March 10,2011 Energy efficiency improvements in Indian brick industry Girish Sethi Director, Industrial Energy Efficiency Division TERI 10 March 2011
March 10,2011
Energy efficiency improvements in
Indian brick industry
Girish SethiDirector, Industrial Energy Efficiency Division
TERI
10 March 2011
March 10,2011
About TERI
• An independent, not-for-profit research organization established in 1974
• Pursuing activities related to energy, environment, and sustainable development
• Staff strength of over 900 drawn from multidisciplinary and highly specialized fields
• Great emphasis on capacity building and education. Set up TERI university in 1999 offering doctoral and master programmes
• Based in New Delhi; regional centres in southern; western and north-eastern India; and staff presence in Japan and Brussels
• Affiliate: TERI-NA in Washington DC, TERI-Europe in London, TERI-Gulf in Dubai
March 10,2011
Indian Brick Sector: Salient features
� Construction sector– Important contributor of GDP; annual growth rate of around 9%
� Solid clay fired bricks – Most popular building material – Annual production ~ 140 billion bricks (2000 – 01 data)– Per capita consumption ~ 100 bricks/capita/year
� Decentralized unorganized production– Decentralized Production: No. of units > 0.1 million – Seasonal operation (Dec to Jun)– Employment for about 10 million workers directly
� Resource Intensive process:– 3rd largest coal consumer (about 24 million tonnes/year)– Large consumption of good quality top soil (400 million tonnes/year)
March 10,2011
Brick making in India
Clamps
BTK
No Bricks
March 10,2011
BTKs - Characteristics
� Production capacity - From few millions to more than 10 millions/ annum
� Market:– Caters to both local and regional markets (up to a distance of 200 km) – Segregation based on quality (generally 5 classes)
� Fuel – Coal transported from larger distances or even imported (e.g
Indonesian/Australian coal).– Agricultural residue
� Production process: Continuous� Workforce:
– Different categories: moulders, loaders/unloaders, firemen
– Migratory labour from far-off regions : Workers contracted through labour contractors by paying advance money
March 10,2011
Key issues facing brick industry
� Technological obsolescence� Increasing fuel prices� Labour shortage – seasonal industry� Unskilled manpower� Increasing demand for quality
products – Niche market for new products
March 10,2011
UNDP-GEF project
� Project objective:To make India’s major brick producing clusters more energy efficient
� Executing Agency – UNDP; Implementing Agency –MoEF; Responsible Partner –TERI
� Project focusing major brick producing clusters in different regions – East, West, North, South and North-East
� Project being implemented through 5 Local Resource Centres
� Project duration – 4 years (2009-13)
Local Resource Centres (LRCs)
PSCST
Varanasi
INP
Bangalore
TERI
Agartala
TSCST
Chandigarh
Ahmedabad
CEPT
March 10,2011
Project focus
� Promote manufacturing of REB products in different parts of the country
� Facilitate market creation of such products� Capacity building of stakeholders� Develop linkage with banks and financial
institutions
March 10,2011
Need for technology upgradation
� Switching over from manual moulding to mechanization e.g. use of extrusion for brick making
� Adoption of better firing technologies e.g. tunnel kiln, Hoffman kiln etc.
� Better control on raw material and product characteristics
� Changes in product profile – Hollow blocks and perforated bricks
� Use of alternate material for brick making e.g. Fal-G bricks with curing instead of baking
� Brick industry to operate round the year
March 10,2011
Challenges
� Technology transfer and adaptation to local needs
� Financing
� Capacity building and awareness generation of large end-users
� Implementation of ECBC guidelines to promote green construction practices
Transformation of brick industry into an organisedindustry set up
March 10,2011
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