+ mg/l), Cr (420 mg/l) Dung dch trung tnh ha bn ra ngoi 6,2%: - Cr6+ 20,5mg/l - Ni2+ 25,8 mg/l Nc thi c cha soda, 2+ Ni (6,4 mg/l), 6+ Cr (5,8 mg/l) Nc cha cht: mg/l), mg/l) thi cc 2+ Ni 6+ Cr c ha (2,2 (3,5
Chy trn
14
Trung ha V=20 l
1000 chic 0,67 kg 10 lt
1000 chic
10,67 lt cha:
0,000218kg 0,000275 kg Khng xc nh
15
Ra 7 V= 30 l
1000 chic
Chic bn thnh phm Chic bn thnh phm Thnh phm
1000 chic
16
Ra 8 V= 50 l
1000 chic
1000 chic
Khng xc nh
17
Sy
1000 chic 7 KW 801000C
1000 chic
Hi nc, nhit
Khng xc nh
Cng on Ra 3 sau khi m Ni bng v ra 6 sau khi m crm c thc hin trong cng mt b, v th nc thi t b ny c cha Ni, Cr, v cc ha cht c trong hai b trc .
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Cn bng nng lng: Tin hnh mt php cn bng nng lng l mt cng vic phc tp hn cn bng nguyn liu. Nguyn nhn l c th truy tm nguyn liu u vo cho mt hot ng thng qua cc u ra nh lng v c th quan st c, cn i vi cc dng nng lng th khng phi lc no ta cng c th lm c iu ny. Mc d i vi cc dng nng lng, 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 trng hp cc thit b s dng in nh my bm, my nn kh, v.v... 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, v.v...) li khng th nh lng trc tip c. Sau y l nhng v d v cc trng hp in hnh khi nu ch xem xt cc dng nng lng hu hnh th c th s b st cc tn tht nng lng u ra: Tn tht do vn hnh khng ti i vi thit b s dng in. Tn tht do vn hnh khng ti (hiu qu thp) cc thit b s dng in. Tn tht do in tr i vi dng chy (in tr cao nhng c th trnh c cc dy dn in v cc ng ng dn cht lng) Tn tht nng lng do thit b xung cp (bnh cng tc ca bm, vng m ca bm, v.v... xung cp s lm tng tiu hao).
xc nh c chc chn u ra (c dng nhn bit c v khng nhn bit c) t h thng nng lng, trong nh gi SXSH cn phi nh gi/quan trc mt s thng s khc bn cnh thng s thit yu nh nhit , dng chy, m, c, phn trm thnh phn, v.v... Cc thng s cn phi c nh gi/quan trc b sung c th l: kW (kilowatt in u vo); kV (kilovoltsin th vo); I (amperes dng in); PF (h s cng sut ca thit b in cm ng); Hz (tn s dng in xoay chiu); N (s vng/pht hoc tc quay ca thit b); P (p sut cc dng cht lng/kh); DP (st p trong cc dng cht lng v kh u vo/ra); Lux ( ri); GCV, NCV (gi tr calo tng th v rng ca nhin liu); v.v... Trong thc t c th khng thc hin c php cn bng nng lng chnh xc v ng hon ton, nhng cc thit b ph tr nh ni hi, l, thit b ha hi, v.v... bng cn bng nng lng s c ch trong vic xc nh v c lng tn tht nng lng cc thit b v t cc h thng . Phiu cng tc 7 l mt bng cn bng nng lng c thc hin i vi mt xng l hi. Cn bng cu t: Vi mt nh my hon tt kim loi php cn bng cu t ch yu c lin quan n cc kim loi nng nh nickel, crm hoc km b tht thot t cc b m chnh trong khi vn chuyn cc cu t t b m v b ko theo ra cc b ra. Phiu cng tc 8 s gip thc hin cn bng cu t kim loi mong mun tng ng.
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PHIU CNG TC 7: Cn bng nng lng cho l hi
ThanThan
PhunPhun nc nc
Bi than
Than mn (bi than bi mt) Pht thi
ThanThan
in
Nc
Sng th cng & tn nh
in
Ha cht cht iu ha Ha iu ha 17.0 MkJ/gi (thc) 17.0 MJ/gi (thc)
Than 1.1 tn/gi (thc) Qut ht
Bm BFW Thng s chun 8 tn/gi, 13kg/cm2
0.5 MJ/gi (thc) Cng on Thng s quy trnh
THNG S THAM CHIU Sinh hi
Khi thi Thng s chun 250mm WC, 200oC, 20kw Tn tht 13.2% Tn tht 13.2% (thc) (thc) 2.25 2.25 MJ/gi Mkj/gi (thc) (thc) Vn hnh Tn tht x y 1.4% 0.24MJ/gi (thc) Tro khng chy ht theo x 4.85% 0.83 MJ/gi (thc)
Chun p Lng 12kg/cm

2
Qut y Thng s chun 100mm ct nc; 30oC, 15kw
10kg/cm
6 tn/gi Ni hi
4 tn/gi
Thit b
11.40 MJ/gi (thc) in 9kw (thc) Khng kh 12.61 tn/gi (thc) 14.34 tn/gi (chun)
Hi t Tn tht n
Tch hi
Nc ngng nng 3% 0.09 MJ/gi (thc) Hi kh 97% 11.31 MJ/gi (thc)
H2 v m: 2.5 MJ/gi (thc ), 14.4% Bc x:0.17 Mj/gi (thc), 1% m trong khng kh: 0.03 MJ/gi (thc), 0.15%
Phiu cng tc 7: Cn bng nng lng (v d xuyn sut)

Hu ht cc nh my Vit Nam u quan tm ti vic thc hin cn bng nng lng v nghin cu kim ton. Tuy nhin, v y l mt cng vic kh khn nu mun t ti mt cn bng nng lng hon chnh cho ton b qu trnh sn xut, nn cc cng ty u thc hin cc cn bng nng lng nh trn c s cu t, v d: quay vng nc ngng, v.v... tm ra cc la chn SXSH. Cho ti nay, cha c mt cn bng nng lng chi tit no c thc hin.
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PHIU CNG TC 8: Cn bng cu t

n v hot ng Kim loi (mg/l) = A Th tch ca nc ra tnh theo lt =B Tng lng kim loi ra = A*B Kim loi mt Ghi ch
M Ra Ra
Phiu cng tc 8: Cn bng cu t (V d xuyn sut) * Cn bng nguyn liu Nickel: Lng tiu th NiSO4, v NiCl2 trung bnh tng ng l 0,005 kg/sn phm; 0,0023 kg/sn phm; v 0,002 kg/sn phm. Sc cha ca b m Ni bn sng (half-bright) l 2000l, v m Ni sng l 1800l. C hai b u c pha cng mt lng ha cht. Hm lng ha cht trong cc b ny c xem l n nh: NiSO4 trong b Ni bn sng l 250g/l, trong b Ni sng l 300 g/l; NiCl2 60 g/l; H3BO3 40 g/l. Lng dung dch trn ra t b Ni bn sng trn 1000 sn phm (trong mt ca lm vic 8 gi) l khong 1 lt; Lng dung dch ri vi v bay hi ti b Ni sng trn 1000 sn phm l khong 2 lt. - Lng ha cht thm vo mt b cho 1000 sn phm l: + NiSO4 = (0,005 kg/sp x 1000 sp)/ 2 b = 2,6 kg + NiCl2 = (0,0023 kg/sp x 1000 sp)/ 2 b= 1,15 kg + H3BO3 = (0,002 kg/sp x 1000 sp)/ 2 b = 1 kg - Lng ha cht tht thot trong b Ni bn bng: + NiSO4 = (1l x 250 g/l)/ 1000 sp = 0,25 kg + NiCl2 = (1 l x 60 g/l) / 1000 sp = 0,06 kg + H3BO3 = (1 l x 40 g/l) / 1000 sp = 0,04 kg - Lng ha cht tht thot trong b Ni bng + NiSO4 = (2 l x 250 g/l)/1000 sp = 0,5 kg + NiCl2 = (2 l x 60 g/l) / 1000 sp = 0,12 kg + H3BO3 = (2l x 40 g/l)/ 1000 sp = 0,08 kg * Cn bng nguyn liu Crm: Lng tiu th CrO3 thc t l 2g/sp (0,002 kg/sp). Nng Crm trong b m c xem nh n nh ti mc 300 g/l. Dung tch ca b l 900 lt. Lng dung dch trn v bay hi l: 5,6 l/ 1000 sp. Lng CrO3 thm vo cho 1000 sp l 0,002 kg/sp x 1000 = 2 kg Tiu th CrO3/1000 sp l (4 l x 300 g/l)/1000 = 1,2 kg
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4.2.3 Nhim v 5: Xc nh tnh cht ca dng thi

Vic xc nh tnh cht cc dng thi s gip ta nh gi c ti lng nhim i vo mi trng v h s pht thi ring. iu ny s gip xc nh c chi ph x l v thi b. Cn phi theo di cc dng thi c xc nh; sau c th ly mu v cc thng s khc nhau phn tch trong phng th nghim. Nu cng ty khng c phng th nghim ring th c th ly mu ri gi i phn tch ti cc phng xt nghim khc phiu cng tc 9 c th gip xc nh tnh cht ca cc dng nc thi. PHIU CNG TC 9: Xc nh tnh cht ca nc thi
n v hot ng Ty du m Ra 1 M Ra 2 Ra 3 Ra 4 M 2 Ra 5 Ra 6 Trung ha Ra 7 Nc thi (lt) BOD (mg/l) COD (mg/l) TS (mg/l) Nhit (0C )
4.2.4 Nhim v 6: nh gi cho cc dng thi

