Adaptation of Energy Efficiency in Nepalese brick industry
-
Upload
eecfncci -
Category
Technology
-
view
1.342 -
download
0
description
Transcript of Adaptation of Energy Efficiency in Nepalese brick industry
CHANCES OF ADAPTATION OF ENERGY EFFICIENT PRODUCTION METHODOLOGY/TECHNOLOGY IN BRICK INDUSTRY”
1
INTEGRATION environment & energyBahnhofstrasse 9D-91322 GrafenbergGERMANY
Federation of Nepalese Chambers Commerce and IndustriesTeku, KathmanduNepal
Energy Efficiency Centre FNCCI, Teku, KathmanduNepal
04/11/23
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?
04/11/23 2
GIZ/NEEP & FNCCI InitiativeComponent 3, Industrial Energy Efficiency
componentEnergy Efficiency Centre within FNCCIPilot Energy AuditAuditors trainings and certificationAwareness & Knowledge Management CentreFinancial institutions for EE market environment
Component 1: Energy Efficiency policyComponent 2: House hold appliance and ICS
04/11/23 3
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
04/11/23 4
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.
04/11/23 5
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
04/11/23 6
Overview
• Specific coal consumption is 240.97 kg/1000 bricks and 21.27 kWh/1000 bricks in BTK530 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
04/11/23 7
GHG emission
• Per kiln – consumption – 15189 MT out of which 5142 MT can save.- 33500 MT CO2 out of which 11322 MT of CO2
• Total GHG emission = 14572500 MTOut of which 4925070 MT Saving potential( 435 kilns in operation)
04/11/23 8
Brick Making Process
04/11/23 9
04/11/23 10
04/11/23 11
04/11/23 12
04/11/23 13
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
04/11/23 14
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?
?
04/11/23 15
How?
• Size of Name block• Depth of the Block 6mm Saving: Rs. 2000 Per day?
04/11/23 16
Transportation of Green(Unfired) Bricks
04/11/23 17
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
04/11/23 18
Clamp(Thado Bhatta) Kiln
• Village•Still running for tile making
04/11/23 19
Hoffman Kilns“Chinese Bhatta”Very Few in No.02 in Lalitpur01 in Bhaktapur
Hoffman Kilns“Chinese Bhatta”
04/11/23 20
Moveable BTK( Movable Chimney Bhatta)
These are in operation but legal issues!!!
04/11/23 21
Moving Chimney BTK
04/11/23 22
Fixed Chimney- BTK
04/11/23 23
Fixed chimney (Chimey Bhatta) – Natural Draught
•Straight line stacking
•Zig –Zag stacking
04/11/23 24
Fixed Chimney- Forced Draught
•Straight line stacking
•Zig –Zag stacking
04/11/23 25
PHOTO OF TWO BRICK KILN - Sizing
DUCT SIZE 25 FTDUCT SIZE 8 FT04/11/23 26
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
saving04/11/23 27
House keeping options-Spoon sizesimple 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.
04/11/23 28
Energy balance of BTKs
Energy Balance in Fixed Chimney04/11/23 29
Opportunity -Thermal Insulation
04/11/23 30
Opportunity -Duct design• Single wall outside caused significant heat loss.• Wall should be from fired brick( Not from green brick)
04/11/23 31
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 BenefitsTo Eliminate the Carpet loss which is around 4% To Minimize the moisture content of the fuel
04/11/23 32
Operating practicesSize of Coal
• Recommended coal size: ¾"
IF large size CoalThat causes • Over burnt Brick,• Coal Deposition in Duct.• Environment Problem
Large size Coal
04/11/23 33
Fuel Feeding Pattern( Fixed Chimney)
Fig: traditional practice Fig: improved practice (four line firing)
Which Benefits
•Fuel saving
•Minimize the Emission Level04/11/23 34
Fuel Feeding Pattern
04/11/23 35
åf/L
Leakage on Wicket Gate leads on
• Combustion that means more energy( Coal) Consumption.
• Problem in Brick quality
•Problem in fire travel rate04/11/23 36
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
04/11/23 37
Thank you
04/11/23 38