Varanasi Brick

MANUAL ON ENERGY CONSERVATION MEASURES IN BRICK CLUSTER VARANASI
Bureau of Energy Efficiency (BEE)

Ministry of Power, Government of India Prepared By
Feedback Ventures Pvt. Ltd., Gurgaon
Manual on Energy Conservation Measures in Brick Cluster, Varanasi
Contents
Acknowledgement ................................................................................................................................ ................................ .................................................... I Executive Summary................................................................................................................................ ................................ ................................................ II 1.1 Project Objectives ................................................................................................ ................................ .............................................. 1 1.2 Expected Project Outcomes................................................................................................ ................................ 1 1.3 Project Duration ................................................................................................ ................................ ................................................ 2 1.4 Identified Clusters in the Programme................................................................ ................................................. 3 2. Cluster Scenario ................................................................................................................................ ................................ .............................................. 4 2.1 Overview of SME Cluster................................................................................................ .................................... 5 2.1.1 Cluster Background ................................................................................................ ................................ ............................................ 5 2.1.2 Product manufactured................................................................................................ ........................................ 6 2.1.3 Classification of units ................................................................................................ ................................ .......................................... 6 2.1.4 Production capacity (in tonnes or pieces per year) detail ................................ ..................................................... 7 2.1.5 Raw materials used ................................................................................................ ................................ ............................................ 8 2.2 Energy Situation in the cluster ........................................................................................... ........................... 8 2.2.1 Types of fuels (fossils, biomass, waste, byproducts, etc) used and prices ................................ 8 2.2.2 Fuels and electricity consumption in a typical unit ............................................................... ............................... 9 2.2.3 Specific energy consumption (in appropriate unit)............................................................... ............................... 9 2.3 Manufacturing process/technology overview in a typical unit ................................ ......................................... 10 2.3.1 Process technology ................................................................................................ ................................ ........................................... 10 2.3.2 Process flow diagram................................................................................................ ................................ ........................................ 11 2.4 Current policies and initiatives of local bodies, if any ....................................................... ................................ 16 2.5 Issues related to energy usage and conservation and barrier in technology up gradation . 18 2.5.1 Energy availability ................................................................................................ ................................ ........................................... 18 2.5.2 Technological issues ................................................................................................ ................................ ......................................... 18 2.5.3 Financial issues ................................................................................................ ................................ ................................................ 19 3. Energy audit and technology assessment ................................................................ ........................................................... 20 3.1 Methodology adopted for................................................................................................ ................................. 20 3.1.1 Energy Use and Technical Study ................................................................ ........................................................ 20 3.2 Observations made during the energy use and technology studies carried out in the cluster23 3.2.1 Manufacturing process and technology/equipments employed................................ ........................................... 23 3.2.2 Energy consumption profile & availability ................................................................ ......................................... 26 3.2.3 Capacity utilization factor ................................................................................................ ................................ 26 3.2.4 Housekeeping practices ................................................................................................ .................................... 26 3.2.5 Availability of data and information................................................................ .................................................. 27 3.3 Technology gap analysis................................................................................................ ................................... 27 3.3.1 Technology up-gradation gradation ................................................................................................ .................................. 27 3.3.2 Process up-gradation ................................................................................................ ................................ ........................................ 27 3.4 Energy conservation measures identified ................................................................ ........................................ 28 3.4.1 Proposals for energy conservation including technology up-gradation up ............................... 28 3.4.2 Availability of technology/ product in local/national/international market ....................... 46 3.4.3 Availability of local service providers who can take up abovementioned proposals.............. 47 3.5 Identification of technologies/equipments for DPR preparation ................................ ...................................... 52 3.5.1 Justification (e.g. potential, replicability, etc. in the cluster) for technologies/equipments identified for DPR preparation.......................................................................................... .......................... 52 4. Environmental Benefits ............................................................................................................................. ................................ ............................. 53 4.1 Reduction in waste generation (if applicable) ................................................................ .................................. 53 4.2 Reduction in GHG emission such as CO2, NOx, etc ............................................................ ............................ 53 5. Conclusion ................................................................................................................................ ................................ ...................................................... 54 5.1 Summary of proposals for energy saving ................................................................ ......................................... 54 5.2 Summary of level of awareness on energy efficiency and energy efficient products in the cluster ............................................................................................................................. ................................ ............................. 56 Pictorial Acknowledgements................................................................................................ ................................ ............................................................ 58 Annexure1: 1: Detailed technology/equipment assessment report including the design technical specifications, in the th format provided by BEE. ................................................................ ....................................... 59

Annexure 2: Details of technologies/services providers for the cluster................................ ........................................ 62 Annexure3: 3: Quotations or techno-commercial techno commercial bids from service/technology providers (Sample)................................................................ ................................................................................................................................ ................................... 63
LIST OF TABLES
Table 1: Cluster Energy Consumption............................................................................................. ............................. III Table 2: Savings per typical Unit................................................................................................ ..................................... III Table 3: Total Cluster wide Savings (226 units) ................................................................ ............................................... IV Table 4: BEE identified clusters under the SME Programme Progr .............................................................. .............................. 3 Table 5: Varanasi at a Glance ................................................................................................ ................................ ............................................. 4 Table 6: Cluster Product Manufactured Break Up ................................................................ .............................................. 6 Table 7: Annual Production Capacity ................................................................................................ ................................. 8 Table 8: Deviations in Manufacturing Processes ................................................................ .............................................. 25 Table 9: Zig-Zag Zag Firing Energy Savings Calculations: ................................................................ ....................................... 30 Table 10: Zig-Zag Zag Firing Cost Benefit Be Analysis ................................................................ ................................................. 30 Table 11: Zig-Zag Zag Firing Cost of Implementation ................................................................ ............................................. 30 Table 12: Best Practices Energy Savings Calculations: ................................................................ ..................................... 32 Table 13: Best Practices Cost Benefit Analysis ................................................................ ................................................. 33 Table 14: Best Practices Cost of Implementation ................................................................ ............................................. 33 Table 15: Induced Draft Energy Savings Calculations:................................................................ ...................................... 34 Table 16: Induced Draft Cost Benefit Analysis ................................................................ ................................................. 34 Table 17: Induced Draft Cost of Implementation ................................................................ ............................................. 35 Table 18: VSBK Energy Savings Calculations:................................................................ ................................................... 38 Table 19: VSBK Cost Benefit Analysis .............................................................................................. .............................. 38 Table 20: VSBK Cost of Implementation .......................................................................................... .......................... 39 Table 21: Hoffman Kiln Energy Savings Calculations ................................................................ ....................................... 42 Table 22: Hoffman Kiln Cost Benefit Analysis ................................................................ .................................................. 43 Table 23: Hoffman Kiln Cost of Implementation ................................................................ .............................................. 43 Table 24: Perforated Bricks Energy Savings Calculations ................................................................ ................................. 44 Table 25: Perforated Bricks Cost Benefit Analysis ................................................................ ............................................ 45 Table 26: Perforated Bricks Cost of Implementation ................................................................ ........................................ 45 Table 27: Technology Availability ................................................................................................ .................................... 46 Table 28: Justification n and Replicability of identified Measures ....................................................... ................................ 52 Table 29: Summary of Proposals for Energy Savings................................................................ ........................................ 54
Manual on Energy Conservation Measures in Brick Cluster, Varanasi LIST OF FIGURES

Figure 1: Cluster Products Manufactured ................................................................ .......................................................... 6 Figure 2: Annual Brick Production ................................................................................................ .................................... 7 Figure 3: Coal Source and Rate ................................................................................................ ................................ .......................................... 8 Figure 4: Coal consumption per lac bricks ................................................................ ......................................................... 9 Figure 5: Chamber Layout and Gas Flow through BTK ................................................................ ..................................... 10 Figure 6: Brick Making Process ................................................................................................ ....................................... 11 Figure 7: BTK zone Classification flow............................................................................................. ............................. 13 Figure 8: BTK operation and Zones ................................................................................................ ................................. 13 Figure 9: Methodology for Energy Use and Technical Study ............................................................. ............................. 20 Figure 10: Preliminary Audit Methodology................................................................ ...................................................... 21 Figure 11: Detailed Audit Methodology ........................................................................................... ........................... 23 Figure 12: Process Observations ................................................................................................ ..................................... 24
LIST OF IMAGES
Image 1: Varanasi District Overview................................................................................................ .................................. 5 Image 2:Traditional Fixed Chimney BTK ........................................................................................... ........................... 7 Image 3: Clay Winning & Moulding Area (Pathai) ................................................................ ............................................ 11 Image 4: Wet Green Brick drying ................................................................................................ ..................................... 12 Image 5: Combustion Zone with lines covered by metallic lids ................................ ........................................................ 14 Image 6: Green brick stacking pattern ............................................................................................. ............................. 14 Image 7: Fired Brick Extraction ................................................................................................ ....................................... 15 Image 8: Pre Audit Workshop................................................................................................ ................................ .......................................... 21 Image 9: Coal Feeding Pattern ................................................................................................ ................................ ......................................... 26 Image 10: Double Zig-Zag Zag Firing Schematic ................................................................ ..................................................... 29 Image 11: Vertical Shaft Brick Kiln ................................................................................................ .................................. 37 Image 12: VSBK Working Schematic ................................................................................................ ................................ 37 Image 13: Hoffman Kiln Side View ................................................................................................ .................................. 41 Image 14: Layout Plan of a Hoffman Kiln ......................................................................................... ......................... 41
Acknowledgement
We express our sincere gratitude to the Bureau of Energy Efficiency, Ministry of Power for giving the opportunity to be a part of SME Programme. We thankfully acknowledge the support and guidance provided by all concerned officials during the conduct of this exercise. Bureau of Energy Efficiency Shri Dr. Ajay Mathur Shri Saurabh Kumar Shri Jitendra Sood Shri Pawan Kumar Tiwari Shri Gaurav Kumar Director General Secretary Energy Economist Advisor SME Project Engineer
We would also like to thank Int Nirmata Parishad an and brick makers kers in the Varanasi Cluster for their support in undertaking this task of energy use and technology analysis a within the brick making Industry. The field studies would not have been completed on time without their interaction and timely support. We are grateful for their co co-operation, especially during field studies for their wholehearted support and hospi hospitality. Their willingness to undertake energy efficiency measures was key in reducing the energy intensity of the brick manufacturing industry. .
