Adaptation of Energy Efficiency in Nepalese brick industry
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The document outlines the energy efficiency challenges and opportunities within Nepal's brick industry, highlighting the prevalence of traditional brick kilns and the potential for adopting more efficient production methodologies. It presents data on fuel consumption, greenhouse gas emissions, and existing technologies while suggesting improvements through better housekeeping practices and technology transfer. The document emphasizes the importance of government policies and awareness in promoting energy-efficient practices in brick production.
Adaptation of Energy Efficiency in Nepalese brick industry
- 1. CHANCES OF ADAPTATION OF ENERGY EFFICIENT PRODUCTION METHODOLOGY/TECHNOLOGY IN BRICK INDUSTRY” 1 INTEGRATION environment & energy Bahnhofstrasse 9 D-91322 Grafenberg GERMANY Federation of Nepalese Chambers Commerce and Industries Teku, Kathmandu Nepal Energy Efficiency Centre FNCCI, Teku, Kathmandu Nepal 07/31/13
- 2. 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? 07/31/13 2
- 3. GIZ/NEEP & FNCCI Initiative Component 3, Industrial Energy Efficiency component Energy Efficiency Centre within FNCCI Pilot Energy Audit Auditors trainings and certification Awareness & Knowledge Management Centre Financial institutions for EE market environment Component 1: Energy Efficiency policy Component 2: House hold appliance and ICS 07/31/13 3
- 4. 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 07/31/13 4
- 5. 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. 07/31/13 5
- 6. 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 07/31/13 6
- 7. Overview • Specific coal consumption is 240.97 kg/1000 bricks and 21.27 kWh/1000 bricks in BTK 530 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 07/31/13 7
- 8. GHG emission • Per kiln – consumption – 15189 MT out of which 5142 MT can save.- 33500 MT CO2out of which 11322 MT of CO2 • Total GHG emission = 14572500 MT Out of which 4925070 MT Saving potential( 435 kilns in operation) 07/31/13 8
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- 14. 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 07/31/13 14
- 15. 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? ? 07/31/13 15
- 16. How? • Size of Name block • Depth of the Block 6mm Saving: Rs. 2000 Per day? 07/31/13 16
- 18. 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 07/31/13 18
- 19. Clamp(Thado Bhatta) Kiln • Village •Still running for tile making 07/31/13 19
- 20. Hoffman Kilns “Chinese Bhatta” Very Few in No. 02 in Lalitpur 01 in Bhaktapur Hoffman Kilns “Chinese Bhatta” 07/31/13 20
- 21. Moveable BTK( Movable Chimney Bhatta) These are in operation but legal issues!!! 07/31/13 21
- 22. Moving Chimney BTK 07/31/13 22
- 23. Fixed Chimney- BTK 07/31/13 23
- 24. Fixed chimney (Chimey Bhatta) – Natural Draught •Straight line stacking •Zig –Zag stacking 07/31/13 24
- 25. Fixed Chimney- Forced Draught •Straight line stacking •Zig –Zag stacking 07/31/13 25
- 26. PHOTO OF TWO BRICK KILN - Sizing DUCT SIZE 25 FT DUCT SIZE 8 FT07/31/13 26
- 27. 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 saving07/31/13 27
- 28. House keeping options-Spoon size simple 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. 07/31/13 28
- 29. Energy balance of BTKs Energy Balance in Fixed Chimney 07/31/13 29
- 31. Opportunity -Duct design • Single wall outside caused significant heat loss. • Wall should be from fired brick( Not from green brick) 07/31/13 31
- 32. 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 Benefits To Eliminate the Carpet loss which is around 4% To Minimize the moisture content of the fuel 07/31/13 32
- 33. Operating practices Size of Coal • Recommended coal size: ¾" IF large size Coal That causes • Over burnt Brick, • Coal Deposition in Duct. • Environment Problem Large size Coal 07/31/13 33
- 34. Fuel Feeding Pattern( Fixed Chimney) Fig: traditional practice Fig: improved practice (four line firing) Which Benefits •Fuel saving •Minimize the Emission Level 07/31/13 34
- 36. åf/L Leakage on Wicket Gate leads on • Combustion that means more energy( Coal) Consumption. • Problem in Brick quality •Problem in fire travel rate 07/31/13 36
- 37. 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 07/31/13 37