m t c tim nng thu li t cc dng thi, mt yu cu c bn l phi tnh c chi ph cho cc dng thi . Chi ph ny cn phn nh tn tht bng tin theo cht thi. R rng mt dng thi khng d thy c cc chi ph c th nh lng, tr khi gn lin vi s tn tht trc tip v nguyn liu hoc sn phm, v d: hao ph crm do ra thu hi km hiu qu, hao ph cc loi ha cht do thi gian ch ro dung dch dch khi di chuyn chi tit t b ny sang b khc khng . Tuy nhin, khi phn tch su hn th ta c th thy mt s yu t chi ph trc tip v gin tip c lin quan n cc dng thi. Cc yu t chi ph c th c gm: Chi ph cho nguyn liu trong ph thi; Chi ph cho sn phm trong dng thi; Chi ph cho hi nc v in s dng trong qu trnh; Chi ph x l v thi b; Chi ph cho nc, x l v bm nc; Cc chi ph khc.
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Cc yu t chi ph k trn cn phi c xc nh cho tng dng thi v sau ta c th tnh ton tng chi ph cho tng n v cht thi. Trong hu ht cc trng hp, rt kh tnh ton tt c cc thnh phn chi ph. tnh ton tht thot nguyn liu ta cn tin hnh phn tch xc nh cc thnh phn khc nhau ca cht thi v khi lng ca chng. Tng t tnh ton chi ph x l dng thi, s liu v chi ph x l trung bnh c th tham kho t Qun c trm x l nc thi. Chi ph ny sau c th p c cho cc dng thi tng ng. i khi dng thi khng phi lc no cng c tnh bng ti lng nhim, m c th l tn tht nhit nh nc ngng khng c thu hi. Trong nhng trng hp nh vy, chi ph dng thi c th tng ng vi tn hao nhit nng c tnh tng ng vi lng than , du, ga hoc in ty thuc vo bn cht ca loi nhin liu s dng trong quy trnh. Phiu cng tc 10 s gip nh gi cho cc dng thi. PHIU CNG TC 10: Chi ph ca cc dng thi
n v hot ng Dng thi Nc thi (lt) Thnh phn cht thi Khi lng Chi ph n v theo thnh phn Tng chi ph cho cc thnh phn Chi ph dng thi
Ty du m Ra 1 M Ra 2 Ra 3 Ra 4 M 2 Ra 5 Ra 6 Trung ha Ra 7 tnh
Phiu cng tc 9 v 10: Xc nh tnh cht v chi ph cc dng thi (v d xuyn sut)
STT 1 2 3 4 5 6 Dng thi Dng thi 1: Lau mn Dng thi 2: Ty g Dng thi 3: ty du m Dng thi 4: Ra 1 Dng thi 5: Lm sch nh Dng thi 6: Ra 2 Xc nh khi lng ca dng thi Gi bn: trung bnh khong 0,15 kg/1000 cn s Nc thi: 1,5 lt/1000 trc ly hp Dung dch ri vi, 17 lt Khng xc nh Dung dch lm sch nh b ri vi, 20 lt Nc trn, khng xc nh c Tnh cht ca dng thi Gi c dnh du, cht nh bng, bi Cha: g st, bi, soda Cha du, ha cht v hm lng COD cao Cha du, ha cht pH thp, hm lng COD cao pH thp n nh chi ph Khng xc nh Khng xc nh Khng xc nh Khng xc nh Khng xc nh Khng xc nh
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Phiu cng tc 9 v 10: Xc nh tnh cht v chi ph cc dng thi (v d xuyn sut)
STT 7 Dng thi Dng thi 7: M Ni bn bng Xc nh khi lng ca dng thi Dung dch m ri vi, khong 1 lt dung dch/1000 sn phm Tnh cht ca dng thi Hm lng COD cao, c cha cc ha cht: NiSO4: 0,25kg NiCl2 : 0,06 kg : H3BO3 0,04 kg C cha cc ha cht sau: NiSO4: 0,6kg NiCl2 :0,12 kg : H3BO3 0,08 kg Hi nc n nh chi ph - Nguyn liu tn hao: x 53.000VND/kg = 13.250VND x 55.000VND/kg= 3.300VND x14.000 VND/kg= 560VND - Nguyn liu b mt: x 53.000VND/kg = 31800VND x 55.000VND/kg= 6.600VND x14.000 VND/kg= 1120VND x 6000VND/m3= 120VND Khng xc nh
Dng thi 8: M Ni bng
+ Dung dch m b ri vi, khong 2 lt/1000 sp + Nc bay hi, 20 lt/1000 sp
Dng thi 9: Ra 3 Dng thi 10: Ra 4 Dng thi 11: M crm Dng thi 12: Ra thu hi 5 Dng thi 13: Ra 6
Nc thi c cha dung dch m Nc thi c cha dung dch m 4 lt dung dch m b ri vi 1,6 lt nc b bay hi Dung dch thu hi b ri vi, 1,5 lt/1000 sn phm Nc trn, khng nh lng c
10
11 12
Hm lng COD cao, cha kim loi nng 2+ 6+ Ni (30 mg/l), Cr (420 mg/l) Hm lng COD cao, c cha cc kim loi 2+ nng Ni (4,5 mg/l), Cr6+ (5,5 mg/l) Hm lng ha cht cao: C cha Cr6+ (1,2kg) Hm lng ha cht cao, C cha Cr6+ Hm lng COD cao, c cha mt lng ln cc h cht nh: 2+ 6+ Ni (30 mg/l), Cr (420 mg/l)
Khng xc nh
- Nguyn liu b mt: x 2600VND/kg = 31.200VND Khng xc nh
13
Khng xc nh
14
Dng thi 14: Trung ha
Dung dch ri vi, c tnh khong 10,67 lt
Hm lng COD v pH cao, c cha: - Cr6+ 0,000218 kg - Ni2+ 0,000275 kg

Hm lng COD cao, cha soda v cc kim 2+ loi nng: Ni (6,4 6+ mg/l), Cr (5,8 mg/l) Hm lng COD cao, 2+ 6+ Ni (2,2 mg/l), Cr (3,5 mg/l)
Nguyn liu b mt: x 26.000 = 5,668 VND x 53.000 = 14,575 VND

Khng xc nh
15
Dng thi 15: Ra 7
Nc thi chy trn
16
Dng thi 16: Ra 8 Dng thi 17: Sy
Nc thi chy trn
Khng xc nh
17
Hi nc, nhit Tng trn 1000 cn s = Tng theo nm =
Khng xc nh 108,193 VND
19,500,000 VND
Nhn xt: Cn xem xt ch ph x l v thi b vi dng thi. Khi c tn hao nc ngng cn xem xt k hn nhng tn hao nng lng.
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4.2.5 Nhim v 7: Xc nh nguyn nhn

By gi ta c th r sot quy trnh i vi cc dng thi tn km nht. Thng qua php cn bng nguyn liu v nng lng, ta cn tin hnh phn tch nguyn nhn xc nh cc nguyn nhn pht sinh dng thi. (C rt nhiu cng c gip thc hin cng vic phn tch ny. Biu xng c hay cn gi l biu Ishikawa l mt trong nhng cng c nh vy xem s cui chng). Cc nguyn nhn ny s l nhng c s xut cc gii php SXSH. Cc nguyn nhn ny c th gm c nhng nguyn nhn v tnh hoc hu , ta c th dng phiu cng tc 12 ghi chp li nhng nguyn nhn ny. C th c rt nhiu cc nguyn nhn khc nhau t nhng li n gin n nhng l do k thut phc tp. Chui cu hi di y c th tham kho khi xy dng cc c hi SXSH. 1. Mc ch tin hnh cng on ny l g? S n mt lc m nhm SXSH thy rng cng nhn vin ti mt cng on no khng c kh nng a ra cc cu tr li tha ng cho vn . iu hon ton c th xy ra y l bi v y chnh l cc thc hnh sn xut c v tr thnh thng l m h vn tip tc tun theo. Trong trng hp ny, gii php tt nht l trnh lp li hot ng mt cch trit l sau mt vi ln th nghim thnh cng phng php thc hnh khc. iu ny s gip trnh pht sinh dng thi do hot ng vn hnh c ti cng on ny, v ng thi dn n vic gim tiu th nguyn liu th ti y. 2. Lng ha cht b sung c vt qu lng cn thit khng? Nu cu tr li cho cu hi trn l c th nhm SXSH cn tm ra nguyn nhn ng sau vic thm d ha cht v gim lng a vo. Nng ha cht ny trong dng thi l cao th c ngha l dng d tha ha cht . V d, hm lng cc mui trong b m nn c duy tr mc nh nht trong khong cho php trnh gy hi cho b m. 3. Rt nhiu cc loi ha cht s dng trong quy trnh c tc hi g ti mi trng? Nu cc ha cht ang dng c tc ng xu n mi trng (cc ha cht c hi hoc c hm lng COD/BOD cao), th cn phi c gng thay th cc ha cht ny bng cc loi ha cht thn thin sinh thi hn. V d, cc cht dung mi ty du m nn thay th bng cc enzim ty du m. 4. Hin trng ca cc hot ng qun l ni vi nh th no? C th c thiu st trong qun l ni vi do: a) s sut ca con ngi; b) nhn cng cha c o to y ; . Nhng thiu st bao gm vi/van/bch b r r; lng ha cht, b trn ra; hay vi nc chy lin tc. Nhng thiu st nh th c th khc phc bng cch o to, hng dn cng nhn v nng cao thc v SXSH.
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5. C th gim lng kh thi tin hnh iu chnh ci tin thit k ca thit b khng? Nu cu tr li l c th cn phi thc hin iu chnh trn thit k ca thit b hin c sn loi b cc im khng hiu qu trong h thng. V d: Nhc k chi tit m ra khi b m trong thi gian hp l. Tng thi gian gi trn khay hng dung dch m dnh theo ra ngoi. 6. Liu sao nhng trong vn hnh/bo dng c lm pht sinh thm cht thi khng? Cn tin hnh cc bin php ph hp gim thiu lng cht thi sinh ra do s sao nhng trong qu trnh vn hnh/bo dng. Nhm SXSH cn tin hnh kho st thc a pht hin s thiu nht qun ny. V d, c th gim hao ph nhit khi thay th by hi b hng hay bo n nhit trn ng dn hi nc. 7. Cc xu hng cng ngh mi nht trong ngnh cng nghip hon tt kim loi l g? Hu ht cc nh my thuc ngnh ny u s dng cc cng ngh truyn thng. y chnh l l do dn n quy trnh c hiu qu thp. V vy vic nng cp cc thit b ny bng cng ngh tn tin nht l iu v cng quan trng. Ngoi vic ci tin cht lng sn phm, th vic lm ny cn c th gim thiu c vn pht thi. lm c iu ny, i SXSH s phi i thm thc t c s v kho st thu thp cc thng tin chi tit v cc cng ngh mi nht v nh gi tnh kh thi da trn cc iu kin hin c. V d, s dng phng php m khng c xyanua thay cho m xyanua s mang li kt qu ci thin to ln v mt mi trng. 8. Dng thi c gi tr ti ch/thu hi/ ti s dng khng? Tim nng nm trong dng thi c hm lng nguyn liu u vo cao hoc l c kh nng sn xut ra cc sn phm ph t ngun ph thi ny. C th s dng biu mu cn bng nguyn liu nh gi tim nng thu hi/ ti s dng/ ti ch ca dng thi. v d thu hi cc kim loi nng trong nc ra s dng phng php trao i ion hoc k thut thm thu ngc c th tit kim c kh nhiu chi ph sn xut trong cc nh my sn xut quy m ln.
Biu Ishikawa hay cn gi l biu xng c ch yu c s dng xc nh cc nguyn nhn ca vn nhn nh vn hoc xut gii php nhm trnh hoc loi b cc nguyn nhn . Biu Ishikawa c s dng khi mt nhm c gng tm kim cc gii php tim n cho mt vn v tm kim nguyn nhn gc r. Biu ny rt hu ch i vi vn tng i ln, v khai thc t nhiu kha cnh hot ng. Ta c th s dng biu xng c cu trc ha cc mi quan h nhn-qu cho mt vn . Phn tch nhn qu cho php phn tch vn mt cch h thng hn l ch a ra c cc gii php khc phc tc thi xung quanh vn .
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Mi trng
Nguyn liu
Con ngi
Ch vit trn bn v khng r rng Ngi s dng th vin khng c thng bo y Ngi dng qu ph thuc vo ngi qun l h s Kh khn khi xc nh v tr bn v
Khng gian cht hp My in xanh c mi
Bn v c phn nhm di qu nhiu ch s Bn v khng cp nht
Ni dung ca h kh h Thiu nhn lc
Bn v c t chc di qu nhiu nhm
Lp ch dn khng tt
Cc ngn ti liu nm ri rc
Cc t ti liu Khng c nhn r rng
Khng c th my to ra cc nhn tiu chun
Phng php
My mc
V d trong hnh trn v th hin cch s dng biu Ishikawa c th p dng c xc nh nguyn nhn ca vn . xy dng mt biu xng c th mt phng php n gin nht l s dng phng php phn nhm 4M1E. Theo phng php ny tt c cc nguyn nhn chnh v ph phi c chia thnh cc nhm nh hng l Con ngi, My mc, Nguyn liu, Phng php v Mi trng. Vic chia nhm i tng theo m hnh 4M1WE c th l im xut pht v c th lm k hn na. Cc bc chnh trong cng c ny l: - Xc nh vn v t pha bn phi ca biu , ti im cui ca ng k ngang - Xc nh cc nguyn nhn chnh v ni vo ng k ngang bng cc mi tn - ng no tm nhng nguyn nhn ph v nh vo cc ng nguyn nhn chnh. - Tm ra nguyn nhn gc r bng cch xc nh cc nguyn nhn lin quan - xut cc gii php cho nguyn nhn gc r.
PHIU CNG TC 11: Tm tt nguyn nhn

