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Transcript of Brick Industry Base Line Study
8/2/2019 Brick Industry Base Line Study
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BASELINE STUDY
OF
THE BIHAR BRICK SECTOR
Amit Kumar Singh
KIIT School of Rural Management KIIT UNIVERSITY, BHUBANESWAR, ODISHA
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It is a non-profit organization engage in research and action for sustainable rural
development. It was established in 1983 and is registered under the Societies Registration Act with the
Government of India
VISION:
A world where every citizen can live a secure, healthy and fulfilling life in harmony withnature.
MISSION:
To promote sustainable national development
OBJECTIVE:
To design options & promote sustainable development through programmes of Economic efficiency
Eq uity & social justice
Environmental harmony
Resource conservation
Self-reliance
DEVELOPMENT ALTERNATIVES ± AN OVERVIEW
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Development
Alternatives
Group
Innovation
Services
Branch (ISB)
Technology
Innovation
Group
Enterprise
Incubation
Group
Sustainability
Research
Group
Development
Services
Branch (DSB)
TARA Livelihood
Academy
Bundelkhand
Development
Group
Community
Partnerships
Group
TARA Technical &
Management
Services Group
Business
Services
Branch (BSB)
Technology & Action
for Rural Advancement
(TARA)
TARA Nirman Kendra
(TNK)
TARAhaat Information
& Marketing ServicesLtd.
Decentralised Energy
Systems India Ltd.
(DESI Power)
Communication
Services
Branch (CSB)
Corporate
Positioning
Group
Knowledge
Communications
Group
Sustainability
Policy Group
Corporate
Management
Branch (CMB)
FUNCTIONAL STR UCTURE - D A
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Objectives:
Objectives of the project
To understand the present Scenario of Brick Industry in Bihar.
To assess the market potential & business viability for Clay firedbricks in allocated cluster area.
PHASE-I
SAMPLE DESIGN
FIELD WORK
DATA ANALYSIS
REPORT WRITING
PHASE-II
CONSULTATION WITH
REPORTING OFFICER OBSERVATION &
PERSONAL INTERVIEW OF
KILN OWNER
UNDERSTANDING THE PROJECT
QUESTIONNAIRE DESIGN
SURVEY DESIGN
FINAL REPORT
PREPARATORY WORK
Methodology:
PHASE-III
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No. of FC-BTK sample taken for study in Bihar are
The sampling was ClusterCluster sampling for selecting area, namely
Cluster1Cluster1
Patna and Ara
Cluster2Cluster2
Saharsa, Supaul, Madhepura and Katihar.
I have taken convenience (non probability) sampling for
collection of primary data.
DistrictDistrict PatnaPatna AraAra SaharsaSaharsa SupaulSupaul MadhepuraMadhepura KatiharKatihar
SampleSample 55 55 55 55 55 55
Sampling:
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Indian Brick Sector: Salient f eatures
Solid clay fired bricks
- Second largest brick producer in world
- Annual production 170 billion/year (approx.)
Decentralized unorganized production
- Decentralized production > 120,000 units
- Annual turnover Rs. 500 billion
- Employment to 1.20 crore workers
Resource intensive process- Coal consumption 6 crore tones/year
- Largest consumer of agricultural top soil
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Technologies used:
- Predominantly FCK, sporadic instances of HDK, no alternatematerials e.g. fly ash
Production:
- No. of brick kilns around 4,500
- Annual production 11 billion (4th. largest in India)
Raw materials:
- Soil and coal
Waste materials used:
- Sporadic use of coal slurry
Quality:- Good to medium
Mechanization:
- Mechanized pugging, excavation of soil
The Bihar Brick Sector
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Cluster districtUrban
Red brick fly ash Adobe
Cluster1
Ara Major NA NA
Patna Major NA NA
Cluster2
Saharsa Major NA NA
Supaul Major NA Occasional
Katihar Major NA NA
Madhepura Major NA Occasional
Rural
Red brick Fly ash Adobe
Major NA Minor
Major NA Minor
Major NA Minor
Major NA Minor
Major NA Minor
Major NA Minor
In Bihar, Red bricks is the major brick being practice to make buildings.
