A Roadmap for Cleaner Brick Production in India - Red Ladrilleras

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Project TeamGreentech Knowledge Solutions Pvt. Ltd., New Delhi (India)Dr.Sameer Maithel, Mr. Dheeraj Lalchandani, Mr. Gaurav Malhotra, Mr. PrashantBhanwareEnzen Global Solutions Pvt. Ltd., Bangalore (India)Dr. R. Uma, Mr. SanthoshRagavan, Mr. Vasudev Athalye, Ms. Bindiya KR, Mr. Sunil ReddyUniversity of Illinois at Urbana-Champaign, Illinois (USA)Dr. Tami Bond, Ms. Cheryl WeyantClean Air Task Force, Boston(USA)Ms. Ellen BaumEntec AG, Hanoi (Vietnam)Ms. Vu Thi Kim Thoa, Ms. Nguyen Thu Phuong, Ms. TrÇn Kim ThanhA Shakti Sustainable Energy Foundation and Climate Works Foundation supported initiativeDisclaimerThe views expressed in this publication are those of the authors/project team and do notnecessarily reflect the views of Shakti Sustainable Energy Foundation and ClimateWorksFoundation. Shakti Sustainable Energy Foundation and ClimateWorks Foundation do notguarantee the accuracy of the data included in this publication and does not acceptresponsibility for consequence of their use.2
AbstractIntroductionIndia is the second largest producer of clay fired bricks, accountingfor more than 10 percentof global production.India is estimated to have more than 100,000 brick kilns, producingabout 150-200 billion bricks annually, employing about 10 million workers and consumingabout 25 million tons of coal annually. India’s brick sector is characterized bytraditionalfiring technologies; environmental pollution; reliance on manual labour and lowmechanization rate; dominance of small-scale brick kilns with limited financial, technical andmanagerial capacity; dominance of single raw material (clay) and product (solid clay brick);and lack of institutional capacity for the development of the sector.In a first of its kind detailed performance assessment,the principal investigating organizations-Greentech Knowledge Solutions Pvt. Ltd., Enzen Global Solutions Pvt Ltd, and Universityof Illinois,examinedthe energy, environmental and financial performance and brick makerinput for five main brick firing technologies during 2011:Fixed Chimney Bull’s Trench Kiln (FCBTK - India)Zig-zag (natural and forced draft - India)Vertical Shaft Brick Kiln (VSBK – India and Vietnam)Down-Draught Kiln (DDK- India)Tunnel kiln (Vietnam)The study is one of two research components aimed at developing strategies for theintroduction and promotion of cleaner walling materials in India.ResultsEnergy performanceA large variation was observed in the energy performance of the monitored kilns. DDK (leastefficient kiln) consumesfourtimes more energy compared to VSBK (most efficient kiln). TheVietnamese VSBK kiln had the lowest thermal energy requirement, followed by the IndianVSBK, zig-zag kilns and FCBTKs. The tunnel kiln, which incorporates a dryer, had higherenergy use.Environmental performanceVSBK had the lowest emissions of Suspended Particulate Matter (SPM) followed by zigzagkiln, tunnel kiln, FCBTK and down-draught kiln. VSBK also had the lowestParticulate Matter (PM 2.5 ) emissions.Of the gaseous pollutants measured,variations in the SO 2 concentration were observed,with lowest levels in the biomass-fueled DDK. This is because sulphur dioxide (SO 2 ) isdependent on sulphur in coal. Oxides of nitrogen (NO x )emissions were generally belowthe detectable levels. The natural draught zig-zag kiln had the lowest carbon monoxide(CO) emissions. CO 2 emissions show similar ranking hierarchy as for energy.Both tunnel and VSBK had very low black carbon (BC) emissions, followed by zigzags.FCBTKsand DDK had highest BC emissions.3
Page 4 and 5: Financial performanceAmong cleaner
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A Roadmap for Cleaner Brick Production in India - Red Ladrilleras

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