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Executive Summary
Objective of the SME Programme The mission of the SME Programme is to improve the overall energy efficiency of Small and Medium Enterprises. In quantitative terms, there is a general lack of record keeping with respect to energy consumption and energy saving opportunities within these Industries. ndustries. The SME programme intends to enhance the energy efficiency awareness by funding/subsidizing need based studies in SME clusters and giving energy conservation recommendations. The main project activities as stated by BEE under the SME program are: Energy Use and Technology Analysis Capacity Building Implementation of EE measures Facilitation of Innovative Financing Mechanism Brief Overview of the Varanasi Brick Making Cluster There are approximately 226 (Two hundred and twenty six) brick kilns in operation within the greater Varanasi district. The kilns are majorly located in clusters in the following areas of the district. Haruhua Sarnath Sindhora Road Rohania Munari Rameshwar Badagaon
Varanasi Brick cluster snapshot Classification of brick units within the Cluster Raw Material used Bull Trench Kilns with natural draft Sand Clay Water Coal 1.1 -1.5 MJ/kg of fired product Solid Bricks Perforated Bricks Half Bricks
Types of fuel Specific Energy Consumption Manufactured Products
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Manual on Energy Conservation Measures in Brick Cluster, Varanasi Cluster Energy Consumption Based on site visits and the energy data of 226 brick manufacturing units in the greater Varanasi cluster the following table provides a snapshot of the Cluster energy consumption. Table 1: Cluster Energy Consumption Annual Cluster Production Annual Cluster Coal Consumption Annual Cluster Energy Consumption Annual Coal Consumption per unit Annual Energy Consumption per unit Average Coal consumption per lac bricks Average Energy Consumption per lac bricks 7,075.28 1,26,880.77 2907.994 561.42 12.867 18.08 0.414 Lac Bricks Tonnes Terajoules Tonnes Terajoules Tonnes Terajoules
Recommended Energy Conservation & Savings Potential On basis of field studies conducted in the Varanasi cluster and technology gap assessment of available technology/ process up-gradations, up gradations, proposals for energy efficiency are listed in the tables below. The The tables quantify and give tentative saving potentials within the cluster. The entrepreneurs can be convinced to adopt one or more of the below mentioned technologies based on the information provided. Applying a generic ruling for adoption of technologies, s, the probability of low and medium investment technologies will be high as compared to high investment technologies. Table 2: Savings per typical Unit S.No Energy Efficient Technology/ Annual Coal Annual Energy Annual Measure Savings Savings Monetary (Terajoules) (Tonnes) Savings (INR) Process Change from straight 140.85 7,04,250 3.228 line to Zigzag Firing Best Practices in Coal 53.21 2,66,050 1.219 Charging/ Feeding Induced Draft Fan 46.95 2,34,750 1.076 Vertical Shaft Brick Kiln * 128.33 6,41,650 2.941 Hoffman Kiln 125.2 6,26,000 2.869 Manufacture of Perforated 112.68 5,63,400 2.582 Bricks
1 2 3 4 5 6
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Manual on Energy Conservation Measures in Brick Cluster, Varanasi Table 3: Total Cluster wide Savings (226 units) S.No Energy Efficient Technology/ Annual Coal Annual Energy Measure Savings Savings (Tonnes) (Terajoules) Process Change from straight 31832.1 729.563 line to Zigzag Firing Best Practices in Coal 12025.46 275.612 Charging/ Feeding Induced Draft Fan 10610.7 243.187 Vertical Shaft Brick Kiln * 29002.58 664.713 Hoffman Kiln 28295.2 648.500 Manufacture of Perforated 25465.68 583.650 Bricks Annual Monetary Savings (INR) 15,91,60,500 6,01,27,300 5,30,53,500 14,50,12,900 14,14,76,000 12,73,28,400
1 2 3 4 5 6
*Proposals 1&2, 4&5 are mutually exclusive. If one of them is implemented, the other cannot be implemented.