Dng thi Cng on Nguyn nhn ch quan Nguyn nhn khch quan
85
Phiu cng tc 11: Phn tch nguyn nhn v pht trin cc gii php SXSH (V d xuyn sut)
Dng thi 0. gi lau bn Nguyn nhn 0.0 nguyn liu u vo km cht lng, t l g cao 0.1 Dnh du, cht nh bng v t trn cn s bn thnh phm 0.2 Gi lau km cht lng 1. Dung dch b ri vi ti b ty 1.1 Thi gian ro ngn Cc c hi SXSH 0.0.1 Chn loi nguyn liu cht lng tt hn 0.1.1 Bo dng v lu tr cn s bn thnh phm ti ni sch s 0.1.2. Thit k my chi thay v dng gi lau. 0.2.1 S dng loi gi cht lng tt hn 1.1.1 Nng cao nhn thc ca ngi cng nhn m bo thi gian lm ro l 3 giy pha trn ca b trc khi chuyn sang b khc. 1.2.1 Chuyn cc b li gn nhau hn thun li hn cho cng vic ca ngi cng nhn 1.2.2 Lp t mt chic mng nghing t gia b ty v b tip theo, cho mng nghing v pha b ty. 2.1.1 nh 1.1.1 2.2.1 nh 1.2.1 2.2.2 nh 1.2.2 3.1.1 Nghin cu kh nng lp t mt h thng ht thu hi hi t dung dch lm sch 3.2.1 iu chnh v nhit ph hp cho b ty du
1.2 Khong cch gia cc b qu xa
2. Dung dch ri vi t b ty du m 3. Pht thi ti b ty du m
2.1 nh 1.1 2.2 nh 1.2 3.1 Khng c h thng thu hi 3.2 Nhit lm vic khng ph hp dn n t l bay hi tng 4.1 Nguyn liu u vo b g 5.1 Ra khng sch, lng nc ra t 5.2 Thi gian treo ro ngn
4. Bn 5. Nc thi t b 1 c cha dung dch ty du m
4.1.1 Chn loi nguyn liu cht lng tt hn 4.1.2 Ci thin hiu sut lm sch c kh 5.1.1 Lp mt b thu hi trc b ra 5.1.2 Apd dng phng php ra trn chy ngc a cp. 5.2.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b ty du trc khi a sang b khc. 5.2.2 Chuyn cc b x l li gn nhau hn cho cng vic ca ngi cng nhn thun li hn. 6.1.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b ra nh trc khi a sang b khc. 6.2.1 Chuyn cc b x l li gn nhau hn cho cng vic ca ngi cng nhn thun li hn. 6.2.2 Lp mng nghing gia b lm sch nh v b tip theo. Mng t nghing v b lm sch. 7.2.1 Lp t mt b thu hi trc b ra. 7.2.2 p dng phng php ra chy ngc a cp 7.2.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b trc khi a sang b khc. 7.2.2 Chuyn cc b x l li gn nhau hn cho cng vic ca ngi cng nhn thun li hn. 8.1.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b m Ni trc khi a sang b khc. 8.2.1 Chuyn cc b x l li gn nhau hn cho cng vic ca ngi cng nhn thun li hn. 8.2.2 Lp mt mng nghing gia b m Ni bn sng v b m Ni sng. Mng t nghing v pha b m bn sng.
6. Dung dch a-xt b ri vi t cng on ra nh
6.1 Thi gian treo ro ngn
6.2 khong cch gia cc b qu xa
7.Nc trn c cha a-xt
7.1 Ra khng sch, nc ra t 7.2 Thi gian treo ro ngn
8. Dung dch m Ni ri vi
8.1 Thi gian treo ro ngn
8.2 khong cch gia hai b qu xa
86
Phiu cng tc 11: Phn tch nguyn nhn v pht trin cc gii php SXSH (V d xuyn sut)
Dng thi 9. Nc trn t b ra c cha mt lng dung dch m Ni ln Nguyn nhn 9.1 Ra khng sch (nc ra t, mi ln ch ra c mt chi tit) 9.2 Khong cch gia cc b qu xa 9.3 Thi gian treo ro ngn khin cho mt lng ha cht ln b ko t b b sang b ra 10. Dung dch m Cr b ri vi 10.1 B tr cc b m v b thu hi khng hp l, khng thu hi trit 10.2 Thi gian treo ro ngn Cc c hi SXSH 9.1.1 Lp 1 b thu hi trc b ra. 9.1.2 Lp mt mng nghing gia b m v b thu hi, t mng nghing v pha b m. 9.1.3 p dng phng php ra chy ngc a cp 9.2.1 Chuyn cch b li gn nhau hn thun tin cho cng vic ca ngi cng nhn. 9.3.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b m trc khi a sang b khc 10.1.1 lp t li b thu hi dung dch Cr thun tin hn cho cng nhn 10.1.2 Lp t mt b thu hi th 2 ci thin vic thu hi Cr. 10.2.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b m trc khi a sang b khc 11.1.1 Lp t cc h thng ht v x l Cr. 11.2.1 Kim sot nhit b mt b m gim thiu lng dung dch bay hi 12.1.1 p dng phng php ra chy ngc nhiu bc 12.1.2 Tch cc quy trnh ra sau khi m N v sau khi thu hi Cr. 12.2.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b trc khi a sang b khc. 12.2.1 Chuyn cch b li gn nhau hn thun tin cho cng vic ca ngi cng nhn. 13.1.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b trc khi a sang b ra khc. 13.2.1 Chuyn cch b li gn nhau hn thun tin cho cng vic ca ngi cng nhn. 13.2.2 Lp t mt mng nghing gia b trung tnh ha v b tip theo, mng nghing v pha b trung tnh nhm hn ch ti a lng soda b ri vi vo v ra. 14.1.1 p dng phng php ra chy ngc a cp 14.2.1 Nng cao nhn thc ca cng nhn m bo thi gian treo ro l 3 giy pha trn b trc khi a sang b khc. 14.2.1 Chuyn cch b li gn nhau hn thun tin cho cng vic ca ngi cng nhn. 15.1.1 Thay my sy tng gch bng khoang sy kim loi c hiu sut nhin cao hn.
11. Hi dung dch Cr khng th thu hi c trn b mt b m 12. Nc thi trnh c cha cc ha cht v kim loi nng (Ni, Cr)
11.1 H thng ht hot ng khng hiu qu 11.2 T l bay hi cao do b mt b qu nhit trong qu trnh m 12.1 Ra khng sch (nc ra t, mi ln ch ra c mt chi tit, ra trong cng mt b dng cho ra sau m Ni sng) 12.2 Thi gian treo ro ngn dn n mt lng ln ha cht b ko theo t b thu hi sang b ra 13.1 Thi gian treo ro ngn
13. Dung dch trung ha b ri vi
13.2 Khong cch gia cc b xa
14. Nc trn c cha soda
14.1 Ra khng sch 14.2 Thi gian treo ro ngn
15. Chi ph in nng cho quy trnh sy ln
15.1 Thit k my sy khng ph hp, tiu th in nng nhiu
87
4.3 Bc 3: Phn tch cc bc quy trnh

4.3.1 Nhim v 8: Xy dng cc gii php SXSH
Sau khi nhn din v xc nh cc nguyn nhn pht thi, ta c th a ra cc bin php SXSH. Tm tt cc dng thi nh trong phiu cng tc 12 s gip c lng nh tnh nhanh cc kh nng thc hin SXSH. bc ny ta c th ng dng cc k thut nh ng no v tho lun nhm xc nh tt c cc gii php SXSH c th c. Tm ra cc gii php tim nng nh vo kin thc v tnh sng to ca cc thnh vin trong i.
ng no l mt cng c c dng rt ph bin khi pht tng. Tuy nhin cc tng cha cn c gii thch mt cch chi tit ti bc ny. Cng vic kim tra tnh kh thi ca tng c thc hin bng cc cu hi hoc ng no mang tnh phn bin. Mc ch chnh ca qu trnh ng no l a ra cng nhiu tng cng tt khi gii quyt mt vn c th no c xc nh t trc. Cng c ny c ng dng theo nhm khi c gng nhn din nhng nguyn nhn gc r c th c hoc khi tm kim cc gii php cho mt vn . ng no cng c th c s dng trong xy dng v trin khai k hoch khi cn lp u tin v th t cho nhiu gii php khc nhau. C th s dng nguyn tc sau y khi tin hnh ng no. Mc d vy, cc nguyn tc ny l tng i linh hot v c th phi iu chnh cho ph hp vi cc tnh hung c th. Duy tr bui hp trong khng kh thoi mi Trng nhm ch nn h tr cho cuc hp Mi cc thnh vin c lin quan ca nhm tham gia hp Xc nh cc vn mt cch r rng. Mi ngi trong cuc hp cn phi c chung cch hiu v vn , nu khng cc tng s b chch mc ch chnh. S dng phng php bnh xe ln t do (t do cho ra tng) hoc phng php theo vng (tng ngi ng gp tng) a ra cng nhiu tng cng tt. Ghi li tt c cc tng. Cc tng khng nn b loi b ti khi chng minh c l tng khng kh thi.
Bn cnh vic ng no, xy dng c cc gii php SXSH th cn xem xt ht thm cc gii php SXSH nh gi trong Chng 3. Cc gii php SXSH trong chng mi cn phi c phn tch k hn trong bi cnh ca nh my p dng. Mt s ngun h tr xy dng cc gii php SXSH khc c th l: Cc chuyn gia t cc nh my hon tt sn phm kim loi ln khc Cc chuyn gia t vn ngoi cng ty Cc chuyn gia ca cc trng i Hc v TTSXSVN Hip hi ngnh Cc t chc quc t khc nh UNIDO, UNEP v.v
Rt nhiu cc c hi SXSH thuc cc khu vc khc nhau ca nh my c tm tt li v lp bng nh trong phiu cng tc 12. k thut SXSH cho tng gii php s tip tc c xc nh.
88
PHIU CNG TC 12: Tm tt cc dng thi v c hi SXSH

