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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
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