Zero Investment Energy Conservation Measures Apart from the proposals for reducing the energy intensity of the brick making industry in the Varanasi sector, alternatives/ zero and negligible cost measures were identified. There measures typically require minimal to zero investment and can be implemented almost immediately. Due to the nature of operation of Bull trench kilns it is not possible to quantify the actual energy savings from from implementation of these measures/ practices. 1. 2. 3. 4. 5. 6. 7. Replacement of metallic lids with insulated lids in the firing zone Increasing the top layer of fly ash on trench from a minimum of 4 to 6 inches Timely feeding/standardization of coal charging in the combustion zone Proper and timely housekeeping practices Overall periodic maintenance of unit Quality control of green bricks to reduce moisture below 3% Use of powdered/ crushed coal for charging purposes
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Manual on Energy Conservation Measures in Brick Cluster, Varanasi 1. BEE SME Programme The Bureau of Energy Efficiency (BEE) is a nodal agency set up under the Energy Conservation Act, 2001 with the primary objective of reducing energy intensity of the Indian Economy. BEE has identified the Small and Medium Enterprises (SMEs) like foundries, brass, textile, brick and ceramic manufacturing unites etc as having large potential for energy savings. BEE considers it useful to intervene in these SME clusters and build their energy efficiency awareness by funding/subsidizing need based studies in these clusters and giving energy conservation recommendations including technology up up-gradation opportunities. 1.1 Project Objectives The overall objective of the SME programme is to improve the energy intensity of the Indian economy by undertaking actions in the SME sector. The programme also specifies immediate/ short term objectives on accelerating the adoption of EE technologies and practices in the identified clusters through knowledge sharing, capacity building and development of innovative financing mechanisms. The main project activities as stated by BEE under the SME program include: Energy Use and Technology Analysis Capacity Building Implementation of EE measures Facilitation of Innovative Financing Mechanism 1.2 Expected Project Outcomes The expected project outcomes of the above mentioned activities are: Assessment of total energy usage and groundwork for undertaking further actions ctions within the cluster Cluster manual anual to give an overview of the clusters List of 15 projects for the cluster to improve the current state of technology within the clusters Capacity building of the Local Service Providers to undertake implementation of EE measures in the clusters Facilitating arrangement between Financial institutions to enhance capacities of lead banks in the clusters Assessment of impact of the programme and roadmap for future action
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Manual for energy Conservation Measures in Brick Cluster, Varanasi
1.3 Project Duration
Note: M = Month
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi
1.4 Identified Clusters in the Programme The 18 clusters identified by BEE for the SME programme is listed below; Table 4: BEE identified clusters under the SME Programme S. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Cluster Location Alwar Bangalore Batala, Jalandhar & Ludhiana Bhimavam Bhubhneshwar E&W Godavari Ganjam Gujrat Howrah Jagadhri Jodhpur Jorhat Kochi Muzaffanager Orissa Vapi Varanasi Vellore Product Oil Milling Machine Tools Foundry Ice Making Brass Refractories Rice Milling Dairy Galvanizing Brass & Aluminium Limestone Tea Sea Food Processing Paper Sponge Iron Chemical & Dyes Brick Rice Milling Units Surveyed (No.) 65 54 431 28 33 44 205 22 57 91 78 60 35 18 45 180 69 49 Total Units listed in the Cluster 68 62 431 33 44 44 231 22 57 392 78 60 35 26 53 227 226 66
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi 2. Cluster Scenario The Brick manufacturing cluster is located in the greater Varanasi district. Varanasi (Banaras) is one of the oldest cities of India. It is located along the left crescent- shaped banks of the river Ganges in the Eastern part of Uttar Pradesh. It is claimed to be the cultural and spiritual capital of India due to its diversity, temples, ashrams and mythologies. In addition to the tourist & religious aspect, Varanasi also hosts one of the biggest clusters of brick manufacturing industries in the country, Table 5: Varanasi at a Glance Geographical Location Geographical Area (2001) Average Rainfall (2006) Temperature (2004) Population (2001) Estimated Daily floating Population Literacy (2001) No. and Name of Tehsils 83oE , 25o20N 1535 Sq. Km. 244 mm Actual Max. 47, Min. 4.5 31,38,690 30,000 16,94,400 Total: 2 Varanasi Sadar Pindra Total: 8 Kashi Vidyapeeth Cholapur Badagaon Chiraigaon Haruhua Pindra Arajiline Sevapuri
No. and name of Development Blocks
Due its location on the banks of the river Ganges and its rich history Varanasi attracts tourists, devotees on pilgrimages and workers from nearby rural villages. It is estimated to have a floating daily population of around 30,000 and its riverfront and old city heritages zones are densely populated (above 500 people/per hectare).
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Image 1: Varanasi District Overview
2.1 Overview of SME Cluster 2.1.1 Cluster Background There are approximately 226 (Two hundred and twenty six) brick kilns in operation within the greater Varanasi district. The kilns are majorly located in clusters in the following areas of the district: Haruhua Sarnath Sindhora Road Rohania Munari Rameshwar Badagaon
Presently the brick market is highly competitive due to imbalance in demand and supply, late onset of spring weather and scattered rainfall are the two major factors responsible for this. The late onset of spring has led to the currently functioning brick kilns to be operating at loss. This is due to the over consumption of coal in order to keep the brick kiln operating at capacity; With a number of units yet to start operations in February/ March 2010. The local market cost of 1st class bricks is in the range of Rs 3.8 4.2 per brick.
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Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi
2.1.2 Product manufactured The two main product types manufactured in the Varanasi cluster are Bricks and Half Bricks. There is just one standalone unit which produces tiles/ perforated bricks in combination with bricks. Figure 1: Cluster Products Manufactured
Cluster Products Manufactured

0% 25% Solid Bricks Solid & Half Bricks 75% Perforated Bricks
6 Cluster Product Manufactured Break Up Table 6: Total Number of units manufacturing Solid Bricks Total Number of units manufacturing Solid +Half Bricks Total Number of units manufacturing Perforated Bricks 2.1.3 Classification of units The brick kilns in the entire Varanasi cluster are of the traditional coal fired fixed chimney Bulls Trench Kilns (BTK) type,, with fixed natural draft chimneys. A minute percentage of the kilns in the area also operate using induced draft fans for better airflow in the firing/ cooling zones during summers. 170 55 1
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Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi Image 2:Traditional Fixed Chimney BTK
2.1.4 Production capacity (in tonnes or pieces per year) detail The capacities of these kilns vary between 2 9 lac bricks a round (approximately 30 days) with a minimum operation capacity of 15 thousand bricks per day. Kiln operations are highly dependent on weather/ seasons, with the kilns usually operating for a period of 6 6- 8 months from November - December to May - June. Therefore individual kiln production capacities vary greatly depending upon the seasonal operational of the kilns. Figure 2: Annual Brick Production
Annual Brick Production

15% 11% Upto 15 Lacs 34% 40% 16-30 30 Lacs 31-40 40 lacs Above 40Lacs
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Table 7: Annual Production Capacity Annual Production Capacity Upto 15 Lacs 25 16-30 Lacs 75 31-40 Lacs 89 Above 40 Lacs 32
2.1.5 Raw materials used The basic raw materials used for making bricks are; clay, sand and water. Due to the location of brick kilns around the vicinity of the Ganges valley the entire cluster has an abundance of good quality clay possessing near ideal chemical and physical properties. The soil is very suitable and create minimal to negligible difficulties while sun drying or while firing of burnt clay bricks. 2.2 Energy Situation in the cluster 2.2.1 Types of fuels (fossils, biomass, waste, byproducts, etc) used and prices Coal is the main source of energy used in brick making. Very few units within the cluster are also using sawdust / wood in conjunction with coal for the firing of bricks. However the energy usage of these fuel sources is negligible as compared to the overall consumption of coal in the operation and energy usage of the kiln. Many of the units use a combination of different coal types depending upon availability and market price fluctuations. Figure 3: Coal Source and Rate Coal Sourcing and Cost
7000 6000 5000 4000 3000 2000 1000 0 Jharandi Rack Jharandi Market Assam Ramgarh
Cost (Rs/ tonne)
Rate (Rs/ Ton)
Coal Sourcing/Type
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2.2.2 Fuels and electricity consumption in a typical unit The average coal consumption range in a BTK unit is shown as below: Figure 4: Coal consumption per lac bricks
90 80 70
Number of Units
60 50 40 30 20 10 0 Upto 15 Tonnes 15-18 Tonnes 18-21 Tonnes Above 21 Tonnes
Coal Consumption / lac Bricks
Coal Consumption Upto 15 (Tonnes/ Lac bricks) Number of Units in the 33 Cluster
15- 18 80
18- 21 83
Above 21 29
For night time operations, a small percentage of units use electricity for illumination purpose, with a majority using kerosene e lamps or rechargeable lamps. 2.2.3 Specific energy consumption (in appropriate unit) Typically the energy consumption of brick manufacturing units is presented in terms of tons of fuel consumed for firing one lac bricks. This method of representation however is inaccurate in comparing the performance of brick kilns as: It does not account for the varying range of fired brick weight between units in the cluster Does not account for the difference in weight/dimensions weight/dimensions of half bricks and full bricks It does es not account for the quality/source quality/source of coal being used for the firing of bricks.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Therefore by calculating the specific energy consumption required for firing of one kilogram of fired brick, the performance and energy consumption of the brick kilns within the cluster can be accurately documented using this approach. Specific Energy Consumption (Mj/kg of final product) Specific Energy Consumption per Fired Brick Specific Energy Consumption per lac Fired Bricks *1 Lac bricks = 3,00,000 kgs of final products approx. 1.1 to 1.5 3.3 4.5 Mj 0.414 Tj