B phn/Dng thi 1 2 3 4 5 1 2 3 4 5 C hi SXSH QLNV Tim nng Gim thiu ti ngun TDNL KSQT CTTB TDCN Tun hon TH&TSD SPP
Cc thit bi ph tr
Ghi ch: QLNV (Qun l ni vi), TDNL (thay i nguyn liu), KSQT (kim sot quy trnh), CTTB (ci tin thit b/quy trnh ), TDCN (thay i cng ngh), TH&TSD (tun hon v ti s dng), SPP (to ra sn phm ph)
Phiu cng tc 12: Tng kt cc dng thi v tim nng SXSH (V d xuyn sut)
DNG THI Qun l ni vi TIM NNG GIM NGUN Thay Kim Sa i sot ci tin thit b nguyn quy liu trnh TI CH Tun Sn hon/ phm ti s ph dng
Thay i cng ngh
0. Bn bn, gi bn 1. Dung dch b ri vi t b khc n mn 2. Dung dch b ri vi t b ty du m 3. Pht thi ti b ty du m 4. Bn 5. Nc thi t b 1 c cha dung dch ty du m 6. Dung dch a-xt ri vi t cng on lm sch nh 7. Nc trn c cha a-xt 8. Dung dch m Ni b ri vi 9. Nc thi trn t b ra c cha lng ln dung dch m Ni 10. Dung dch m Cr b ri vi 11. Hi Cr khng th thu hi c pha trn b mt b 12. Nc thi trn c cha cc ha cht v kim loi nng (Ni, Cr) 13. Dung dch trung tnh ha b ri vi 14. Nc trn c cha soda 15. Chi ph tiu th in cho cng on sy qu cao
89
4.3.2 Nhim v 9: Sng lc cc c hi SXSH

Cc gii php c xy dng trn s c kim tra tnh kh thi. Quy trnh lc b nn n gin, nhanh v trc tip v thng ch mang tnh cht nh tnh. Mi im cn phi tht r rng, khng nn c bt k thnh kin m h no. Mc ch ca vic lc b nhm trnh tin hnh phn tch kh thi chi tit khng cn thit cho cc c hi khng thc t hoc khng kh thi. Phiu cng tc 13 s gip nhn din v lit k cc c hi SXSH: (a) c th trin khai ngay m khng cn phn tch kh thi (cc gii php r rng); (b) cn phi phn tch kh thi t m hn; v (c) c th loi b. Trong bng ny ch cn nh du vo mc ph hp, v khng cn phn tch chi tit. PHIU CNG TC 13: Sng lc cc c hi SXSH c th thc hin c
TT 1 2 3 4 5 C hi SXSH Trin khai ngay Phn loi Phn tch thm
Loi b
Phiu cng tc 13: Sng lc cc c hi SXSH (V d xuyn sut)

TT 1 2 Gii php SXSH Bo tr v lu tr cc khp ly hp bn thnh phm ti ni sch s Thit k my chi thay cho dng gi lau La chn nguyn liu tt hn, t g hn S dng gi lau cht lng tt hn Nng cao nhn thc ca ngi cng nhn m bo l chi tit c treo 3 giy trn b x l trc khi chuyn sang b khc Chuyn cc b li gn nhau hn thun li hn cho cng vic ca cng nhn. Lp mng nghing gia b ha cht v b tip theo, mng nghing v pha b ha cht Nghin cu kh nng lp t mt h thng ht thu hi hi t dung dch ty du m inha. iu chnh nhit ti b ty du m cho ph hp Phn nhm QLNV CTTB Thc hin ngay X Nghin cu thm Loi Nhn xt/l do n gin d thc hin x Cn thi gian u t v thit k, khng th thc hin vo thi im hin ti.
3 4 5
QLNV QLNV KSQT
X X X C th rt hiu qu nhng cn mt nhiu thi gian thay i nhn thc v thc hnh ca ngi cng nhn Tm hiu khu vc sn xut ca nh my b tr cc b cho hp l hn. u t t, d thc hin x u t ln, phc tp, cn nghin cu thm D thc hin
QLNV
7 8
QLNV CTTB
KSQT
90
Phiu cng tc 13: Sng lc cc c hi SXSH (V d xuyn sut)

TT 11 Gii php SXSH p dng phng php ra chy ngc a cp cho cc quy trnh nh lm sch nh, ty du m, m Ni v Cr, v trung tnh ha Ci tin cc h thng x l v thu hi Cr, h thng ht Thay my sy tng gch bng khoang sy kim loi s dng t in nng hn Nhm CT Thc hin ngay X Nghin cu thm Loi Nhn xt/l do u t t, nng cao hiu qu ra, t cht bn trong b ha cht hn C nhiu ch li mi trng
11 12
Qun l ni vi tt Sa i thit b
X X
Tt c cc gii php xut u c th trin khai ngay do chng mang li li ch kinh t cho nh my. Mt khc cc gii php ny cng mang li li ch v mt mi trng nh vic gim thiu ng k lng nhim kim loi nng trong nc thi. Tuy nhin c mt gii php b loi (gii php 2) do nh my khng kh nng thit k loi my xut. Gii php ny vn c th c trin khai trong tng li khi c nh cung cp thit b ph hp cho sn xut ca nh my. Mt gii php khc (gii php 8) cn phi c nghin cu thm v c cho vo k hoch hnh ng trin khai trong tng lai.
4.4 Bc 4: La chn cc gii php SXSH

Vic chn mt gii php SXSH thc hin i hi khng ch phi xem xt tnh kh thi kinh t-k thut m cn phi c li cho mi trng. Danh sch cc c hi cn phn tch thm trn s c nghin cu theo cc kha cnh sau:
4.4.1 Nhim v 10: Tnh kh thi k thut

nh gi tnh kh thi k thut nhm xc nh xem liu gii php SXSH c xut c thc hin c vi mt ng dng c th no khng. Vic nh gi thng bt u bng cch kim tra tc ng ca gii php xut i vi quy trnh, sn phm, t l sn xut, an ton, v.v Nu trong trng hp c s khc bit ln so vi thc hnh quy trnh hin ti th c th cn phi tin hnh th nghim trong phng th nghim v chy th nh gi tnh kh thi k thut. Phiu cng tc 14 l mt bng mu c th nh gi v k thut. Cc gii php khng c tnh kh thi v k thut (do khng c sn cng ngh, thit b, khng gian hoc bt c l do no khc) cn phi a vo danh sch ring cc cn b k thut nghin cu k hn. Cc gii php c tnh kh thi v mt k thut th s c tip tc phn tch tnh kh thi v mt kinh t.
91
PHIU CNG TC 15: Phn tch tnh kh thi k thut

A) Ni dung C 1 Phn cng Thit b Thit b o Cng ngh 2 3 4 Khng gian Nhn lc Dng sn xut B) TC NG K THUT Khu vc Tch cc Sn lng Cht lng sn phm Tit kim nng lng Hi nc in Tiu th ha cht An ton Bo dng linh hot khi vn hnh Khc Tc ng Tiu cc YU CU K THUT Yu cu Khng Sn c trong nc
4.4.2 Nhim v 11: Tnh kh thi kinh t

Tnh kh thi kinh t thng l cc thng s chnh ban lnh o chp nhn hoc t chi xut SXSH. mi vic c thun li th cn phi c mt vi gii php SXSH tht hp dn v mt kinh t bo co ln ban lnh o. Chin lc ny s gip thu ht c s quan tm v cam kt cao hn. Phn tch kinh t c th c thc hin bng rt nhiu phng php khc nhau, v d, phng php tnh ton thi gian hon vn, phng php IRR (t l hon vn ni ti), phng php NPV (gii tr hin ti rng), v.v Vi cc khon u t nh, cc gii php ngn hn c tnh kh thi kinh t cao th ch cn p dng phng php n gin nht l tnh thi gian hon vn l . Phiu cng tc 15 di y s gip phn tch tnh kh thi kinh t. Phiu ny c th c iu chnh cho ph hp vi cc gii php khc nhau, nhng cn phi ch xy dng n cng n gin v cng r rng cng tt. Khng nn b i bt c gii php no k c nhng gii php khng c tnh kh thi v kinh t. C th c mt s gii php em li ci thin ng k v mi trng v v th, c th c thc hin d khng c tnh hp dn v kinh t.
92
PHIU CNG TC 15: Phn tch tnh kh thi v kinh t

Tn/m t gii php SXSH: u t Phn cng 1 2 3 4 5 6 Thit b Yu cu v t Chi ph khc TNG Chi ph vn hnh hng nm Li Khu hao Bo dng Nhn cng tay ngh cao Nhn cng tay ngh thp Hi nc/ nhin liu in Ha cht Chi ph do dng my Chi ph khc TNG VND Tit kim Hi nc in Ha cht 1 Ha cht 2 Bt Nc Nhn cng Gim ph x l cht thi Gim ph thi b cht thi Chi ph khc TNG VND
VND TIT KIM RNG = TIT KIM CHI PH VN HNH
HON VN = (U T/TIT KIM RNG) X 12 THNG
4.4.3 Nhim v 12: Tnh kh thi mi trng

Cc gii php SXSH phi c nh gi t kha cnh tc ng ti mi trng. C rt nhiu trng hp, li ch mi trng th hin rt r rng: gim c tnh v/hoc lng cht thi. Cc tc ng khc c th l nhng thay i kh nng x l, thay i v kh nng p dng cc quy nh v mi trng. cc bc u tin, kha cnh mi trng c v nh khng phi l yu t thc p nh cc kha cnh kinh t. Tuy nhin, cn phi nhn thc rng trong tng lai gn, v hin din ra cc nc ang pht trin, cc kha cnh mi trng s tr thnh yu t xem xt quan trng nht bt k tnh kh thi kinh t l g. Phiu cng tc 16 l bn danh mc gip nh gi tnh kh thi mi trng.
93
PHIU CNG TC 16: Phn tch tnh kh thi mi trng

Tn/m t gii php: Mi trng Khng kh
Thng s Bi Kh xx Khc BOD COD TS Khc Cht thi rn Bn ha cht Bn hu c
Tc ng mi trng nh tnh nh lng
Nc
Cht thi rn
4.4.4 Nhim v 13: La chn gii php thc hin

Sau khi nh gi v k thut, kinh t v mi trng, ta s la chn cc gii php SXSH trin khai. Hin nhin l cc gii php hp dn nht chnh l nhng gii php c li ch kinh t ln nht, tnh kh thi k thut cao. Tuy nhin, ngy cng c nhiu trng hp, c bit l khi chu p lc, th cc yu t v mi trng li l tiu ch la chn u tin. C nhiu trng hp khi c rt nhiu gii php SXSH c xy dng th s dn n kh khn trong vic chn la cng nh t u tin thc hin cho cc gii php. Phiu cng tc 17 s gip nh gi v lp th t u tin thc hin cc gii php. Ta cng cn xc nh cc ngun lc cn thit (ti chnh, nhn lc, thi gian, v.v) v xy dng mt k hoch thc hin. Phiu c cho im theo phng php chuyn gia, da trn nhn xt ch quan ca cc thnh vin. PHIU CNG TC 17: La chn cc gii php SXSH thc hin
Gii php SXSH Kh thi k thut (25) T TB C Kh thi kinh t (50) T TB C Kh thi mi trng (25) T TB C Tng im Hng
Ghi ch: H s 25, 50, 25 ch mang tnh v d. im c cho vi loi kh thi thp (T): 0-5, trung bnh (TB): 6-14, cao (C): 15-20
94
4.5 Bc 5: Thc hin cc gii php SXSH