There is no fly ash brick industry.
In rural areas people made adobe houses (low income people made) but
it is not at large scale.
R esults-Technologies being practiced
Products:
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Bricks:
J
CB:
Pug mill:
Dimension (l*b*h) Inch Average Weight (kg)
10*5*3 3.7
Company If own then
price(lacks)
If rent then
price/hr
Capacity
trolley/day
Service Time period
(years)
JCB 20 800 100 yes 1
Name Head
office
Average
price
Capacity
bricks/day
Service Time period
year
Durga engineering Kolkata 40000 10000 No 0
Jamuna engineering Patna 80000 8500 Yes 1
Biswash engineering Kolkata 50000 8000 No 0
Harnaut engineering Harnaut 90000 8000 Yes 1
R esults-Technologies being practiced
Mechanization:
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Cluster Districts Pug mill Moulding machine Fly ash JCB
Cluster 1 Ara No No No Yes
Patna Yes No No Yes
Cluster 2
Saharsa Yes No No Yes
Supaul No No No No
Katihar Yes No No Yes
Madhepura Yes No No Yes
R esults-Technologies being practiced
Mechanization:
Cluster District Coal coming from Distance
Cluster 1 Ara Ghato 250
Dhanbad 350
Jhariya 300
Patna Jhariya 250Ghato 200
Hazaribag 230
Dhanbad 300
Cluster 2 Saharsa Guwahati 516
Supaul Guwahati 535
Madhepura Guwahati 500
Katihar Guwahati 591
Source of raw materials
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Resource use
Agriculture
land
River bed
soil
90%
10%
R esults-Technologies being practiced
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Resource use
Agriculture
land
River bed
soil
90%
10%
R esults-Technologies being practiced
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Cluster Average land
area for kiln
(acre)
If land on lease (
lease period)
year
If lease
(acre/month)
Rs.
Market value of
land (lack/acre)
Rs.
Cluster 1 2.6 6 1878 14.6
Cluster 2 6.3 4 1460 29.2
Land particular:
R esults- Economic information
Mining tax (yearly in Rs.):
Urban area mining tax- 72000
Rural area mining tax- 52000
Interior rural area tax- 40000
VAT (yearly in Rs.):
Urban area VAT- 80000
Rural area VAT- 60000
Tax:
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0
2000
4000
6000
8000
10000
12000
2007 2008 2009 2010 2011
c o a l c o s t
/ M T ( R s . )
Trend in coal price
Ara
saharsa
supaulkatihar
madhepura
patna
Cluster Rate /MT Average for season per kiln
(MT)
Average exp per kiln
(lakhs)
Cluster1 5800 450 26.19
Cluster2 9500 540 50.08
R esults-Energy consumption
Trend in coal price:
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Technology Diesel (litter/ hr)
JCB 5
Pug mill 1.5
Diesel pump for water 1
Diesel detail
R esults-Energy consumption
Use of diesel in various technology:
0
20000
40000
60000
800001
00000
120000
140000
Ara Patna Saharsa Supaul Katihar Madhepura
Average diesel exp seasonal/kiln(R s.)
Average diesel exp. seasonaly
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Fire wood detail:
0
20000
40000
60000
80000
Ara Saharsa Supaul Katihar Madhepura Patna
Average exp for season/kiln(R s.)
Total exp for season(Rs.)
Energy consumption
ParticularAverage brick
production (lakhs)
Coal consumption/kiln
(MT)
Average cost of
coal/ (MT)
Total coal cost
(Rs.) Coal cost/ brick (Rs.)
Coal 26.55 525 8,275 43,44,375 1.67
Average brick
production (lakhs)
Diesel consumption/kiln
(litter)
Average cost of
diesel/litter
Total diesel cost
(Rs.) Diesel cost/ brick (Rs.)
Diesel 26.55 1162 44 51,128 0.02
Average brick
production (lakhs)
Fire wood
consumption/kiln (MT)
Average cost of
firewood/ (MT)
Total firewood
cost (Rs.)
