International Conference on TIM, 2012, Nepal Viable Charring Technology to Meet the Industrial Demand of Brick Kilns Presented By: Sushim Man Amatya Venue:

International Conference on TIM, 2012, Nepal

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Viable Charring Technology to Meet the Industrial Demand of Brick Kilns

Presented By: Sushim Man Amatya

Venue: Technology and Innovation Management ConferenceDate: Oct 12, 2012


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Overview of Brick Industries

• 436 brick kilns registered with total production capacity of 872 million, Census of manufacturing establishments, Nepal 2006-2007

• About 700 brick kilns in Nepal (Source: All Nepal Brick Kiln Entrepreneurs Association, 2011)

• Estimated total annual production capacity of about 1,423 million bricks

• Coal is the major fuel .


Brick Kiln Technology Composition

MCBTK57%

FCBTK33%

Clamp7%

VSBK4%

Kiln composition

S. No. Type of Kiln No. of Kilns % Remarks1 Clamp 42 6.0 2 MCBTK 399 57.0 3 FCBTK 233 33.0 4 VSBK 26 4.0


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Major Brick Kiln Technologies

Clamp

VSBKFixed Chimney BTK (FCBTK)

Moving Chimney BTK (MCBTK)


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• 80,000 tones of coal is consumed annually by 120 brick kilns within Kathmandu valley out of 700 in Nepal.

• 1.12 billion Rupees are spent in India. Yet the quality and supply of coal is unreliable.

• Emission of 200,000 tones CO2 annually by brick kilns in the valley. (1kg. Coal = 2.465 kg. CO2 )

Case of Brick Industries in Kathmandu Valley


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Kathmandu Valley & FCBTKs

Total No of Kilns: 108Source: 103 FCBTKs - All Nepal Brick Kiln Entrepreneurs Association, 2011. 3 VSBK units and 2 Hoffman Kilns.

No of FCBTKs: 103Average brick production per year: 720 millionAverage brick production per kiln is estimated to be 7 million per kiln

Annual coal consumption in FCBTKs(Tons): 68,500Average coal consumption per brick in FCBTK in Kathmandu Valley is estimated to be 95gm per brick

Annual expenditure in coal (NRs): 1.23 billionPrice of coal – Nrs 21,000 per ton, March 2012, Brick Entrepreneurs

Annual CO2 emission (Tons): 169,0002.465 Kg of CO2 is emitted per Kg of coal fired, Project Design Document for VSBK

Annual emission of dust particles (Tons): 18002.51 Kg of SPM per 1000 fired bricks in FCBTKs, Stack and Energy Monitoring of Brick Kilns in Kathmandu Valley, IEM 2005


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Energy

• Coal is major fuel used in the brick production. • Other non coal fuel such as agricultural residue, firewood, rice husk, saw dust etc• Coal consumption per lakh bricks in the FCBTK is 15.45 tons and MCBTK 14.18 tons (CEN Baseline report, 2009).


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• In 2008/09, Nepal imported about 293,000 tons of coal from India. KTM alone consumed about 40% of imported coal. It is mainly used in the industrial sector mainly in the brick kilns and cement factory

Energy Dependency on imported coal

• Rising coal price is 200% increment in 6 years without considering inflation, (NRs 7.3 in 2006 and NRS 22 in 2012 per kg of coal ).

2006 2007 2008 2009 2010 201102468

101214161820

Annual increment in coal price

Year

Pric

e in

NRs


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In-depth into the issues

Environmental issues

Prime source of air pollution2nd largest air polluter in the

valley 2.5kg dust emission per 1000

fired bricks (Average dry wt of bricks = 2.2 Kg)

Serious occupational health hazards

Emission of RPM-PM higher than prescribed limit, in some cases 7 times more than limit

1,600 die of air pollution every year in Kathmandu Valley, People’s Daily Online, Feb 2008


Energy consumption in Brick

MCBTK FCBTK VSBK Clamp0

0.5

1

1.5

2

2.5

3

1.25 1.16 0.830000000000001

3Specific Energy Consumption

Kiln Type

MJ/

Kg o

f fire

d br

ick

Firewood67%

Sawdust7%

Agri-culture residue

1%

Rice husk4%

Others21%

Non coal fuel consumption

Source: Baseline Study of Brick Kilns in Nepal, Minergy, 2009


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In-depth into the issues

Climate change issues

One of the prime source of CO2 and Black Carbon emissionBurning a Kg of coal emits about 2.5 Kg CO2 – major GHG

Brick kilns have also been identified as one of the prime cause for BC emission – primary cause of melting Himalayan glaciers

(ICCT 2009)


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More than 15300 CFUGs, 40% of total households of Nepal, own and manage community forests in 1,22,000 hectare of

land.