Sau khi la chn cc gii php s c trin khai thc hin, c rt nhiu gii php c th thc hin c ngay, nhng cng c nhiu gii php khc li yu cu phi c mt k hoch mang tnh h thng trin khai.
4.5.1 Nhim v 14: Chun b thc hin

Nhm SXSH cn phi chun b cho bn thn cng nh nhng ngi lin quan khc trong nh my trin khai gii php chn. Cng tc chun b c th bao gm xin ph duyt ti chnh, yu cu phi hp t cc b phn c lin quan, thit lp cc mi lin kt trong trng hp cc gii php c lin quan n nhiu b phn, v.v Cc cng vic ny, ngoi kha cnh k thut, cn cn phi c nhng ngi lin quan thc hin cn thn m bo rng s h tr v cng tc ca h c lin tc xuyn sut giai on trin khai. Lin kt tt, nhn thc tt v trao i thng tin tt rt c ch cho cng vic thc thi cc gii php. Cc bng kim nh cng vic lin quan, cc b phn phng ban cn phi lin h, cc a ch cn bit, v.v cng rt hu ch. Phiu cng tc 18 s h tr cho vic lp k hoch trin khai. Phiu ny ghi li nhng ngi chu trch nhim trin khai, theo di tin trin khai v hn hon thnh. Phiu ny cng cho thy tng quan v nhng li ch kinh t v mi trng c th so snh vi cc kt qu thc t t c sau qu trnh trin khai. PHIU CNG TC 18: K hoch trin khai
Gii php c chn Ngy trin khai Ngi ph trch Kt qu Kinh t Mi trng D Thc D Thc kin kin nh gi tin Phng Giai on php
Phiu cng tc 18: K hoch trin khai v quan trc (V d xuyn sut)
Cng vic Cc gii php lin quan n QLNV v KSQT ti phn xng Cc gii php v CTQT Ngi chu trch nhim Cc qn c phn xng Bi K Ln Thi gian thc hin Thng xuyn Thng xuyn Cch thc theo di Xc inh tiu th ha cht, nng lng, in v nc hng thng Xc nh lng nguyn liu, ha cht, nng lng, nc tiu th v cht lng sn phm sau khi trin khai cc gii php
Cc gii php lin quan n Thng Th Ng QLNV v KSQT ton nh my xuyn Vic theo di v gim st chung ca chng trnh SXSH do b Thi Ng, ph gim c nh my chu trch nhim. ng Bui Ky Lan, qun c phn xng c kh chu trch nhim thc hin cc gii php k thut cn tin hnh ti phn xng ca ng. V qun c ny cng phi bo co nh k ln ban lnh o nh my. Cc qun c phn xng chu trch nhim cho cc gii php SXSH c trin khai ti b phn ca mnh, bao gm cc gii php lin quan n qun l ni vi tt, kim sot quy trnh, sa i quy trnh v thit b, theo di kt qu... - Cc gii php cn nghin cu su hn c bn giao li Phng k thut ca cng ty. Phng ny chu trch nhim ln k hoch hnh ng v bo co vi banh lnh o nh my. Ti liu hng dn Sn xut sch hn ngnh hon tt sn phm kim loi 95
K hoch hnh ng cho cc cng vic lin quan ti SXSH

Cng vic Chu trch nhim chung cho ton b cng tc trin khai SXSH Kim sot vic trin khai cc gii php khng cn phi u t ln v c th trin khai ngay Tp hun nh k cho cng nhn lm vic ti cc quy trnh cng ngh Nghin cu kh thi cc gii php cn u t ln Khi ng vng nh gi SXSH tip theo Ngi chu trch nhim Th Ng Qun c cc phn xng Bi K Ln Phng k thut Th Ng Thi gian thc hin Thng xuyn Thng xuyn Thng xuyn 2004 6/2004 Cch thc theo di
4.5.2 Nhim v 15: Trin khai cc gii php

Vic trin khai cc gii php SXSH cng tng t nh cc ci tin cng nghip khc v khng cn phi m t qu chi tit y. Cc nhim v bao gm chun b s v bn v, ch to/mua sm thit b, v vn chuyn n cng trng, lp t v vn hnh. Khi cn c th tin hnh o to nhn lc song song v ngay c nhng gii php tuyt vi nht cng c th b tht bi do khng c tip qun bi nhng ngi c o to y . Nhm trin khai cn bit r v cng vic cng nh mc ch cng vic mc c th, v c nhng gi hu ch thng xut pht t i trin khai.
4.5.3 Nhim v 16: Quan trc v nh gi kt qu

Cui cng, cc gii php c trin khai cn phi c quan trc nh gi vic thc hin. Cc kt qu thu c cn phi ph hp vi nhng g c tnh/tnh ton trong nh gi k thut; v cc nguyn nhn sai lch, nu c, cng phi c nu ra. C th dng phiu cng tc 19 thc hin mc tiu ny. Cc vn sp xy ra cn phi c bit nh du v lu tm. Cn phi chun b bn bo co y trnh ln ban lnh o. Nhng ngi c lin quan cn phi c bit cc kt qu ny. Cng tc trin khai ch c coi l kt thc sau khi thc hin thnh cng v duy tr hot ng n nh trong mt thi gian di. PHIU CNG TC 19: Quan trc kt qu thc hin SXSH
Tn u vo Cc li ch k thut n v Trc khi p dng SXSH Sau khi p dng SXSH Tit kim hng nm Cc li ch kinh t Tng tit kim hng nm: Cc li ch mi trng
Ha cht Nc in Du .
Gim tiu th Ha cht 3 Gim ...m nc thi Gim tn CO2 Gim ... kg ho cht thi Gim BOD, COD
96
.. ng
Phiu cng tc 19: Theo di v nh gi kt qu (V d xuyn sut)

Tn nguyn liu hoc ngun lc in cho cng on sy Nc ti xng DEMO (th im) Ha cht chnh: Chromic Nc phn khc cc xng Trc SXSH Cc li ch k thut Thc t sau Nguyn liu v SXSH nng lng tit kim c 80kwh/ngy 0,0026 m3/dm2 0,579 2 gram/dm 630m3/thng 120kwh/ngy 0,0005m3/dm2 Cc li ch kinh t (VND/nm) Cc li ch mi trng (lng pht thi gim/nm) Pht thi CO2 gim 40,44 tn /nm Nc thi gim 312 m3 /nm Crom thi ra mi trng gim 63,76 kg /nm Nc thi gim 3 1440m /nm
200kwh/ngy 0,0031m3/dm2
59.904.000
1.872.000
0,681 2 gram/dm 750 m3/ thng
0,102gram/dm2
2.359.000
120m3/ thng
8.640.000
Tng: 72.775.000 VND/nm Nhn xt: S liu v in cho sy v nc cc phn xng khc bng ny tnh theo n v lng/thi gian, v th m php so snh l khng khch quan v thiu chnh xc. c con s theo di li ch do cc gii php SXSH mang li mt cch ng tin cy, cn thu thp s liu tiu hao cc u vo trn mi dm2 nh hai thng s cn li trong bng trn.
4.6 Bc 6: Duy tr hot ng SXSH

Thch thc ln nht cho cc hot ng SXSH cc nh my nh l lm th no duy tr bn vng chng trnh SXSH. Thnh cng ca chng trnh SXSH d b tiu tan, v nh my li tr v tnh trng nh ban u. S nhit tnh v tc ca i SXSH cng c xu hng trng xung. Thng th lnh o cao nht l ngi chu trch nhim cho nhng ci kt ng bun . Rt b cam kt, chi ph sn xut ph tri, khng c chnh sch khen thng v khch l cng vic v hon i cc u tin chnh l nhng l do thng gp phi m chng ta cn phi kim tra v trnh. Vic quan trc v xem xt li cc gii php trin khai cn phi c trnh by c th khch l c mong mun gim thiu cht thi. Cn phi c n lc tch hp SXSH vo quy trnh lp k hoch thng ngy ca cng ty. Vic tham gia ca nhiu nhn vin v khen thng cho ngi xng ng s l mt cha kha chc chn m bo s bn vng ca chng trnh. Trin khai xong cc gii php SXSH trong khu vc nghin cu, nhm SXSH nn tr li bc 2 Phn tch quy trnh tin hnh xc nh cng nh la chn cc bc quy trnh gy lng ph tip theo. Chu trnh ny s li din ra lin tc ti khi tt c cc bc c thc hin y . Khi ti bc u tin c trin khai, cc c hi SXSH khc s c th xc nh c, v iu ny cho php tip tc chu trnh. Ni tm li, trit l SXSH cn phi c xy dng ngay chnh trong cng ty. iu ny c ngha l SXSH cn phi tr thnh mt phn khng th tch ri ca hot ngsn xut ca cng ty. Mi chng trnh SXSH thnh cng cho ti nay u p dng trit l ny.
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Tr ngi trong vic thc hin SXSH v cch khc phc

Chng ny cp n cc tr ngi khc nhau khi tin hnh nh gi SXSH. ng thi cc bin php khc phc cc tr ngi ny cng c xut. Cc bin php ny c th thuc phm vi ngnh hoc cng c th l cc quyt nh mang tnh chnh sch ca chnh ph.
Gn y SXSH c chng minh l mt trong nhng cch thc tip cn ch ng nhm nng cao kh nng sinh li, ci thin mi trng lm vic v gim nhim trong ngnh x l hon tt sn phm kim loi. Tuy nhin, cn tn ti mt s loi ro cn c th lm ngng tr hoc cn tr tin ca mt chng trnh SXSH. Chng ny s bn n mt s ro cn i vi vic trin khai chng trnh SXSH, gm: Ro cn thi Ro cn h thng Ro cn t chc Ro cn k thut Ro cn kinh t Ro cn chnh ph
Vic xc nh cc tr ngi thng s h tr pht sinh ra nhng gi vt qua. V th chng ny s a ra nhiu bin php i ph v g b cc ro cn. y l nhng bc ch ng, tch cc m nhng ngi ng h SXSH c th p dng khc phc tr ngi khi xy dng tng v thc hnh mi thng km hm chng trnh SXSH. Th t trnh by cc ro cn cng nh gii php trong phn ny phn nh trnh t m cc ro cn thng pht sinh. Tuy nhin, cch phn loi ny khng phi l bt buc p cho tt c cc nh my, bi l cc ro cn gp phi trong bt k nh my no cng u c th l kt qu ca nhiu cn tr ng thi. Xin c li khuyn cho cc cn b lnh o nh my l nhng ro cn cng nh bin php cn phi c xc nh c th cho tng doanh nghip v khng bao gi c bin php chung no ph hp cho mi doanh nghip.
5.1 Cc ro cn thi
Thi phn nh trong cc cu ni nh S lun phi chu tn km nu quan tm n mi trng v SXSH trong thi gian ti l iu khng tng vn cn ph bin trong cng nghip. Tuy nhin nhng cch nhn ny s t i nu xem xt n kinh nghim thc tin hoc c tnh chi ph thc t, v v th, chnh l cc v d hon ho v nhng ro cn thi cn tr doanh nghip quan tm cc gii php SXSH. Cc nh gi SXSH hoc cc nghin cu khc thng ch ra rng nhiu loi ro cn khc nhau c a ra di cc thut ng ti chnh hoc k thut nhng k thc li l vn thi . Ta c th phn loi ro cn thi nh sau: Bng quan vi cc vn qun l ni vi v mi trng Khng mun thay i
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5.1.1 Bng quan vi cc vn qun l ni vi v mi trng