2.3 Manufacturing process/technology overview in a typical unit In Varanasi, brick making is still a traditional process with minimal use of mechanization and technologies. Traditionally majority of the brick kilns in this area are moving chimney Bull Trench kilns. However after the minimum national emission standards for brick kilns under the prevention and control of Pollution Act 1996, it has seen the implementation of the more efficient fixed chimney BTKs replacing the moving chimney BTKs with a visible effect on the quality and quantity of brick produced. 2.3.1 Process technology The brick manufacturing process in a typical unit is centered around the Bull Trench Kiln (BTK) and the associated processes supplementing the firing and cooling within the BTK. The Bull Trench Kiln is the popular choice of brick manufacturing unit in the Varanasi cluster. It is an oval/circular shaped brick kiln with its chimney usually in the middle. The trench is connected to the chimney by means of evenly spaced chambers along the trench. A schematic of a BTK is shown below. Figure 5: Chamber Layout and Gas Flow through BTK
Chamber Schematic Pre Heating Zone Cooling Zone Combustion Zone Gas Flow through Chimney Chambers
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2.3.2 Process flow diagram While the principles of brick manufacture in BTKs is fairly consistent, individual units may and sometimes do depart from these basics to fit their particular requirements, raw materials and mode of operations. The essential steps in brick making are shown show in the diagram below. Figure 6: Brick Making Process Clay Winning and Soil Preperation Shaping or Moudling of green bricks Firing and cooling Brick Extraction
Drying
The first three steps of the brick making process usually start around about 20-40 40 days before the actual firing of the kiln. This is done to build up a decent stockpile of dried green bricks for continuous operation of the brick kiln. The firing up process proces of the brick kiln takes 10-20 20 days to make the kiln reach its appropriate temperature for the bricks to solidify and acquire its pre requisite fired brick attributes. The entire process is continual and once the firing is initiated, very rarely is the kiln kiln operation course halted. A. Clay Winning and Soil preparation Clay is usually dug from the local vicinity of the brick kiln. The clay is then processed as to be free from gravel, lime and other bio wastes/ matter. This soil once excavated is then watered watered and left over a period of 8 12 hours for weathering and processing. After aging the moistened soil is kneaded/ pugged as required. Image 3: : Clay Winning & Moulding Area (Pathai)
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B. Moulding / Brick formation The Plastic clay after been through the previous process is then moulded into the required brick shape and size with its makers mark using a metal/ wooden / PVC mould. C. Brick Drying Once the clay has been formed into the pre required green brick shape, it is then left out in the sun to dry and reduce its moisture content. Fast drying on extremely hot days may lead to creation of cracks in the green brick which is undesirable. Therefore to minimize crack creation and quick moisture loss, the drying process takes place over a period of 8 -12 days with the bricks left out in the Sun. The bricks are usually laid out in stacks with a horizontal vertical alignment as to maximize usage of space and Sun light. Image 4: Wet Green Brick drying
D. Firing and cooling The firing and cooling is done in the bull trench kiln (BTK). Relative to combustion zone within the kiln, the trench can be divided into cooling, firing and pre heating zones.
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Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi Figure 7: BTK zone Classification flow
Cooling Zone
Firing / Combustion Zone
Pre heating zone
The cooling zone is the upstream region in which the fired brick extraction takes place. This area is also vital in the mechanics of the brick kiln functionality as it allows cool air to flow into the combustion zone. The cool air while flowing through the fired brick arrangement cools the brick arrangement while at the same time gaining heat from the previous lines of fired bricks. Figure 8: BTK operation and Zones
Pre Heating Zone Combustion Zone Cooling Zone
Chimney
The combustion zone is the area where the firing of bricks takes place. To achieve the desired/ required properties of fired bricks the green bricks in this zone are subjected to temperatures of 800 1080 degree Celsius. Holes are made in lines on the top layer of the brick arrangement through which coal is fed in regular intervals into the combustion zone. To minimize heat losses during feeding, feeding, these holes are covered with metallic lids. Coal feeding of a line within the combustion zone may take anywhere from 3 to 6 hours depending on the draft and temperature of the Pre heating line.
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Image 5: : Combustion Zone with lines covered by metallic lids
The pre-heating heating zone is located downstream to the combustion ombustion zone. Sufficiently dried green bricks are brought over from the Pathai (brick moulding oulding area) and systematically stacked within this zone. This stacking arrangement is then covered with a top layer of fly ash (3 6 inches) to offer insulation and minimize heat losses. The hot air/gases coming from the combustion zone flow through these lines of bricks further reducing their moisture and heating these bricks. bricks. A hole connected to the chimney is opened at a suitable location downstream to allow for maximum heating of bricks in the pre heat zone before it is discharged through the chimney. The difference in temperature between the hot air in the chimney and the he cold ambient air creates a draft which sucks in air from the cooling zone. Image 6: Green brick stacking pattern
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E.
Brick Extraction The extraction of bricks takes place in the beyond the cooling zone of the brick kiln. As the brick firing and cooling is a continuous process the brick discharge takes place daily in tandem with the position of the firing/cooling of the lines. Image 7: Fired Brick Extraction
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2.4 Current policies and initiatives of local bodies, if any A. UNDP-GEF project: Energy efficiency improvements in Indian brick industry Project objectives With this background, UNDPGEF is Ludhiana supporting a project Varanasi (UP)/ Kolkata on Energy efficiency (West Bengal) improvements in South Bangalore (Karnataka) Indian brick industry West Pune (Maharashtra)/ Gujarat for a period of four North East Tripura years staring June 2009. The project is implemented by the Ministry of Environment and Forests (MoEF) and TERI is the responsible partner for implementation. The main objectives of the project include: Enhancing public sector awareness on resource-efficient products Facilitating access to finance for brick kiln entrepreneurs Improving knowledge on technology and marketing Demonstrating and making available the technologies and models for producing REBs in at least five brick producing clusters through its local resource centers; Improving capacity of brick kiln entrepreneurs, supervisors and workers. Region North East Cluster Advantages of Resource Efficient Bricks (hollow, perforated bricks) 1. Lowering rate of consumption of top soil (about 30%) 2. Reduced fuel requirements (about 20%) for brick firing 3. Reduced CO2 emissions 4. Improved crushing strength (more than 200 kg/cm2) and reduced water absorption (around 10%) compared to handmade bricks 5. About 57% reduction in construction costs 6. About 5% saving in energy bill with reduced heating/cooling loads due to improved insulating properties.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Key Stakeholders in the project End-users such as builders, architects and government departments such as MES (Military Engineering Services), CPWD (Central Public Works Department), State PWD, etc Government organizations such as BIS (Bureau of Indian Standards) and BEE (Bureau of Energy Efficiency) for inclusion of the technical specifications of REBs in their standards Other government organizations such as HUDCO, CGCRI, MSME-DI, BMTPC, CPCB, state PCB Brick kiln entrepreneurs for technology adoption Banks and financial institutions for providing loans to brick kiln units for technology adoption Project outcome The resource efficient technologies are demonstrated in five different brick clusters in India, and the support system in place for technology adoption.
B.
Establishment of Testing Laboratory Int Nirmata Parishad, the brick manufacturers association of Varanasi district, in an initiative along with TERI established a testing laboratory for the brick industry at the associations office in Varanasi through partial financial assistance from the Small Industries Development Bank of India. This laboratory is being used by members of the association for various purposes. The laboratory is having the following equipments: a. Bomb Calorie Meter This instrument is used for testing calorific value of coal. b. Muffle Furnace This instrument is for testing firing temperature of soil to check suitability of the soil for making bricks. c. Weighing Balance It is used for weighing the coal which is to be tested in Bomb Calorie Meter. d. Compressive Strength Testing Machine It is used to check the compressive strength of fired brick. e. Thermocouple and Temperature indictor This instrument is used to measure the firing temperature in brick kilns.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi 2.5 Issues related to energy usage and conservation and barrier in technology up gradation There are common widespread issues plaguing the brick industry in Varanasi which are creating barriers in implementation of new technologies, energy efficiency measures and up gradation of traditional age old processes. To reduce the energy intensity within the cluster, these issues need to be addressed collectively to overcome the barriers the unit owners/operators are currently facing. 2.5.1 Energy availability There are two main energy availability barriers which are prevalent in the Varanasi brick manufacturing cluster; I. Lack of fuel switching options Due to the nature of the brick making process technology in Bull trench kilns (BTKs), the energy options are limited. There are no available fuel alternatives to coal in this mode of process technology. Fuel switching alternative/ renewable fuel options can only be implemented successfully, if the current brick manufacturing process and the current state of technology is improved. II. Shortage of quality Coal The shortage of quality B grade coal and its high price required for brick manufacture poses another barrier in Energy Conservation within this sector. Due to lack of quality coal, kiln owners resort to low quality and rack coal sources which have lower calorific value and carbon content. A lower quality fuel would be required a larger quantity to prepare the same amount of bricks as opposed to higher grade of fuel. Along with higher energy consumption, using lower grades of coal also results in increased air pollution. 2.5.2 Technological issues Technological barriers pose a very pertinent threat to adoption of Energy conservation, up gradation of current traditional process/operations and growth of the brick cluster in Varanasi. These issues can largely be attributed to:
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I.
