CHANCES OF ADAPTATION OF ENERGY EFFICIENT PRODUCTION METHODOLOGY/TECHNOLOGY IN BRICK INDUSTRY”

1

INTEGRATION environment & energyBahnhofstrasse 9D-91322 GrafenbergGERMANY

Federation of Nepalese Chambers Commerce and IndustriesTeku, KathmanduNepal

Energy Efficiency Centre FNCCI, Teku, KathmanduNepal

04/11/23

Contents• GIZ/NEEP & FNCCI Initiatives• General overview of brick sector• Process• Brick Kilns technology prevalent in

Nepal• Opportunity of efficient production

methodology within the sector• Major Housekeeping issues• Way forward?

04/11/23 2

GIZ/NEEP & FNCCI InitiativeComponent 3, Industrial Energy Efficiency

componentEnergy Efficiency Centre within FNCCIPilot Energy AuditAuditors trainings and certificationAwareness & Knowledge Management CentreFinancial institutions for EE market environment

Component 1: Energy Efficiency policyComponent 2: House hold appliance and ICS

04/11/23 3

General Overview of Nepalese Brick Sector

• Traditional and seasonal business

• There are 435 brick industries in Nepal (ref: baseline GIZ/NEEP)

• There are more about 30 VSBK kilns.

• Most of brick kilns are Bull trench kill(BTK)

• Capacity of brick industry range between 15000- 50,000 bricks per day

• Major cluster Locations Kathmandu and Terai( Jhapa, Morang sunsari, Sarlahi, Bara, Narayanghat, Butwal- Bairahawa Dang, Nepalgunj.

• Movable BTK Banned in 2003(Kathmandu valley), 2005 Out side Kathmandu

04/11/23 4

General overview……

• Coal is the main fuel used which comes from Assam in India

• Apart from coal, a small fraction of sawdust /fire-wood is also used as fuel in these kilns.

• Brick making is an energy and labour intensive process. Hand moulding of green bricks is widely practiced in Nepal

• Few cases of Mechanization from extruders and pug mills.

04/11/23 5

Overview….

• Government has also promulgated the standards on Chimney Height and Emission for the Brick Kiln Industries on 25th Feb 2008 (700 mg/Nm3, 600 mg/Nm3, 400 mg/Nm3)

• As per base line Report GIZ/NEEP, In fiscal year• Production of 24 BTKs – 82,304,400 pcs and 3

VSBKs – 2,650,000 pcs• 34000 per day /kilns(100 operating days), 8833

per day/kilns(100 operating days)• Energy cost is 31.51 % of total turnover in BTK

and 14.41 % in VSBK

04/11/23 6

Overview

• Specific coal consumption is 240.97 kg/1000 bricks and 21.27 kWh/1000 bricks in BTK530 MT of CO2

Thermal saving potential = 33.86%

Per kiln – consumption – 15189 MT out of which 5142 MT can save

• VSBK- 104.75 kg/1000 bricks and 17.07 kWh/1000 bricks , 277.7 MT of CO2

04/11/23 7

GHG emission

• Per kiln – consumption – 15189 MT out of which 5142 MT can save.- 33500 MT CO2 out of which 11322 MT of CO2

• Total GHG emission = 14572500 MTOut of which 4925070 MT Saving potential( 435 kilns in operation)

04/11/23 8

Brick Making Process

04/11/23 9

04/11/23 10

04/11/23 11

04/11/23 12

04/11/23 13

What are alternate bricks

• Differ by Size and Shape• Differ by Weight , light

weight & hollow• Application of bricks

– Decorative bricks– Tiles– Main walls – Side walls– Partition walls

04/11/23 14

Size??

• What is suitable size of brick?

Can we change the size and shape of brick?

?Can we change weight of

Brick with same size and Shape?

?

04/11/23 15

How?

• Size of Name block• Depth of the Block 6mm Saving: Rs. 2000 Per day?

04/11/23 16

Transportation of Green(Unfired) Bricks

04/11/23 17

Intermittent kilns

.Clamps

.Scoves

.Scotch

.Down draught

Continuous kilns

.Moving fire annular kilns-Hoffmann-Bull's trench-Zigzag: Habala, High draught

.Moving ware kilns-Tunnel-Vertical shaft

Brick kilns

Classification of brick kilns

04/11/23 18

Clamp(Thado Bhatta) Kiln

• Village•Still running for tile making

04/11/23 19

Hoffman Kilns“Chinese Bhatta”Very Few in No.02 in Lalitpur01 in Bhaktapur

Hoffman Kilns“Chinese Bhatta”

04/11/23 20

Moveable BTK( Movable Chimney Bhatta)

These are in operation but legal issues!!!

04/11/23 21

Moving Chimney BTK

04/11/23 22

Fixed Chimney- BTK

04/11/23 23

Fixed chimney (Chimey Bhatta) – Natural Draught

•Straight line stacking

•Zig –Zag stacking

04/11/23 24

Fixed Chimney- Forced Draught

•Straight line stacking

•Zig –Zag stacking

04/11/23 25

PHOTO OF TWO BRICK KILN - Sizing

DUCT SIZE 25 FTDUCT SIZE 8 FT04/11/23 26

Opportunities for EE/GHG emission Reduction

• Technology change?- Within BTK’s- Induced draught? Zig Zag setting for

better combustion. - Tunnel Kilns??- VSBK??- Internal fuel? Fly ash brick?- Hand moulding and Extruder ?• Good housekeeping measures for immediate

saving04/11/23 27

House keeping options-Spoon sizesimple measures with Big impacts

• Use of large spoon of capacity 1.5 –2.0 kg leads to the wastage of fuel and over-burning of bricks. Therefore,

• Feed coal at uniform intervals with a spoon of capacity as 750-1000 gms.

• Large size spoon may be used rarely for raising the temperature in particular lines only.

04/11/23 28

Energy balance of BTKs

Energy Balance in Fixed Chimney04/11/23 29

Opportunity -Thermal Insulation

04/11/23 30

Opportunity -Duct design• Single wall outside caused significant heat loss.• Wall should be from fired brick( Not from green brick)

04/11/23 31

Storage of coal

Concrete floor

Coal

Shed

•Never allow dust and Rapis to mix with coal.•Stack coal on a raised platform having proper flooring and drainage.•Coal should be stored in a shed with proper ventilation.

Which BenefitsTo Eliminate the Carpet loss which is around 4% To Minimize the moisture content of the fuel

04/11/23 32

Operating practicesSize of Coal

• Recommended coal size: ¾"

IF large size CoalThat causes • Over burnt Brick,• Coal Deposition in Duct.• Environment Problem

Large size Coal

04/11/23 33

Fuel Feeding Pattern( Fixed Chimney)

Fig: traditional practice Fig: improved practice (four line firing)

Which Benefits

•Fuel saving

•Minimize the Emission Level04/11/23 34

Fuel Feeding Pattern

04/11/23 35

åf/L

Leakage on Wicket Gate leads on

• Combustion that means more energy( Coal) Consumption.

• Problem in Brick quality

•Problem in fire travel rate04/11/23 36

Way forward

• Awareness within BTK’s…………………….• Implementation of housekeeping

measures…• Technology Transfer……………….• Government policy……..? Example

Hallow Brick for government procurement?

• Consumer awareness ………… Building construction companies

04/11/23 37

Thank you

04/11/23 38