The potentials of economic return from the community forests are under-utilized

mainly due to lack of knowledge, efficient

technology and market linkage for forest-based products.

The current demand for char is low and the income generated

does not even cover the minimum wage or opportunity cost.


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Our experiences with internal fuel in VSBK

37 % less

External Fuel Internal Fuel 0

50

100

150

200

250

300

350

400

258.28

162.850000000001

Emission of Suspended Particulate Matters (SPM)

SPM

(mg/

Nm

3)

External Fuel Internal Fuel 1.15

1.2

1.25

1.3

1.35

1.4

1.451.4

1.25

Emission of Sulphur-Di-Oxide (SO2)

mg/

Nm

3

Environmental performance

18% lessThe results are based on the applied research carried out in a VSBK plant The research was

carried out by firing 75,000 bricks with three different fuel composition in a VSBK shaft. Results are derived by scientific monitoring of stack emission and energy performance.


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External Fuel Internal Fuel 0.580.60.620.640.660.680.70.720.740.760.78

0.760000000000003

0.640000000000003

Specific Energy Consumption (SEC)

MJ/

Kg

ofr

fire

d br

ick

Our experience with internal fuel in VSBK

16% less energy consumption

Energy performance & brick quality

External Fuel Internal Fuel 0

50

100

150

200

250

185

228

Compressive Strength

Kg/

cm2

22% improvement in strength


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Potentials

10% improvement in energy efficiency can result into• Reduction of 6900 tons of coal

• Annual saving of NRs 125 million in coal cost

• Reduction of 17000 tons of CO2

20% improvement in environmental performance can result into• Reduction of 275 tons of mass emission load

• Improvements in occupational health and safety status

• Reduction in black carbon emission


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Potentials/ScopeKathmandu Valley & FCBTKs

15% savings 25% savings

Annual average brick production 720 million

Annual coal consumption in FCBTK (Tons)

68,500 10,274 tons reductions

17,124 tons reduction

Annual expenditure in coal (NRs) 1.23 billion 185 million saving

308 million saving

Annual CO2 emission (Tons) 169,000 25,326 tons saving

42,210 tons saving

Annual emission of dust particles (Tons)

1800 271 tons 452 tons

• Improvements in occupational health and safety status• Reduction in black carbon emission• Viable for small-scale CDM


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Missing Links

According to action research conducted ,

biomass based carbonized fuel (char) generated from non

timber woody plants and forest waste can be used for brick firing instead

of coal in brick industries


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International Conference on TIM, 2012, Nepal Field & laboratory works

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Summary of CV testsAverage Top layer

CV (Pit System) 4096.665kcal/kg

17.12406 MJ/kgAverage Middle

layer CV (Pit System) 6332.464

kcal/kg26.4697 MJ/kg

Average Bottom layer CV (Pit

System) 5518.343kcal/kg

23.06667 MJ/kgAverage Random

CV 5453.458 kcal/kg 22.79546 MJ/kg


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Collection of Char and CV test (Coal and Char) (About 5 tons of char has been collected)

Green Brick Making with Internal Fuel

Baseline study to calculate the Specific Energy Consumption (SEC) SEC = 0.48 MJ/ kg of fired brick

Calculation of char quantity in terms of energy value 40% coal substitution = 0.011 kg/brick 50% coal substitution = 0.014 kg/brick 60% coal substitution = 0.017 kg/brick 70% coal substitution = 0.020 kg/brick

Green brick making with internal fuel as • Char mixing • Soil ageing• Green Brick Making (on process)`


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Charring Retorts: Portable Type


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Fixed Type Charring Retort

Fig: Schematics of the fixed type charring retort


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27


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Construction Phase of the Retort


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Other Potentials• Establishment of market links for industrial

demand• Efficiency of char production technology

increased by at least 20%• Increment of income from the increased

efficiency is at least 40%• Improved occupational health safety for char

producers• Increased income opportunity for

disadvantaged members of CFUGs• Potentials using char in other SMEs


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Thank You!!

International Conference on TIM, 2012, Nepal Viable Charring Technology to Meet the Industrial Demand of Brick Kilns Presented By: Sushim Man Amatya Venue:

Documents

nepal energy coal

bricks coal

tons of coal

coal fuel

imported coal

coal price

international conference

tones of coal