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Improving Energy Efficiency of Current Brick Making ProcessSachin KumarTERI, New Delhi

Independent not-for-profit research organization, pursuing activities related to energy, environment, and sustainable development

Based in New Delhi; regional centres in southern; western and north-eastern India; and staff presence in Duabi, Japan and Moscow

Affiliate institutes: TERI-NA, USA & TERI-Europe, UK

TERI University focusing on environmental and sustainability studies

About TERI

Energy Efficiency studies

Energy Efficiency

+Environment

Energy efficiency

+Environment

+Policy

Energy efficiency +

Environment+

Policy +

Capacity building (Ind. Focused)

+Technology demo./ dissemination

+Social issues

1993

Energy efficiency +

Environment+

Policy +

Capacity building (Ind. Focused)

+Technology

demo./ dissemination

+Social issues

+Knowledge

sharing (Firemen focused)

TERI’S initiatives in Brick Sector

Technology demo./ dissemination

+Social issues

+Energy efficiency

+Environment

+Policy

+Capacity building (Ind. Focused)

+Knowledge sharing (Firemen focused)

+Alternate Walling

Materials+

Zig-zag Technology

2001 2006 2009

SDC, UNDP, USEAP, ESPS, Entec AG, Stratus consulting, DFID and CPCB

Infrastructure development

• In 2012, shortage of 18.78 million housing units in urban India (MoHUPA)

• Housing demand at the end of 12th

FYP will be 88.78 million housing units (Cushman & Wakefield, 2014)

• Total Floor space requirements by 2030 will be 41 billion square meter (McKinsey 2009)

• Initiatives like– Smart cities Mission– Housing for all by 2022– Atal Mission for Rejuvenation and

Urban Transformation

Demand of Total Floor Space in India (in billion square feet)- McKinsey 2009

Brick: Walling Material Signature mark of the entire

Indus Cultural Tradition (7000 BC)

Preferred walling material across globe

Solid and hollow bricks: load bearing as well as non-load bearing walling material in wooden or concrete frames.

Indian Brick Sector: Estimates for Resource Consumption

SrNo. Parameter 2000-01 study 2013-15 study*

1 Number of brick kilns 90000 221000

Clamp kiln 58000 175000

Bulls Trench kiln (BTK) 31000 42000

2 Annual brick production (billion) 144 236

3 Annual coal consumption (million tonnes) 24 31

4 Annual biomass consumption (million tonnes) 3 14

5 Annual top soil consumption (million m3) 259 424

6 Annual water consumption (million m3) 130 213

* Joint analysis by TERI and PSCST

Energy Consumption

Electricity, 427.2

Steel and washery, 23.1

Cement, 12

Paper, 1.7

Textile, 0.4Others, 107.5

Industry-wise consumption of raw coal (2013-14 (p))

Source: MoSPI (2015)

Indian Brick Sector: Estimates for Resource Consumption contd…

S.No. State No. of brick kilns Annual Brick Production Annual Coal Consumption Annual biomass consumption

Billion (Million tonne) (Million tonne)

1 Uttar Pradesh 15531 57.7 7.9 2.1

2 Maharashtra 16663 28.3 3.3 0.2

3 Gujarat 31533 19.8 4.4 1.2

4 Bihar 6564 19.7 4.3

5 Punjab 3239 18.7 2.0 0.7

6 West Bengal 4250 14.9 2.9

7 Haryana 2811 14.1 0.2 2.5

8 Tamilnadu 65623 11.9 0.4 3.0

9 AP & Telangana 8046 9.3 1.3 1.4

10 Rajasthan 1849 9.2 0.1 1.8

11 MP 23216 8.3 1.3 0.2

12 Karnataka 2136 5.3 0.8

13 Orissa 12315 4.5 0.7 0.1

14 Chattisgarh 8563 3.8 0.3 0.3

15 Kerala 17050 2.2 0.2

16 J&K 635 1.9 0.3

* Joint analysis by TERI and PSCST

Indian brick industryApplicable Acts• Pollution Control Board

– Siting Criteria– Emission norms– Stack height

• Mining Act• Labor Act

– Minimum Wages– Migration

• Factory Act– Provident Fund

Changing Scenario• MGNREGA• Mining• Emission Norms

• Increased awareness on energy and environment issues

– Switching over to mechanisation– Adoption of alternate walling

materials– Changing buyer expectations

• Increasing fuel prices– Adoption of BoP– Use of locally available fuel /

agricultural residue

• Entry of multinational brick providers/ technology suppliers

Existing Practise

Option for improvement Assumption

Estimated Investment

per kiln (INR in milion)

Average energy saving

potential (mtoe)

Other benefits

BTK technology

• Better operating practices (BoP)