Qun l tt ni vi mang tnh vn ha nhiu hn l k thut. Rt nhiu doanh nghip va v nh (SMEs) l nhng doanh nghip gia nh v v vy hiu bit v vn ha qun l ni vi cha y . Cc doanh nghip ny t khi hnh thnh khng c c mt h thng qun l chuyn nghip. T nhng ngi cng nhn n ngi iu hnh cao nht u coi nhng thiu st trong qun l ni nh mt phn tt yu ca hot ng cng nghip ch khng phi l do li qun l hoc hiu qu km. Li suy ngh ny trong cng nghip gy ra cc vn mi trng, l kt qu do s th trc cc vn mi trng v mt h thng nh gi khng ng mc cc vn mi trng khi ch quan tm ti cc chin lc kinh doanh v mc ch kim li trong thi gian ngn.
5.1.2 Khng mun thay i

Nhn s ca nh my thng khng mun thay i do s tht bi hoc do khng hiu bit. Rt nhiu cng nhn vn hnh khng c o to mt cch chnh quy v ngn ngi trc cc hot ng th nghim v h s rng nhng thay i so vi thc hnh tiu chun lm h mt kh nng kim sot quy trnh v gim nng sut. V th m ngi ta thng t chi th nghim cc gii php SXSH. S e ngi chnh l nn tng pht sinh hi chng ng bt ti l ngi u tin (NMF not me first), ngha l ngi ta khng sn sng th bt k tng no nu nh cha c thc hin thnh cng u trc.
5.1.3 Cc bin php khc phc cc ro cn thi

Cc gii php sau y rt c hiu qu i ph vi cc ro cn thi : Thnh cng sm C s tham gia ca cng nhn Khch l hot ng th nghim Cng b nhng thnh cng u tin v SXSH
Thnh cng u tin v SXSH Nhng thnh cng u tin c th khch l ban lnh o cng nh cng nhn vn hnh v qun c tip tc cc th nghim SXSH. Cc nh gi trc ht cn phi nhn din cc gii php hin nhin vi chi ph thp hoc khng tn chi ph. Cc gii php ny dn n vic loi b cc thiu st trong qun l ni vi, bo dng v kim sot quy trnh, c con s tit kim ti chnh r rng, v thng c xc nh trong cuc kho st thc a ln u tin ti cng ty. C s tham gia ca cng nhn loi b c cc ro cn thc trong ton b i ng cng nhn vin ca doanh nghip, th ngay t u mi nhn vin u phi c tham gia xy dng cc gii php SXSH.
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Khch l cc hot ng th nghim (c bit l vi cc gii php chi ph thp hoc khng tn ph). Ni lo s v tht bi v nhng iu v hnh c th c loi b bng nhng hng dn c th ng trng tm th nghim nh sa i quy trnh lm vic hoc chn loi nguyn liu th hoc cc ph gia thay th. hn ch ti a ri ro, cc hot ng th nghim nn bt u bng nhng thc hnh khng tn chi ph hoc chi ph thp, chng hn nh ci thin cng tc qun l ni vi v ti u ha quy trnh, v dn dn s m rng da trn cc bi hc kinh nghim thu c. Cng b nhng thnh cng ban u trong thc hin SXSH: Cc nh my nn nhn mnh nhng li ch c v ti chnh ln mi trng ca nhng thnh cng ban u trong thc hin SXSH nng cao nhn thc trong ton th lc lng lao ng v duy tr s cam kt cng nh s tham gia ca nhng ngi c thm quyn quyt nh chnh.
5.2 Cc ro cn mang tnh h thng

Cc d liu quan trc sn xut v cc quy trnh thng thng phn tch d liu c ngha rt quan trng gip trnh c nhng cuc tho lun mang tnh ch quan v phin din trong khi tin hnh nh gi SXSH. Vic thu thp d liu v xy dng cc h thng thng tin trong ni b cng ty l iu kin tin quyt thit lp ln mt c s chnh xc v ng tin cy trong SXSH v cc hot ng khc. Tuy nhin, c kin cho rng cc li ch kinh t mang tnh tc thi ca vic khng lu gi h s sn xut c th lm lu m cc u im ca hot ng thu thp v nh gi d liu mt cch thch hp nhm hng ti ti u ha quy trnh sn xut. Mc d vic thu thp cc d liu nn l mt iu kin quan trng bt u cc hot ng SXSH nhng thng th cc cng vic ny cha phi bt buc phi lm ngay cho ti khi nhng thiu st trong qun l ni vi v bo dng thit b c hon ton loi b. Cc ro cn mang tnh h thng c th c xc nh nh sau: Thiu k nng qun l chuyn nghip, Cc h s sn xut s si, Cc h thng qun l khng y v km hiu qu,
5.2.1 Thiu cc k nng qun l chuyn nghip

Hin nhiu cng ty vn c th cn c s thiu ht trong nhng lnh vc sau thuc cc k nng qun l chuyn nghip: K nng lnh o: rt t ch doanh nghip hoc nhng ngi c quyn quyt nh l nhng nh qun l chuyn nghip v thng khng thc hin ng vai tr lnh o v dn dt cn thit pht trin doanh nghip. Kt qu l nhn vin b hn ch t duy sng to trong nhng cng vic chi tit hng ngy m khng c cc mc tiu cho tng lai.
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K nng gim st: Nhng ngi qun c trong cc doanh nghip va v nh thng l nhng ngi c c ln v h c thnh tch tt trong cng vic m khng phi l ngi c o to k nng gim st: nh hng dn, qun l v dn dt nhng ngi cng nhn khc. V vy m nhng ngi cng nhn vn hnh thng xem cc qun c nh nhng ng nghip cp cao thay v xem h nh nhng qun c phn xng ngi c nhng ch o v tm nhn rng, v l ngi chu trch nhim trc h.
5.2.2 Cc h s sn xut s si
Cc nh my thng khng thc hin c y cng tc ghi chp h s tiu th nc, nng lng, nguyn liu; kim k ha cht, nhin liu v nguyn liu th; cc phiu ghi chp hng ngy ti xng v thng tin u vo, u ra, thi gian dng my, v.v...; hoc cc ghi chp v mi trng nh cht lng v khi lng cht thi lng, rn v kh. Do duy tr hot ng ghi chp h s nn cc k nng phn tch nh gi d liu khng c rn ra, y l mt thiu st lm nh hng n vic xc nh cc gii php mt cch c h thng.
5.2.3 Cc h thng qun l khng y v km hiu qu

Khi khng c mt h thng qun l tt, th cc lung chc nng, trch nhim bo co, v trch nhim cng vic s khng c r rng. S m h v cc tiu ch thc hin s lm cho cng nhn ln trnh cc cng vic khng thng l nh cc gii php lin quan n SXSH. Cc l hng trong h thng qun l c bit r rng trong cc kha cnh sau: Nng cao tnh chuyn nghip cho cng nhn: rt nhiu cng ty cha thc hin y hoc khng thc hin cng tc o to mt cch h thng nhm nng cao cc k nng ngh nghip cho cng nhn v vy m ngi cng nhn khng c cp nht vi nhng khi nim mi trong cng nghip nh SXSH. Lp k hoch sn xut: Cc k hoch sn xut thng c lp trn c s tng ngy mt, iu ny lm cn tr cng vic lu di mang tnh h thng, chng hn nh vic thu thp s liu u vo hoc nh gi tc ng cho cc bin php trin khai.
5.2.4 Cc bin php khc phc ro cn mang tnh h thng

Cc bin php khc phc sau y c a ra nhm gii quyt cc cn tr mang tnh h thng: Lp h s v bn v s nh my chi tit y Xy dng b phn bo dng SXSH trong ni b cng ty o to mt nhm SXSH cp nh my Xy dng cc ch s qun l n gin Phat ng qun l tt ni vi t tt c cc cp. Qung b cc v d thnh cng
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Lp h s v bn v s nh my chi tit y Cc nh my c th hon thin cc bn v s v ti liu v c s mnh bao gm tt c nhng d n sa cha v m rng cng sut gn y nht. Cc ti liu ny s l ngun thng tin quan trng cho cng tc phn tch v nh gi d liu trong cc nh gi SXSH. Xy dng b phn bo dng SXSH trong ni b cng ty Thng thng, cc cng ty c b phn bo dng ni b v cc thit b ch to c bn s lun i trc mt bc so vi cc cng ty phi ph thuc vo cc nh thu bo dng v sa cha bn ngoi. o to mt nhm SXSH ca nh my Vic t chc mt cuc tp hun cho nhm SXSH ca nh my khi bt u tin hnh nh gi SXSH l mt trong nhng khuyn co hng u. Cuc tp hun ny cn phi lm r cc mc tiu SXSH gim cc tc ng mi trng bng cch nng cao hiu qu sn xut v chng minh c nhng li ch ca vic sn xut c k hoch v s cn thit phi thu thp v nh gi cc h s sn xut mang tnh thc cht. Cng ty cng cn phi ch minh ha nhng phng php gii quyt vn , nu c km cc v d ca chnh cng ty th cng tt, chng hn nh nhng thiu st trong qun l ni vi hoc bo dng. c c nhng kt qu tt nht, nhng ngi ra quyt nh ch cht, bao gm c ch s hu doanh nghip ln cc qun c phn xng cn phi tham gia hot ng ny. Xy dng cc ch s qun l n gin Khi khng c nhng k nng qun l chuyn nghip, th cng ty cn xy dng cc ch s n gin gip ban lnh o v cc qun c c th kim sot c cc quy trnh sn xut v hn ch ti a vic lng ph nguyn liu, nc v nng lng. Cc ch s n gin nh lng nguyn liu u vo v nng lng tiu th trn mt n v sn phm u ra c th l th hin c cc li ch khi ci thin cng tc qun l ni vi, v l c s khi xng cc n lc lin tc trong vn ny. Pht ng qun l ni vi tt c cc cp Nh c th thy rt nhiu cng ty thc hin kim sot cng tc qun l ni vi, cng tc ny s c ci thin khi c cp lnh o lm gng. Ban lnh o cao nht ca doanh nghip c th u n xc nh nhng thiu st trong vic qun l ni vi, v d nh thit b v ng ng b r r v nguyn liu ri trn, v theo di st vic loi tr nhng thiu st ny. Qung b cc v d thnh cng Cc v d thc hin SXSH thnh cng c th gip to ra v nng cao nhn thc v SXSH. Nhng trng hp ny cn phi c ghi chp li chi tit gm cc d liu trc v sau lin quan n c kinh t v mi trng, qua chng minh vai tr quan
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trng ca h thng thng tin chnh xc i vi s thnh cng ca chng trnh SXSH. Ti liu v cc cuc hi tho chung cng nh chuyn ngnh c th l nhng bin php qung b hu hiu cho nhng thnh cng t c.
5.3 Cc ro cn t chc
C cu t chc ca mt cng ty c th cn tr vic a vo p dng cc thc hnh qun l mi trng. V th, vic nh gi mi lin h ca cc nhim v v trch nhim n qun l sn xut v cc vn mi trng c phn chia nh th no trong cng ty v khuyn ngh thay i thun li cho chng trnh SXSH l rt quan trng. Qun c phn xng v cc nhn vin k thut cn tham gia vo nhm d n, cng nh s hp tc vi cc t vn vin bn ngoi. Cc ro cn mang tnh t chc c th c phn thnh 3 nhm tch bit nhng lin quan vi nhau (c bit l trong cc SMEs): Tp trung ho quyn ra quyt nh Qu ch trng vo sn xut Khng c s tham gia ca cng nhn.
5.3.1 Tp trung ho quyn ra quyt nh

