Phu Yen Tunnel Brick Factory is one of major brick production facilities under Phu Yen Mineral Joint Stock Company in Phu Yen, a coastal province in Southern Central Vietnam. The factory was built and began operations in 1999 and shortly after that it has become one of major construction brick suppliers in the province and outlaying localities.

Producing diverse kinds of bricks under traditional methods by tunnel kilns, the factory consumes a huge energy amount. Each year, it spends over VND3 billion (VND1 billion on electricity cost and over VND3 billion on coal expenses) on energy expenditure.

Cutting-edge technology

Phu Yen Tunnel Brick Factory uses electric power and heat as major energy sources in which electric power is used for lighting and production purposes while heat is taken from coal dust burning chamber to fuel brick production process.

Survey results show that around 123kg of coal dust and around 37,238kWh are used in producing 1,000 bricks. Though electrical power holds a minor role in the whole production process, however as the electricity charge is high, particularly in peak hours the spending on electricity makes up as high as 22 percent in the production cost.

Unlike many other brick producers employing obsolete production lines that incur huge fuel wastes and pose a real threat to the environment, Phu Yen Tunnel Brick Factory is a bright example for effective use of energy. The factory director, Nguyen van Le, said proudly about cutting-edge production lines the factory had employed “The factory’s major power-consuming equipment are part of a cutting-edge production process that has brought online for a short period of time, therefore they are in good conditions. The burning chamber is running efficiency, particularly in thermal insulation and procurement. Close eyes are set to ensure smooth equipment performance and effective burning chamber’s heat control to be able to draw timely adjustments. Therefore, the factory reaps positive results in its efforts to conserve energy.”

In addition, the factory has mulled over coal mixing recipes to specific kinds of bricks to turn out best quality items with an effective use of energy. Accordingly, it has set standard norms for coal consumption to specific brick types, making it comfortable to trace the coal volume being used in production each month, from there drawing rectification measures in a timely manner when detecting any problem.

Moreover, the management sought support from consultants and auditors to help the factory best conserve energy.

Myriad opportunities

With active support from energy auditors under Phu Yen Industrial Consultation and Energy Efficiency Center, Phu Yen Tunnel Brick Factory has become accessible to a series of highly feasible energy efficiency solutions.

Phan Tuan Vu, as the manager of an auditing project at the factory, said “Lots of businesses are cautious when being asked to embark on energy efficiency measures. However, sometimes low-cost solutions such as bettering awareness of employees or management capacity can bring exceptional outcome.”

Reality shows that the factory can easily detect a surge in electric power and coal dust consumption by setting close eyes on the production process. Based on the factor, the auditors suggested the factory establish an energy watchdog team whose core functions are to increase propagation and host training courses on how to operate energy-consuming equipment in an efficient manner, and to sum up reports on energy consumption situation, from there introducing timely remedies. Besides, it is also necessary to present a suitable reward and fine regime to heighten employees’ responsibility in saving energy.

The factory is expected to save VND344 million per year through effectively managing the power and coal volume alone.

As for the lighting system, the factory san save VND10.2 million per year and avoid emitting more than four tonnes of carbon dioxide into the environment annually if it replaces existing 1.2m T10-40W fluorescent lamps with magnetic ballasts with 1.2m T8-36W or T5-28w with magnetic ballasts with shades, changes incandescent lamps with compact lamps and existing high-voltage 250W lamp sets with high-voltage 75W or 150W lamp sets.

The factory can save another VND160 million per year by installing three inverter sets for specialized machines. However, the solution is relatively costly with a long time for capital recovery. However, alongside energy efficiency effect, these inverter sets help extend the durability of machines.

The inverter set is also proposed to be installed in other parts in the factory such as it is suggested to be installed at tunnel kiln fans. The proposed solutions can help the factory save around VND115 million per year and avoid emitting 48 tonnes of carbon dioxide into the environment.  

 By Nga Nguyen