Traditional outlook of industry Majority of the kiln owners have a closed outlook, choosing to look at only the immediate future rather than long term benefits and improvements. There is a fairly dominant mindset of working it till it breaks and an unwillingness to look at repercussions of kiln operations in terms of land degradation, energy conservation and pollution control.
II.
Lack of Research and Development in this sector There is a definitive void in development and existing facilities for Research and Development in this sector. Institutes in the past have been integral in facilitating technology transfers and improvement in the brick manufacturing cluster all over India, However there is need for continuous Research and Development associated processes (Green brick moulding) other than the thermal firing/cooling to encounter the problems whenever they may arise. Providing Technical support to this industry is key to keep them abreast with international best practices in brick making.
2.5.3 Financial issues The greater part of the entrepreneurs in the brick community cite lack of financial support and access to credit from financial institutions. Due to the current technology of the brick manufacturing process; i.e. its dependence on weather conditions, constant relocations and its modulus operandi, financial institutions are hesitant to offer a line of credit to interested and progressive kiln owners. Such is the disposition of the brick manufacturing process in this cluster, any major technology upheavals are almost always at a high cost measure, making it inaccessible to be owners without suitable financial interventions. 2.5.4 Shortage of Trained Manpower Varanasi brick cluster faces shortage of trained manpower at every level. There is a void of competent consultants and qualified masons for planning & supervision of kiln improvements and kiln construction/renovations respectively. The current state of process technology is such that there are no formal training options available to the managers and coal feeders.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi 3. Energy audit and technology assessment 3.1 Methodology adopted for 3.1.1 Energy Use and Technical Study To determine the Energy use and technical study, individual units are identified within different clusters in the main Varanasi sector. It is integral to target different clusters as it accounts for deviations in soil properties, sourcing of raw materials, fuel, and variations in manufacturing and housekeeping operations. The overall step by step methodology followed for Energy use and technical study is as below: Figure 9: Methodology for Energy Use and Technical Study
Identification of units for preliminary and detailed study
Information workshop for brick users
Preliminary Study
Detailed Study
Technology Gap Assessment
Proposals for Energy Conservation
3.1.1.1 Pre-Energy Audit Activities Before any activities take place at the brick manufacturing units within the cluster it is integral to create awareness and inform the brick owners associations about any proceeding goings on to be done within the cluster. This ensures cooperation from the individual brick manufactures and collective associations within the cluster.
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Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi Image 8: Pre Audit Workshop
An Information and cooperation workshop was conducted in Varanasi, where invitations were extended to the brick owners/operators and the associations in the cluster to keep them abreast of the scheduled activities to take place in the cluster along with the programme outcomes, objective objectives s and relevant stakeholders involved of the SME programme. 3.1.1.2 Preliminary Energy nergy study The preliminary study is the first stage in conducting an energy and technology assessment of the brick manufacturing units in the cluster. The aim of the preliminary stu study dy is collecting information relating to kiln operating and energy use to get an overview of energy sources, raw materials, processes involved, etc of the units within the cluster. Figure 10: Preliminary Audit Methodology
Site Visits to Identified units
Collection of General information about kilns
Measurement of kiln and fixed assest dimensions
Overview of Energy usage in manufacturing process
Documentation of raw materials used
Documentation and Measurement of manufactured product
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Preliminary energy studies were conducted at 69 brick manufacturing units in the Varanasi cluster. 3.1.1.3 Detailed Energy Study Detailed energy studies are conducted to get an in depth break up of energy usage of each of the associated processes in the operation of brick kilns. It covers the quintessential steps in preliminary study and provides a thorough analysis of the kiln functioning. Detailed Energy audits were conducted at 22 units with the team utilizing the following instruments: Flue-Gas Analyzer Thermocouple Basic dimension Measurement instruments Weighing Scale Laser Temperature Gun To minimize errors in Measurement and Analysis, there are some guidelines which need to be maintained while analyzing and measuring the coal consumption of the unit. a. Location of Combustion zone The combustion/ firing zone should be in/along the straight position. If the fire is in the curved portion of the kiln the rate of fire travel is higher and therefore it adversely affects the accuracy of the results. b. Regular loading of kiln during the study period Ensure that the kiln has sufficient quantity of dry bricks (either already loaded or available for loading) and labor for loading of the kiln during the course of the trials. c. Weekly off-day should not fall during the Study duration The kiln firing operation is a continuous process, taking place 24 hours, 7 days a week. The associated loading / unloading, moulding process workers are given a weekly day off. It is necessary to ensure the weekly off day does not fall during the study duration as it may affect the firing of the kiln.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi d. Bad Weather As the brick manufacturing operation in BTKs is open to weather, the precision of detailed study is affected by adverse weather conditions (rain, wind, storms, etc). The methodology followed for conducting detailed energy studies at the brick manufacturing units in the Varanasi cluster is listed sequentially below. Figure 11: Detailed Audit Methodology
Collection of General information about kilns
Computation of Energy Losses
Documentation and Measurement of Fired Bricks
Measurement of kiln and fixed assest dimensions
Analysis of Combustion gases
Documentation of raw materials used
Weighed Determination of fuel consumption
Detailed documentation of Coal Feeding operation
Overview of Associated Processes
3.2 Observations made during the energy use and technology studies carried out in the cluster 3.2.1 Manufacturing process and technology/equipments employed The bulk of the Manufacturing processes in a BTK are labor intensive with minimal mechanization. Observations made during on site studies are listed as per the process break up below:
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Figure 12: Process Observations

Clay Winning & Pugging All operations (digging, mixing, etc) done manually using shovels. Very small percentage using excavators for digging Pathai Area approximately 60% of the Total Brick manufacturing area Approximately 10 people involved in this process Operation during early morning and late evenings Green Brick Moulding Labor Intensive Done using PVC, Metal or Wooden moulds Manpower shared between Green Brick Moulding and Brick Drying Processes Operation during early morning and late evenings Brick Drying Done in and around the Clay Winning and Green Brick Moulding area Stacked in horizontal and vertical stacks to maximise space utilization Process operation is continuous untill bricks are ready to be fired Firing and Cooling Coal carried from storage to feeding area by 2-3 labors. Coal carried in baanks and used for filling typically 2 metal tubs, from which the coal feeders charge the coal in the combustion zone Baank and tub sizes vary by +/- 10-15 % in kilns within the clusters Coal feeders operate in 6 hour shifts Manual crushing/breaking of coal peices/ boulders Hand shovels used for coal feeding Hand shovel quantities vary from 0.5 - 1.5 kgs Feeding operation is carried out 24 hours Fired Brick extraction Extraction process carried out in the morning and evenings Labor shared in loading and extraction process due to labor shortages Brick carried to and fro storage areas using mules, Rickshaws
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Some of the deviations we observed during on site studies are listed below: Table 8: Deviations in Manufacturing Processes S. No. 1. Deviations in No. of Manufacturing Process units in Description / Technology/ the Methodology Cluster Clay Pugging Machine 1 Mechanized operation Considerable Reduction in workforce Uniform mixture for green brick moulding Requires semi-trained workforce/ machine operators Efficient and streamlined operation with increased output Induced Draft Fans 4
2.
Diesel Engine installed for Fan operation Longer cooling and pre heating zones Can be operated on Electricity Requires continuous feeding of coal lines Smaller hand shovels used for feeding Smaller tub sizes and increase in the number of tubs by 2 per line fed. Insulated metal lids being used for covering feeding holes during coal feeding Reduction in Surface losses due to heat dissipation Uniform Positioning of exhaust holes to lines being fed.