Thng ngi a ra mi quyt nh l gim c iu hnh, d ch l nhng quyt nh v gii php n gin t tn km. Cc v lnh o ny thng khng nm c nhng tc ng tch cc ca cc cng c to ng lc, v d nh cng nhn v tng thng cho nhn vin hoc cc ch khen thng v khch l. Khng c chia s trch nhim a ra quyt nh, cc nhn vin khc thiu ch ng tham gia cc nhim v mi c tnh thch thc nh SXSH, v nu thnh lp nhm SXSH, cc thnh vin ca nhm c th s cho l h khng c vai tr g thc s trong chng trnh ny.
5.3.2 Qu ch trng vo sn xut

Sc p sn xut c th dn n vic khng ch trng dnh thi gian v cng sc cn thit tin hnh nh gi SXSH. mt s cng ty, s ch trng ny c duy tr bi thc t l tin lng cho cng nhn c thanh ton theo hnh thc khon sn phm, theo cng lm ra nhiu sn phm th thu nhp ca ngi cng nhn cng cao. V trong mt h thng kiu ny th s c khuynh hng b b qua vn v SXSH v cc tiu chun v qun l ni vi nng cao s lng sn phm.
5.3.3 Khng c s tham gia ca cng nhn

Ngi lao ng b phn sn xut khng tham gia vo cc hot ng SXSH tr phi h c gim c iu hnh ra lnh. Cc cng nhn k thut thng gp phi tnh trng cng vic qu ti v khng c thi gian tham gia vo thc hin nh gi SXSH. i khi h c cc nhn vin trnh thp tham gia vo cc cuc hp nhm SXSH vi l do cng vic qu ti.
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5.3.4 Cc bin php khc phc cc ro cn mang tnh t chc

Cc c ch i ph vi cc ro cn mang tnh t chc gm: Chia s thng tin T chc nhm d n c nng lc Cng nhn v khen thng nhng n lc thc hin SXSH Xc nh chi ph i vi sn xut v pht thi.
Chia s thng tin Chia s cc d liu v chi ph gia cn b qun l v cc cng nhn vn hnh s khuyn khch nhng cng nhn vn hnh lm vic cn thn hn vi cc nguyn liu t tin. Chia s thng tin v cc nguyn nhn hng thit b nhn din c hoc cc sn phm khng t tiu chun, gia cc cng nhn vn hnh, gia ngi cng nhn k thut v qun c, s to iu kin thun li cho tip cn gii quyt vn loi b cc nguyn nhn pht sinh lng ph. T chc mt i d n c nng lc Mt i SXSH c t chc tt v c nng lc l mt iu kin then cht thc hin nh gi SXSH v loi b cc ro cn ca SXSH. Tuy nhin, vic thit lp mt nhm SXSH hiu qu c th khng phi l mt vic d dng khi tnh n kh nng t c cng nhn v mc u tin dnh cho hot ng SXSH hin cn ang thp, t l tham gia cng nhn t, v cung cch qun l chuyn quyn. V th cn phi to ra c th cn bng gia tnh hung mong mun l mt i d n thc hin tt chc nng ca mnh - c th t mnh xy dng v thc thi gii php SXSH - v tnh hung ph bin l cu trc t chc hn ch quyn quyt nh v cn tr s sng to trong gii quyt vn . Cc cng ty nn chn i trng l ngi c thm quyn quyt nh vic thc thi ch t l cc gii php chi ph thp v khng tn chi ph. Nhm ny cng cn phi c mt hoc vi v qun c v cng nhn c lin quan trc tip nht (cc cng nhn trong phn xng). Cng nhn v khen thng cc n lc thc hin SXSH Khi nhm nhn nh v nh gi c cc c hi SXSH, th cng ty cn phi thit lp ra cc c ch khch l ng vin cho nhm chng hn nh cng nhn rng ri v chng trnh, cc phn thng, v cng b nhng thnh cng ban u. Xc nh chi ph sn xut v pht thi m rng phm vi qun l vt ra ngoi qun l thnh phm nhm tin ln mt bin php qun l ton din hn v tnh hiu qu ca sn xut th vic xc nh cc chi ph cho tng yu t sn xut khc nhau v dng thi l v cng cn thit. Thng thng, cc nh qun l c th c khuyn khch thc hin nh nhng php tnh n gin v gi tr bng tin ca nguyn liu, ha cht v nhng sn phm b tht thot cho mt dng thi c bit no .
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5.4 Cc ro cn k thut
SXSH thng yu cu phi c nhng thay i k thut trong cc h thng thit b, cng c, cc nguyn liu u vo, ph gia, quy trnh v thit b. Do vic trin khai SXSH ph thuc vo cng ngh, cc yu t k thut thng tr thnh nhng ro cn trong qu trnh ny. Cc ro cn k thut trong cc nh my hay doanh nghip va v nh (SMEs) c th nhm li nh sau: Nng lc k thut hn ch Tip cn thng tin k thut cn gp hn ch Cc hn ch cng ngh
5.4.1 Nng lc k thut hn ch

Vi hu ht cc SMEs, nng lc sn xut b gii hn trong phm vi kinh nghim ca ngi cng nhn m hu ht khng c nng lc trnh k thut gim st, iu khin v ci tin cng ngh sn xut. Cc hn ch v tay ngh k thut c th nm di cc dng: Ngun nhn lc khng c o to hoc c o to khng y : khng c nhn s k thut trong cng ty hoc ti a phng, v vy m nhiu cng ty phi ph thuc vo cc chuyn gia bn ngoi tin hnh nh gi SXSH. Thiu cc phng tin quan trc: khng c cc phng tin quan trc trin khai nh gi SXSH nn nhiu cng ty phi ph thuc vo mt s lng c hn cc c quan bn ngoi, chi ph tn km v thng c tr s xa. Khi khng c y trang thit b quan trc th vic thu thp d liu nn s b nh hng. Cc iu kin bo dng cn hn ch: B phn bo dng ti cc doanh nghip va v nh thng ch c trang b v cung cp nhn s va cho cc hot ng bo dng thng thng v ng tic l nh vy th khng c kh nng ng ph vi cc trng hp s c thit b h hng xy ra. cc cng ty ny, cc cng vic bo dng ln nh i tu, qun li ng c v lm v sinh ni hi thng phi nh n cc cng ty bn ngoi vi chi ph m cc SMEs u e ngi v v th lm nh hng n cng tc trin khai SXSH.
5.4.2 Tip cn thng tin k thut cn gp hn ch

Thng thng cc SMEs hay gp hn ch trong vic tip cn cc ngun thng tin k thut v nhng trng hp thnh cng v gim tiu th ti nguyn v cc k thut t lng ph. Ngoi ra, hu ht cc cng ty u khng c ti liu k thut thch hp. Cc thng tin t nc ngoi khng phi lc no ph hp hoc khng phi l c vit ring cho thc t v quy m k thut trong hot ng ca cc SMEs.
5.4.3 Cc hn ch v cng ngh

Cc khong cch cng ngh vn cn tn ti cc SMEs bt chp nhng n lc hin i ha, do cc quy trnh li v theo li mn bin i hu ht cng ngh c truyn
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thng thiu nghin cu yu t k thut v ha hc c bn ca h thng. Chnh s b qua ny dn n tnh trng tn dng thit b khng hiu qu, di mc ti u v rt cuc l pht thi mc cao.
5.4.4 Cc bin php khc phc ro cn k thut

Cc nh my c kh nng vt qua nhng ro cn k thut l nhng ni c cng nhn c o to nhng k nng k thut ph hp v khng phi ph thuc vo cc ngun bn ngoi v cc nhu cu ch to ca cng ty mnh. Cc ro cn tip cn cng ngh ph hp c th c khc phc thng qua cc bin php sau: Nhn vin c trnh k thut cao Trang b c s vt cht cho cng tc gia cng ti nh my Qung b cc v d thnh cng khi p dng cc k thut v cng ngh SXSH H tr theo nhu cu cho cng tc nghin cu v pht trin v mi trng.
Nhn vin c trnh k thut cao Nhng cng ty s hu nhng cng nhn c trnh k thut s gp t kh khn hn khi bt u tin hnh SXSH. Cc nhn vin ny c th d dng tip thu nhng khi nhim mi v SXSH v c th vn dng phng php lm vic chung trong nhng tnh hung c th ti cng ty mnh. Trang b c s vt cht cho cng tc gia cng ti nh my Cc doanh nghip va v nh c truyn thng tn dng cc thit b c, b thi ra ni khc mang v sa cha s dng theo mt cch mi v ci tin, v qua tch ly thm trnh chuyn mn trong vic tm ra k thut sa cha n gin nhng thng minh. c bit cc cng ty thc hin ch to ti ch (nh c cc xng c kh, in hay dn dng) th thng c nhng kh nng chuyn mn gip h c th nhn din ra cc gii php SXSH hoc bin nhng xut ci tin m cc chuyn gia bn ngoi gi thnh cc gii php. Qung b cc trng hp thnh cng khi p dng cc k thut v cng ngh SXSH Qung b cc k thut v cng ngh SXSH thnh cng c th to ra mt ng lc mnh m xa b nhng tr ngi k thut c hu. Vic pht hnh cc ti liu k thut SXSH v t chc cc hi tho v hi ngh chuyn l nhng hot ng hu hiu trong cng tc qung b nhng thnh cng ny. chun ha vic thc hin cc k thut v cng ngh SXSH trong phm vi ngnh th cc k thut cng nh cng ngh ny cn phi c qung b ti cc doanh nghip thng qua cc t chc trung gian nh cc c quan dch v cng nghip, cc t chc chuyn nghip, cc hip hi cng nghip v thm ch l c nhng nh cung cp thit b.
106
H tr theo nhu cu cho cc nghin cu v pht trin v mi trng Cng tc nghin cu v pht trin s gip xa b nhng khu vc m ti ngay c cng ngh tin b nht cng khng th ngn chn c cc vn mi trng theo cc quy m sn xut c th ca cc doanh nghip va v nh.
5.5 Cc ro cn kinh t
Cc ro cn kinh t chnh ca SXSH l: Cc u i ti chnh thng u tin khi lng sn xut hn cc chi ph sn xut Nguyn liu th gi thp v d kim Chnh sch u t hin hnh Vn c chi ph cao v v kh tip cn
5.5.1 u tin cho khi lng sn xut hn l chi phi ph sn xut