Fire wood cost/ brick
(Rs.)
Fire wood 26.55 12.3 4,208 51,758.4 0.02
Total energy cost/brick 1.71
energy expense/brick(Rs.):
R esults-Energy consumption
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
FCK VSBK FLY ASH
Total CO2e emission (kg) per brick from various technologies
R esults-Environmental issues
0
100
200
300
400
500
600
700
Soil excavation Raw material
transportation
Brick making Firing
CO2e emission per 1000 bricks (kg) from various sources and tech.:
Fixed chimney
VSBK
Fly ash
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CO2e trading potential per brick from various technologies
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
FCK VSBK FLY ASH
R esults-Environmental issues
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Yes53%
No47%
Yes
23%
No77%
Yes40%
No
60%
Awareness about Eco Friendly
technology
Knowledge about new energy
saving technology
Willingness to adopt new
technology
R esults-Environmental issues
Awareness, willingness and statuary clearance:
Yes10%
No
90%
DIC registration
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Annual turn over:
Production cost:
2000
2500
3000
3500
4000
4500
2007 2008 2009 2010 2011
r o d u c t i o n c o s t / 1 0 0 0
b r i c k ( R s . )
Production cost/1000 brick (R s.)Ara
saharsa
supaul
katihar
madhepura
patna
R esults-Market trends
0
1000
2000
3000
4000
Annual turn over/district (million)
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Trend in selling price:
Trend in profit:
0
1000
2000
3000
4000
5000
6000
2007 2008 2009 2010 2011
s e l l i n g p
r i c e / 1 0 0 0 b r i c k
( R s . )
Selling price/1000 bricks (R s.)
Ara
saharsa
supaul
katihar
madhepura
patna
0
200
400
600
800
1000
2007 2008 2009 2010 2011
p r o f i t / 1 0 0 0 b r i c k s
( R s . )
Prof it/1000 bricks (R s.)Ara
saharsa
supaul
katihar
madhepura
patna
R esults-Market trends
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Moulder
44%
Supervisor
10%
Firing
6%
Unloader
20%
Loader 20%
Cost of labour
Parameter: labor cost/brick is Rs. 0.99
R esults- Labour issue:
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Issues and opportunities
Technical
Absence of alternate technologies
Only FC-BTK
Brick size and shape
Bigger size bricks (10*5*3), solid
Absence of mechanization
Only pug mill, JCB
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Issues and opportunities
Use of top soil in brick making
consumes 41,55,000 m3 of clay per year
barrens 1026 acres per year
retards 1335 T of rice production / year affects 7417 people every year
Technical
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Small scale brick production
Fly ash, VSBK
Medium scale brick production VSBK
Large scale brick production
HK (Holf-man kiln), VSBK
Issues and opportunities
Technology
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Issues and opportunities
Brick size and shape
Use of standard brick size (8*5*3)
20% savings in soil
Use of hollow bricks
25-40% savings in soil
Use of industrial wastes 5-10% savings in soil
Mechanization
Small scale
Pug mills, extruders
Medium scale
Soft mud moulding machines, extruders
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Issues and opportunities
Energy
Rising cost of fuel
Average around 10% increase per year
Likely to increase each and every year
Scope for low energy technologies
Fly ash technologies
Vertical Shaft Brick Kiln
Reducing energy consumption
Use of industrial wastes as internal fuel
Energy can save of up to 60% of external coal
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Issues and opportunities
Strong pollution control and mining regime
Absence of incentives
Absence of subsidies
Awareness on cleaner brick production technologies
Policy
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R ecommendation
To reduce the f uel consumption and production cost of brick,should use internal f uel like( R ice husk, f ly ash, sugar mill
wastage).
Eco-kiln technology supplier organization should create a modal
in Bihar for inspiring the entrepreneur to adapt the technology.
Bihar brick industry is not mechanized so create awareness about
various technology which will helpf ul to reduce the production
cost and quality enhancement of brick.
Clay brick industry directly aff ected the agriculture and
environment so have to move eco-cleaner technology like f ly ash
and concrete block brick.
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