3.
Zig-Zag Firing
4.
Insulated Lids
5.
Circular Brick Kilns
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi 3.2.2 Energy consumption profile & availability Over a 24 hour period the coal consumption is fairly uniform. Feeding operations take place intermittently at intervals of 30 90mins. The serving quantity of the hand shovels used for coal feeding is between 0.5 1.5 kgs and typically in one feeding operations about 5-10 feeding is done into a hole. The schematic below shows the coal feeding pattern in brick kilns using two man coal charging. Image 9: Coal Feeding Pattern
To ensure the availability of coal in metal tubs for feeding operation in the combustion zone of the kiln, coal topped up regularly in the tubs by coal carriers using a baank (locally modified coal carrying containers). 3.2.3 Capacity utilization factor Individual unit capacity of the kiln depends upon the size of the kiln. Bull Trench Kilns are operated almost always at full capacity. It is not possible to alter the capacity of the kiln due to its unique process methodology i.e. if an unit has a capacity of 6 lac bricks per round; it is always operates at an maximum unit capacity. Weather and labour conditions play a major role in the Annual capacity of brick manufacturing units. Annual capacity of individual units differ based on these two factors as it determines the duration the kiln is operated in one season. Currently only 60-70% of the units in this cluster are operating at full capacity; rest of the units are operating at 60% due to a late start this season. 3.2.4 Housekeeping practices Due to its characteristic disposition of the Bull Trench kiln, proper Page 26
Manual for Energy Conservation Measures in Brick Cluster, Varanasi housekeeping practices are almost non-existent. This can be attributed largely to the brick kiln being open to environmental elements. The housekeeping practices typical to BTKs are listed below; Sealing of ducts, chimney and trench entrances during initial starting of kiln operations Daily laying of fly ash on top layer of brick stacking in the trench Timely sealing of firing holes in the combustion zones. 3.2.5 Availability of data and information Information and data is not readily shared within this industry. Due to the closed and traditional outlook of greater majority of the kiln owners/operators, it takes some amount of persuasion to gain access to kiln operating information. There is also a widespread lack of recordkeeping within industry. This makes it hard to collect previous data regarding kiln operation and accurately form conclusions towards technology/ process upgrades and savings potential of these manufacturing units. It is tricky to verify the accuracy of actual coal consumption of these units due non prevalence of monitoring and verification documentation. 3.3 Technology gap analysis After Review of the operational processes and the current technology within the Varanasi brick Cluster, the following observations in regards to process and technology were noted; 3.3.1 Technology up-gradation
Non-existent suitable model/machines for green brick moulding which can be replicated Need for improved kiln design (Hoffman kiln, Tunnel kilns etc)
3.3.2 Process up-gradation
No standardization/ engineering for Energy saving practices (i.e. use of shunts, draft measurement, temperature measurement) Non-existent standard practices for soil preparation / pugging Need for standardized methodology for coal feeding quantity and duration Development of methodology for pre-heating, and cooling zoning lengths
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi 3.4 Energy conservation measures identified 3.4.1 Proposals for energy conservation including technology upgradation Based on the Technology gap assessment the following measures/ technologies are considered viable and proposed for reducing the overall coal consumption of kilns. These measures and technology upgrades are listed as below: 1. 2. 3. 4. 5. 6. Process Change from Straight line firing to Zigzag Firing Best Practices in Coal Feeding/ Charging Installation of Induced Draft Fans Vertical Shaft Brick Kilns Hoffman Kilns Manufacture of Perforated Bricks
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 1: Process change from Straight line firing to Zig-Zag Firing Description: During straight line feeding, coal is generally fed intermittently into 1-2 rows, with intervals between two successive feeding operations ranging from 30 60 minutes. The coal fed in each line is anywhere between 500grams 1000grams per scoop. This type of coal feeding operation results in either or both of the occurrences listed below: Reduction in temperature of fuel bed, sometimes below ignition temperature Deepening of coal bed in the trench, and difficulties in diffusion of air in the fuel In Zig-Zag mode of operation, the combustion zone is divided into 2-6 chamber (4 -12 lines) using partitioning green brick arrangement and the kiln is operated at a high draught for a fast rate of fire travel. The wall chamber runs along the width of the gallery except one end, where a space of 1.0ft is left for communication to the next chamber. The number of bricks per chamber depends upon the design capacity of the kiln and can vary anywhere from 5,400 10,000 bricks. Zig-Zag firing kilns were at one time widely popular in developed countries like Australia and in Europe. These kilns are typically shorter in size (trench size, and overall kiln length) and have a longer combustion zone than straight line firing kilns. Image 10: Double Zig-Zag Firing Schematic
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Benefits: 1. 2. 3. 4. Less Area Requirement Typhoon Air circulation / higher turbulence in the air allows for better mixing of fuel and air resulting in better combustion High firing rates results in shorter rounds of typically 15 days. This results in reduction in ground and structural losses Reduction in surface heat losses. Table 9: Zig-Zag Firing Energy Savings Calculations: Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks after adoption of Zig-Zag Firing Kiln Average Annual Coal Consumption Kiln Annual Coal Consumption after Zig-Zag Firing Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings Value 31.3 18 13.5 563.4 422.55 140.85 31,832.1 729.5634 Units Lac Bricks Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes Terajoules
Table 10: Zig-Zag Firing Cost Benefit Analysis Description Cluster annual Coal Savings Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Recurring Costs Cost of Implementation (Cluster) Simple Payback Period Typical lifecycle Value 31832.1 5000 159160500 721000 36050 171093300 1.07 5-10 Unit Tonnes INR INR INR INR INR Years Years
Table 11: Zig-Zag Firing Cost of Implementation S.no. 1. 2. a) b) c) d) Particulars Cost of modification in Civil structure Cost of Equipments Feed hole covers 100 nos. @Rs. 550/Insulated Shunt 2 nos. @ Rs. 25000/Temperature gauge for Shunt 2 nos. @ Rs. 1500/Thermocouple 1 set (includes 1 small and 1 big) Cost Rs. 4.5 lack (Approx.) Rs. 55000/- (Approx.) Rs. 50000/- (Approx.) Rs. 3000/- (Approx.) Rs. 10000/- (Approx.) Page 30
Manual for Energy Conservation Measures in Brick Cluster, Varanasi e) Temperature Indicator- 1 no. @3000/Rs. 3000/- (Approx.) 3. Cost of Consultancy and training to workers and Rs. 150000/supervisors Rupees Seven lack twenty one thousand only/- Rs. 721000/Total
Note: Proposals 1 with all its specifications can be adopted by majority of units in the cluster.
Issues /Barriers in Implementation 1. 2. 3. 4. 5. Change in Stacking arrangement may not sit well with managers and labor used to traditional stacking methodology. Bricks might remain too hot for handling at unloading point, due to fast firing of multiple chambers Existing Brick kilns might have to be modified to accommodate Zigzag firing operation. Lack of Consultants and technical support for implementation Lack of Control Measures from Managers
Environmental Benefits 1. 2. 3. Reduction in fly ash due to incomplete combustion of coal Reduction in GHG Emissions visible by reduction in black smoke coming out of chimney. (Typically 1.4 tonnes per ton of coal) Reductions in CO emissions due to efficient combustion of the coal bed and diffusion with air.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 2: Best Practices in Coal Feeding/ Charging Description: During straight line feeding, coal is generally fed intermittently into 1-2 rows, with intervals between two successive feeding operations ranging from 30 60 minutes. The coal fed in each line is anywhere between 500grams 1000grams per scoop. This type of coal feeding operation results in either or both of the occurrences listed below: Reduction in temperature of fuel bed, sometimes below ignition temperature Deepening of coal bed in the trench, and difficulties in diffusion of air in the fuel Both the above cases result in incomplete combustion, signified by the distinctive black smoke observed coming out of the chimney. For achieving better combustion, following methodology for coal feeding should be adopted: Increase in number of fuel feeding lines from 1-2 to 3-5. Continuous charging/feeding of coal, instead of feeding intermittently Using smaller size spoons for feeding (500-700g/ scoop) Change in feeding pattern to single man feeding Use of Mechanized Coal Crusher to crush coal particle size to ~10mm Monitoring rate of fire travel and temperature profile within the combustion zone Benefits: Adoption of the above best practices in coal charging/ feeding would result in better/ efficient combustion of fuel in the combustion zone. This would lead to reduction in coal consumption. By monitoring the temperature of the pre heating lines and the current charging line, coal feeders are able to avoid overconsumption of coal, once the required temperature of 700 and 1000 degrees Celsius has been achieved in the pre heating and current feeding lines respectively. Table 12: Best Practices Energy Savings Calculations: Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks after adoption of Best Practices Kiln Average Annual Coal Consumption Value 31.3 18 16.3 563.4 Units Lac Bricks Tonnes Tonnes Tonnes
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Kiln Annual Coal Consumption after adoption of Best Practices Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings 510.19 53.21 12025.46 275.6128 Tonnes Tonnes Tonnes Terajoules
Table 13: Best Practices Cost Benefit Analysis Description Cluster annual Coal Savings Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Recurring Costs Cost of Implementation (Cluster) Simple Payback Period Typical Lifecycle Value 12025.46 5000 60127300 100000 5000 23730000 0.39 N/A Unit Tonnes INR INR INR INR INR Years -
Note: Proposals 2 with all its specifications can be adopted by all units in the cluster.