Cc u i ti chnh ph bin hin nay, nh min gim v thu thu mn bi, thu thu nhp doanh nghip, v.v... ch yu lin quan n khi lng sn xut v rt t hoc khng c lin quan g ti cc chi ph sn xut. V th cc doanh nghip thng c xu hng tp trung ti a ha sn xut to ra li nhun ti chnh ti a v xp vic thc hnh gim chi ph sn xut nh SXSH sang hng th yu.
5.5.2 Nguyn liu th gi r v d kim

Nhit tnh xc nh v trin khai cc bin php SXSH thng b lm ngui i bi cc ngun ti nguyn thin nhin qu sn v r mt nhiu vng c ti nguyn thin nhin, chng hn nh cc ph phm nng nghip, nc, v nhin liu.
5.5.3 Chnh sch u t hin hnh

Bn cht lm thi ca cc hot ng u t trong ngnh cng nghip x l hon tt kim loi l mt yu t bt li cho SXSH mt s phng din lin quan ln nhau: Gii hn php phn tch kinh t trong phm vi cc chi ph v li ch trc tip: Yu t kinh t ca tt c cc khon u t bao gm c cc gii php SXSH c tnh ch yu da trn c s khon hon vn trc tip v cc khon thu ti chnh ngn hn. V th, ch c tng cng sut sn xut, gim tiu th nguyn nhin liu v gim nhng chi ph sn xut hin nhin, nh lao ng, mi c c bit ch . Nhng li ch tch ly t lng in tiu th gim v chi ph kim sot nhim gim thng khng c tnh n thng xuyn, do cc chi ph thc hin cc gii php nhm thu c nhng khon tit kim cha pht sinh. Cc khon tit kim thu c t cc gii php mi trng thng l mt phn quan trng trong cc li ch kinh t ca cc gii php SXSH. V th, khi khng gp c cc tiu ch vo trong qu trnh phn tch kinh t th cc gii php SXSH kh m c chp nhn.
107
5.5.4 Cc bin php khc phc cc ro cn kinh t

Cc nh my c nn tng ti chnh vng vng, v nhng doanh nghip khng ngn ngi trin khai cc gii php khng tn km hoc chi ph thp thng m rng c cc c hi khc phc cc ro cn kinh t cho mnh. Cc cng ty c th tn dng cc bin php sau: Ti chnh vng mnh Trin khai cc gii php c tnh hp dn v ti chnh Phn b chi ph hp l v u t c k hoch Cc chnh sch cng nghip lu di Cc khuyn khch v ti chnh
V thc t cho thy cc cng ty c kh nng ti chnh vng mnh thng t chu nh hng ca cc ro cn kinh t hn cho nn cn s dng thc trng ti chnh ca cng ty nh mt tiu ch la chn cng ty d trnh din u t cho SXSH.
5.5.5 Trin khai cc gii php c tnh hp dn v ti chnh

Trin khai cc gii php SXSH chi ph thp hoc khng tn chi ph c th m ng cho vic trin khai cc gii php c la chn c chi ph cao hn trong tng lai gn. Trnh din tnh kh thi kinh t ca cc gii php ny c th gip cng ty nh lng c khon h tr ti chnh tng thm.
5.5.6 Phn b chi ph hp l v u t c k hoch

Nhn thc v cc chi ph pht sinh do lng ph l mt im quan trng ca bt c chng trnh SXSH no. dn chng tim nng tit kim nh SXSH, cng ty cn phi tin hnh c tnh chi ph cho rt nhiu yu t trong mt dng thi, v.d: nng lng, nguyn liu th, nc, v sn phm. Khi phn b c cc chi ph ca cc yu t ny, cng ty c th xc nh chi ph cho mt dng thi v c tnh cc khon tit kim thu c t vic gim thiu hoc xa b dng thi . Hot ng ny cng s gip xc nh c khon ti chnh tht thot qua cng thi.
5.5.7 Cc chnh sch cng nghip lu di

Cc chnh ph cn phi trnh vic thng xuyn thay i cc chnh sch cng nghip, mt kiu duy tr vic lp k hoch u t thin cn trong khu vc kinh t t nhn. Cc k hoch u t cng nghip di hn s gip cc nh my tch hp SXSH vo vic lp k hoch u t v khuyn kh h tr nn c tnh cnh tranh cao hn m khng cn c s bo h ti chnh gi to.
5.5.8 Cc khuyn khch v ti chnh

thc y vic trin khai cc gii php SXSH u t ln, cc k hoch ti chnh, trong t u tin cho cc n SXSH hn so vi cc n cui ng ng, c th c nh nc hoc cc c quan ti tr xy dng. Cc k hoch nh th (c tnh d tip cn v th tc n gin) s c nh hng ln ti chi ph vn v tnh sn sng ca cc khon u t cho SXSH i vi cc SME. Cc chnh ph c th to ra nhng u
i ti chnh cho SXSH, chng hn chit khu khu hao 100% cho cc khon u t SXSH t nhn, hay mt chnh sch mua vo ca chnh ph h tr cc cng ty cam kt tham gia thc hin SXSH, hay tr cp thu doanh nghip cho cc cng ty tin hnh nng cp nng lc t ng.
5.6 Cc ro cn t pha chnh ph

Cc chnh sch Nh nc c tc ng n vic ra quyt nh v v vy c th cn tr hoc khuyn khch cc cng ty p dng SXSH. Cc ro cn chnh ph bao gm c cc chnh sch cng nghip trong khuyn khch trin khai SXSH, cc chnh sch mi trng trong khuyn khch hot ng x l cui ng ng thay v cc gii php phng nga.
5.6.1 Cc chnh sch cng nghip

Nh trnh by, chnh sch cng nghip lun thay i s khng c li i vi n lc SXSH. Hin vn cha c cc chnh sch u i nh cp trong phn ny i vi SXSH.
5.6.2 Cc chnh sch mi trng

Cc c quan c thm quyn c xu hng p t mt b gii hn v cc tiu chun pht thi ra mi trng m khng c cc hng dn lm th no gim pht thi. V th cc doanh nghip chn cc gii php kim sot cui ng ng truyn thng nhm p ng nhng quy nh php l, hn l p dng cc thc hnh SXSH hin l iu khng nht thit phi thc hin c tha nhn bi cc c quan cng quyn.
5.6.3 Cc bin php khc phc ro cn chnh ph

Chnh ph c th thc hin cc bin php sau thc y hot ng SXSH: u i ti chnh Thc thi bt buc lut mi trng
u i ti chnh Chnh ph c th xy dng cc k hoch ti chnh, trong t u tin cho cc n SXSH so vi cc n x l cui ng ng. Cc k hoch ny (d tip cn v th tc n gin), c th c tc ng rt ln ti chi ph vn v tnh sn sng ca cc khon u t SXSH i vi cc SME. Chnh ph c th a ra cc chnh sch u i ti chnh cho SXSH, v d nh chit khu khu hao 100% cc khon u t SXSH t nhn, chnh sch mua vo ca chnh ph h tr cc cng ty cam kt thc hin SXSH, v gim thu cho cc cng ty thc hin nng cao nng lc t ng. Thi hnh bt buc lut mi trng Nu lut mi trng khng c cng ch thi hnh th cc doanh nghip s khng nht thit phi nhn ra mt iu l cn gp cc quan ngi v mi trng vo trong hot ng kinh doanh ca mnh.
Ti liu hng dn Sn xut sch hn ngnh hon tt sn phm kim loi 109

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Mc lc

H Ni, thng 2 nm 2010 Nhm bin son

Gii thiu chung

1.1 Ngnh hon tt sn phm kim loi ca Vit nam

1.2 M t quy trnh sn xut

1.2.1 Chun b b mt v lm sch cc chi tit

Chi tit kim loi

Dch ra dng Dch ty g dng

KL/mui KL Cht lm bng Nng lng

Dch m dng Nng lng tht thot

Cc chi tit nhm

A-xt sulphuric/ chromic

bi, cht thi rn

Km 450 C Nng lng

Nhng vo km nng chy

Km bn Nng lng lng ph

Hnh 3: Quy trnh m km cng vi cc u vo v pht thi

Chi tit kim loi

Ci thin cht lng b mt Gia nhit nn

Nng lng hao ph

Hnh 4: Quy trnh sn tnh in

1.3 Cc vn mi trng trong hon tt sn phm kim loi

Dng thi Nc thi Nc thi

c i vi thu sinh c i vi thu sinh c

Percloroetylen, Tricloroetylen, cc dung mi khc Xyanua

M, lm sch bng tang quay, bc lp m, x l nhit, ty g M, crm ho, khc axit

rt nhiu quy trnh

1.3.1 Cc vn mi trng trong cng on tin x l

Cc hp cht hu c bay hi Cht thi nguy hi

Quy trnh Ty du m bng kim

Cc vn mi trng C nguy c gy nhim c cho thy sinh nu nh nc thi ny thot ra mi trng

Ty du m bng phng php in phn

1.3.2 Cc vn mi trng trong cng on m in

S dng cc b dung dch c cha cc ion kim loi v ho cht

Tiu th nng lng Hi axt

1.3.3 Cc vn mi trng trong ph phi kim

Cc b dung dch s dng c cha cc ion kim loi v ho cht

1.3.4 Cc vn mi trng trong hon tt bng sn

Cc ht l lng trong kh thi Mi

Ging nh quy trnh to lp sn lt

Sn xut sch hn Nguyn tc, nhu cu v phng php lun

2.1 Gii thiu v Sn xut sch hn (SXSH)

2.2 Nhu cu v SXSH

2.2.1 Cc tc ng n sc khe v mi trng

2.2.2 Bo ton ha cht v cc cht tr

2.2.3 Kim sot nhim

2.2.4 Sc p cng lun

2.2.5 Cc yu cu ca th trng xut khu

2.3 Tim nng Sn xut sch hn

Chnh sa thit b 9% Equipment

Qun l Good HK ni vi 50% 50%

Kim sot quy trnh Process Control 22%

Technical ch k thut Hnh 6: Li benefits

2.4 Phng php lun nh gi sn xut sch hn

Hnh 7: Phng php lun v nh gi SXSH

BC 2 : PHN TCH CC BC QUY TRNH

BC 3: XUT CC GII PHP SXSH

BC 4: LA CHN CC GiI PHP SXSH

BC 5: THC HIN CC GII PHP SXSH

Hnh 8: Cc bc thc hin phng php lun SXSH

2.5 Cc k thut SXSH

TUN HON V TI S DNG

GIM THI TI NGUN