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.

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?
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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
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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
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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.
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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
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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
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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)
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9. Brick Making Process
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12. 07/31/13 12

13. 07/31/13 13

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
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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?
?
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16. How?
• Size of Name block
• Depth of the Block 6mm
Saving: Rs. 2000 Per day?
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17. Transportation of Green(Unfired)
Bricks
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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
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19. Clamp(Thado Bhatta) Kiln
• Village
•Still running for
tile making
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20. Hoffman Kilns
“Chinese Bhatta”
Very Few in No.
02 in Lalitpur
01 in Bhaktapur
Hoffman Kilns
“Chinese Bhatta”
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21. Moveable BTK( Movable Chimney
Bhatta)
These are in
operation but legal
issues!!!
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22. Moving Chimney BTK
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23. Fixed Chimney- BTK
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24. Fixed chimney (Chimey Bhatta) – Natural
Draught
•Straight line stacking
•Zig –Zag stacking
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25. Fixed Chimney- Forced Draught
•Straight line stacking
•Zig –Zag stacking
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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.
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29. Energy balance of BTKs
Energy Balance in Fixed Chimney
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30. Opportunity -Thermal Insulation
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31. Opportunity -Duct design
• Single wall outside caused significant heat loss.
• Wall should be from fired brick( Not from green brick)
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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
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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
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34. Fuel Feeding Pattern( Fixed Chimney)
Fig: traditional practice Fig: improved practice (four line firing)
Which Benefits
•Fuel saving
•Minimize the Emission Level
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35. Fuel Feeding Pattern
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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
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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
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38. Thank you
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