Table 14: Best Practices Cost of Implementation S.no 1. 2.

3.
4.
Particulars Cost of modification in Civil structure Cost of Equipment (shunts, insulated lids, etc) Cost of Monitoring instruments (Thermocouple etc.) Cost of Consultancy and training to workers and supervisors Total
Cost (INR) N/A 35,000 15,000 50,000 1,00,000
Issues /Barriers in Implementation 1. 2. 3. 4. Savings may vary kiln to kiln. Lack of training at coal feeder/Manager level Lack of awareness at Owner level Lack of Training Facilities and Experts
Environmental Benefits 1. Reduction in fly ash due to incomplete combustion of coal 2. Reduction in GHG Emissions visible by reduction in black smoke coming out of chimney. (Typically 1.4 tonnes per ton of coal) 3. Reductions in CO emissions due to efficient combustion of the coal bed and diffusion with air.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 3: Installation of Induced Draft Fans Description: At present majority of the brick manufacturing units operate with Natural draft within their chimneys. During the extreme hot summer season (March- June); the ambient air temperature is relatively similar to the temperature of the flue gases within the chimney. Due to the reduced temperature gradient between the chimney flue-gases and ambient air, there is a significant loss of pressure and slow propagation of fire travel within the kiln heating zones. Installation of a Low hp Fan powered by an outside motor inside the chimney to increase the draft inside the firing zone ensures substantial exhaust gases draft within the kiln operational zones. Benefits: Induced High Draft within the kiln increases the length of preheating zone and decreases the size of cooling zone, allowing for faster operation of kiln Increases Flue Gas heat recovery hence increasing the pre heating capacity of the kiln Reduction in coal consumption and structural losses due to better propagation of fire travel within the combustion zone. Table 15: Induced Draft Energy Savings Calculations: Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks after installation of Induced Draft Kiln Average Annual Coal Consumption Kiln Annual Coal Consumption after Installation of ID Fan Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings Value 31.3 18 16.5 563.4 516.45 46.95 10610.7 243.1878005 Units Lac Bricks Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes Terajoules
Table 16: Induced Draft Cost Benefit Analysis Description Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Value 5000 53053500 170000 Unit INR INR INR Page 34
Manual for Energy Conservation Measures in Brick Cluster, Varanasi Recurring Costs Annual Cluster Net Savings Cost of Implementation (Cluster) Simple Payback Period Typical Lifecycle 142200 20916300 38420000 1.836844949 <10 INR INR INR Years Years
*The Running cost of the ID fan is on basis of operation on Diesel Fuel and the current Tariff Rate of Diesel fuel in U.P. It is strongly recommended running the ID Fan on Electricity sourced from the Local/ State distribution agency. The Table below encapsulates the Cost analysis of operating a ID Fan (15 Hp motor) on a LT electricity connection: Description U.P. Commercial Tariff Rate (Peak) U.P. Commercial Tariff Rate (Off-Peak) U.P. Commercial Tariff Rate (Off-Peak other) Proposed load of ID Fan Other Demand Charges Yearly operating hours Yearly Units Consumed Cluster Annual Units Consumed Cluster Annual Electricity/Running Cost Cluster Annual Savings Value 5.4 4.3 3.45 11.19 Nil 5040 56,397 12745858 54807188 53053500 Unit INR/ kWh INR/kWh INR/kWh kW Hours kWh kWh INR INR
Table 17: Induced Draft Cost of Implementation S.no 1. 2. 3. Particulars Cost of modification in Civil structure (if Applicable) Cost of Fan Equipment Cost of Consultancy and training to workers and supervisors Total Cost INR 21500 INR 98500 INR 50000 INR 170000
Issues /Barriers in Implementation 1. Only suitable for kilns with low draft 2. May cause increase in Air leakages 3. Chimney modifications may be required Environmental Benefits 1. Reduction in GHG emissions due to increase in combustion efficiency
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 4: Vertical Shaft Brick Kilns Description: The brick manufacturing process in the Varanasi cluster is centered around the Bull Trench Kiln (BTK) and the associated processes supplementing the firing and cooling within the BTK. The Bull Trench Kiln is an oval/circular shaped brick kiln with its chimney usually in the middle. The trench is connected to the chimney by means of evenly spaced chambers along the trench. Brick Manufacture using Bull Trench kilns is an age old, traditional process, which is technologically outdated and kiln-owners encounter numerous problems due to inefficient operation of kiln including: Dependence on weather patterns Largely Labor intensive operations High pollutant emissions Fixed volume production
Vertical Shaft Brick kilns (VSBKs) consist of a vertical shaft of rectangular or square cross section. It works on the principle of counter current heat exchanger with, green bricks moving down (in intermittent movement) and air moving up (continuous flow). Green bricks are loaded from the top with a powdered coal being put along the bricks on the top. The bricks move down the pre heating zone to the combustion zone which takes place in the middle of the shaft. Air for combustion enters from below through the cooling zone, where convective heat transfer takes place between the previously fired bricks and air. This hot air passes through the combustion zone in the middle and pre heats green bricks in the upper portion of the shaft (Pre Heating zone). Brick unloading is carried out from the bottom of the shaft using a trolley.
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Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi Image 11: Vertical Shaft Brick Kiln
Image 12: VSBK Working Schematic
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Typically time between two unloading operations is 2-3 hours and the firing time varies between 20-30 hours. Benefits: High energy efficiency Less polluting emissions Better and uniform quality of fired bricks compared to clamps Occupies less space - low land requirement Can work throughout the year subject to availability of green bricks Quick turnover; bricks are ready for sale after firing within two days of loading. Minimal maintenance requirements Flexibility in volume of production based on market demand Highly suitable where part of fuel is traditionally mixed with clay Construction and operation is easy to learn Table 18: VSBK Energy Savings Calculations: Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks using VSBK Kiln Average Annual Coal Consumption Kiln Annual Coal Consumption after adoption of Best Practices Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings Value 31.3 18 13.9 563.4 435.07 128.33 29002.58 664.713 Units Lac Bricks Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes Terajoules
Table 19: VSBK Cost Benefit Analysis Description Cluster annual Coal Savings Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Recurring Costs Cost of Implementation (Cluster) Simple Payback Period Typical lifecycle Value 29002.58 5000 145012900 1446000 72300 343135800 2.539 20 Unit Tonnes INR INR INR INR INR Years Years
Note: Proposals 4&5 are mutually exclusive. Only one of them can be implemented at a time.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Table 20: VSBK Cost of Implementation S.No. 1 2 Description Land Site Development Civil Works Cost (INR) N/A 50,000 Remarks Lease / outright cost variable based on locality - Leveling/Filling - Fencing/ Compound Walls - Other/ Roads etc - VSBK & chimney - Site Office - Hand Pump - Water Storage tank - Ramps & Others Mechanism w/ Kiln Coal Crusher, etc
7,76,000
4 5 6
Equipment Other Production Costs Running Costs Total Cost:
1,20,000 25,000 5,00,000 14,46,000
Issues /Barriers in Implementation 1. Due to Fast Firing and Cooling, bricks do not produce the signature metallic sound or red color, typical of the bricks manufactured in this area. This may lead to difficulties in marketing and sales 2. VSBK was previously adopted by one entrepreneur. The manufacturing unit subsequently shut down due to the above reason. 3. Due to fast firing and cooling, strength of fired bricks is typically lower than those fired from BTKs Environmental Benefits 1. Reduction in GHG emissions due to increase in combustion efficiency
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 5: Hoffman kilns Description: The brick manufacturing process in the Varanasi cluster is centered around the Bull Trench Kiln (BTK) and the associated processes supplementing the firing and cooling within the BTK. The Bull Trench Kiln is an oval/circular shaped brick kiln with its chimney usually in the middle. The trench is connected to the chimney by means of evenly spaced chambers along the trench. Brick Manufacture using Bull Trench kilns is an age old, traditional process, which is technologically outdated and kiln-owners encounter numerous problems due to inefficient operation of kiln including: Dependence on weather patterns Largely Labor intensive operations High pollutant emissions Fixed volume production
Hoffman Kilns are large oval shaped kilns built entirely of building bricks with a number of simple cast iron and steel non structural components. The kiln consists of a central chimney, approximately 150 200 feet high, connected to a main flue running the length of the kiln. On either side of the main flue there are anywhere between 16-24 barrel-arched firing chambers, each linked to the main flue via damper controlled under floor steam flues. The capacity of individual chambers ranges between 20,000 30,000 bricks. These chambers are connected by small tunnels known as fire trace holes, through dividing walls just above ground level. Fuel (Coal) is added to each chamber through small opening in the roof. Larger opening allow control of temperature by introducing ambient air inflow.