• Improved kiln construction practices

• 10 - 20% fuel saving

• 50% BTKs adopted BOP

0.08 – 0.1 1.32 • Reduced fuel consumption

• Increased production of better quality bricks

Adoption of Zig-Zag technology • 20 – 30% fuel saving

• 30% BTKs adopt Zig-Zag

technology

2 – 4 1.32 • Reduced fuel consumption

• Increased production of better quality

bricks

Production of solid bricks

Switch over to perforated bricks/ hollow blocks

• 15 - 25% fuel saving

• 30% BTKs produce resource efficient products

17 - 23 0.92• Resource saving• Better thermal

insulation• Reduction in dead

load of building • Uniform size and

shape of product

Total energy saving potential in brick sector (including clamp kiln technology)

4.73

Energy Saving Potential in Brick Sector

General Observations

CO (ppm) Feed hole cover temperature (oC)

Kiln 1 216 - 264 398 - 413

Kiln 2 70 – 703 395 - 456

Kiln 3 202 - 2499 283 - 330

Kiln 4 115 - 331 425

Kiln 5 426 - 1576 156.4 - 245

Kiln 6 58 - 985 387

Kiln 7 186 - 2280 310.8 - 323.9

Kiln 8 189 - 832 429 – 439.6

Kiln 9 192 - 850 270.8 – 303.6

Kiln 10 168 - 1886 332.6 – 379.6

Why REBs

Clay-fired perforated bricks

Specifications for burnt clay perforated building bricks(IS 2222:1991 (REAFFIRMED 2007))

• Size: 190x90x90 mm (modular); 230x110x70 mm (Non-modular)

• Perforation– Area : 30 to 45%– uniform distribution– Area of each perforation shall

not exceed 500 mm2

– Thickness of shell and web should not be less than 15 mm and 10 mm

• Minimum Average Compressive strength: 7 N/mm2 on net area

• Water absorption shall not be more than 20 % (24 hour immersion)

Source: Wienerberger

Clay-fired hollow block

• Size (Hollow bricks)– 190x190x90 mm– 290x90x90 mm– 290x140x90 mm

• Size (Hollow Blocks)– 400x200x200 mm– 400x150x200 mm– 400x100x200 mm

• Hollows– Volume of holes shall be more

than 25% of total volume– Hollows at right angle or parallel to

bearing surface• Minimum Average Crushing

strength: 3.5 N/mm2

• Water absorption shall not be more than 20 %

Specifications for burnt clay hollow bricks and blocks for Walls and Partitions (IS 3952: 2013)

REB: Uniformity

Resource saving potential

173 163 125

0

20

40

60

80

100

120

140

160

180

200Am

ount

of c

lay

cons

umed

(MT)

Conventional Perforated Hollow

28%28%28%28%6%

50% solid bricks replaced by clay-fired REBs

Perforated bricks: savings of 30,000 trucks of coalHollow block: savings of 1,40,000 trucks of coal

• Plaster: 20%

• Mortar:- Perforated brick: 11%- Hollow block: 80%

• Steel reinforcement: - Perforated brick: 2 - 3%- Hollow block: 5 - 8%

Resource saving potential contd…

Electricity Consumption Distribution in Commercial Buildings

55%25%

15%5%

HVACLightingEquipment Load Others

1.66%

4.31%

5.86%

0.0% 1.0% 2.0% 3.0% 4.0% 5.0% 6.0% 7.0%

Perforated brick

Hollow Block

Insulated Hollow Block

Annual electricity savings using REBs as comapre to conventional solid bricks

Location - Delhi

42.4 Lacs

41.7 Lacs

40.6 Lacs

39.9 Lacs

3.8 3.9 4 4.1 4.2 4.3

Normal

Perforated brick

Hollow Block

Insulated Hollow Block

Annual Energy Consumption (kWh in Lacs) in Building constructed of different types of Bricks

Location - Delhi

Cooling energy saving in building: composite climate

Source: Wienerberger

Source: Wienerberger

• Government policies (ECBC, CSR, Green ratings etc.)

• Social Responsibility (towards environment)

• Sustainable Development of Nation

• Benefits to manufacturer, builder & user

REB production: opportunities

Challenges for Brick Sector

Lack of awareness and in-house capacities

Lack of technology suppliers and local service providers

Lack of focused R&D

Lack of customized financing options

Present construction practices

Absence of Capacity Building Mechanism

Brick industry (in the vicinity of urban areas) is expected to undergo a major transition

Upgradation in process technology

Moulding (semi-mechanized)

Drying (under shed, artificial)

Firing (better annular kilns, tunnel kilns)

Large capital investments

Organised, permanent, year-round operation

Diversification of products

Partial substitution of manual labour with mechanical power/electricity

Future Scenario

Thank You