adaptation of energy efficiency in nepalese brick industry
DESCRIPTION
This presentation provides detailed information about energy saving opportunties in brick kilns in Nepal. It explains the brick making process and show energy saving opportunties The findings are based on a GIZ study conducted in 200 industries in 2012.TRANSCRIPT
CHANCES OF ADAPTATION OF ENERGY EFFICIENT PRODUCTION METHODOLOGY/TECHNOLOGY IN BRICK INDUSTRY”
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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?
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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
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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
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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.
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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
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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
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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)
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Brick Making Process
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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
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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?
?
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How?
• Size of Name block• Depth of the Block 6mm Saving: Rs. 2000 Per day?
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Transportation of Green(Unfired) Bricks
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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
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Clamp(Thado Bhatta) Kiln
• Village•Still running for tile making
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Hoffman Kilns“Chinese Bhatta”Very Few in No.02 in Lalitpur01 in Bhaktapur
Hoffman Kilns“Chinese Bhatta”
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Moveable BTK( Movable Chimney Bhatta)
These are in operation but legal issues!!!
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Moving Chimney BTK
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Fixed Chimney- BTK
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Fixed chimney (Chimey Bhatta) – Natural Draught
•Straight line stacking
•Zig –Zag stacking
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Fixed Chimney- Forced Draught
•Straight line stacking
•Zig –Zag stacking
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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
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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.
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Energy balance of BTKs
Energy Balance in Fixed Chimney04/11/23 29
Opportunity -Thermal Insulation
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Opportunity -Duct design• Single wall outside caused significant heat loss.• Wall should be from fired brick( Not from green brick)
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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
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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
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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
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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
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Thank you
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