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Image 13: Hoffman Kiln Side View
Hoffman kilns are continuous kilns operating 24 hours a day and can be operated for 365 days provided enough stock of green bricks is maintained. Once Fired, the fire moves progressively from one chamber to another, with the bricks undergoing drying, pre-heating, firing and cooling in turn. The whole process is controlled manually by manipulating dampers and sliders. Thermocouples are also used to measure the temperature profile of the chambers. Image 14: Layout Plan of a Hoffman Kiln
Sufficiently dried green bricks are set in a chamber and the entrance is bricked up and sealed. Hot air conveyed from cooling bricks in one chamber is used for Page 41
Manual for Energy Conservation Measures in Brick Cluster, Varanasi pre heating the adjacent chamber. Once a temperature of 700 degree Celsius has been reached in the preheating chamber, caps in the roof are opened for subsequent coal charging in the chamber. Bricks are fired at temperatures of usually around 1000 degree Celsius for a period of 30 hours or until the next pre heating chamber is ready. These bricks are then allowed to cool before they are taken out and new green bricks are loaded in. This process cycle starts over again and takes about 10-15 days to complete. The process methodology of a Hoffman kiln is very similar to a Bull Trench Kiln in relation to zoning and firing. Benefits: Shorter Firing Cycles Can be operated all year round provided sufficient stock pile of green bricks Significantly lower Structural Heat losses due to absorbing roof on top of each chamber (Top structure losses account for 5-10% of heat losses in a BTK) Significantly reduced local air pollution due to reduced consumption of coal. Longer operational life ~20 years Table 21: Hoffman Kiln Energy Savings Calculations Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks using Hoffman Kiln Kiln Average Annual Coal Consumption Kiln Annual Coal Consumption after adoption of Best Practices Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings Value 31.3 18 14 563.4 438.2 125.2 28295.2 648.500 Units Lac Bricks Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes Terajoules
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Table 22: Hoffman Kiln Cost Benefit Analysis Description Cluster annual Coal Savings Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Recurring Costs Cost of Implementation (Cluster) Simple Payback Period ** Typical Lifecycle Value 28295.2 5000 141476000 6000000 300000 1423800000 18.40 20 Unit Tonnes INR INR INR INR INR Years Years
Note : Proposals 4&5 are mutually exclusive. Only one of them can be implemented at a time. ** Pay Back Period does not take into account additional revenue from increase in manufactured product
Table 23: Hoffman Kiln Cost of Implementation S.No. Description Cost (INR) 1 Construction Costs 45,00,000 Remarks - Leveling/Filling - Fencing/ Compound Walls - Other/ Roads etc - Hoffman Chimney Coal Crusher, Steel reinforcements for Air ducts, etc
Other Production Costs Total Cost:
15,00,000 60,00,000
Issues /Barriers in Implementation 1. 2. 3. 4. 5. Lack of supporting regulation, fiscal incentives and standards to encourage energy efficient practices and technology Lack of skilled manpower Cluster Industry absorption capacity to new technology is low Financial Barriers due to very high investment costs Lack of Consultants and Agencies within the cluster
Environmental Benefits 1. Reduction in GHG emissions due to increase in combustion efficiency
Page 43
Manual for Energy Conservation Measures in Brick Cluster, Varanasi Proposal 6: Manufacture of Perforated Bricks Description: In the current Scenario there is only one brick manufacturer making perforated bricks in the entire cluster. Solid Brick products are gradually being replaced worldwide by perforated brick products. This is due to increasing awareness among consumers and manufacturers, along with technological advances in brick manufacture. The worldwide brick industry is looking towards reducing raw materials and wastages by means of developing and manufacturing perforated bricks. In developing countries like India, there is an ongoing debate and underlying effort to reduce land usage used for brick manufacture rather than use it for agriculture to feed our masses. Perforated bricks are bricks with perforation made on the longer dimension face of the brick between 30 45% of total brick face area. These bricks are extruded by means of appropriate extruding machining tools and machinery. Benefits: 1. Lowering rate of consumption of top soil (about 30%) 2. Reduced fuel requirements (about 20%) for brick firing 3. Reduced CO2 emissions 4. Improved crushing strength (more than 200 kg/cm2) and reduced water absorption (around 10%) compared to handmade bricks 5. About 57% reduction in construction costs 6. About 5% saving in energy bill with reduced heating/cooling loads due to improved insulating properties. Table 24: Perforated Bricks Energy Savings Calculations Description Average Annual Brick Production Cluster Average Coal consumption Per Lac Bricks Coal consumption Per Lac Bricks using Hoffman Kiln Kiln Average Annual Coal Consumption Kiln Annual Coal Consumption after adoption of Best Practices Kiln Annual Coal Savings Cluster Annual Coal Savings Cluster annual Energy Savings Value 31.3 18 14.4 563.4 450.72 112.68 25465.68 583.650 Units Lac Bricks Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes Terajoules
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Manual for Energy Conservation Measures in Brick Cluster, Varanasi Table 25: Perforated Bricks Cost Benefit Analysis Description Cluster annual Coal Savings Average per tonne Cost of Coal Annual Cluster Total Cost Savings Cost of Implementation per Unit Recurring Costs Cost of Implementation (Cluster) Simple Payback Period Value 25465.68 5000 127328400 4100000 205000 972930000 11.439 Unit Tonnes INR INR INR INR INR Years
Note Proposal 6 can be adopted by all the units in the cluster. ** Pay Back Period does not take into account additional revenue from increase in manufactured product
Table 26: Perforated Bricks Cost of Implementation S.No. Description 1 Extrusion machine including Civil Works 2 Cost (INR) 29,50,000 Remarks - *Weathering Tank - Loading Platform - Machinery Shed - Water storage tank - Office etc Personnel training Feasibility Studies Start up expenses etc
Preliminary and 4,50,000 Pre-operative Studies Others including 7,00,000 Running costs Total Cost: 41,00,000
Issues /Barriers in Implementation 1. Under developed market for perforated bricks 2. Present Technologies favor production of solid bricks 3. Lack of technical support for adoption of perforated bricks Environmental Benefits
1. Reduction in GHG emissions
Page 45
Manual for Energy Conservation Measures in Brick Cluster, Varanasi 3.4.2 Availability of technology/ product in local/national/international market Table 27: Technology Availability S. No. 1 Technology Availability in Local Market Availability in National Market Availability in International Market Readily Available
Available Widely used in different Brick Clusters all over India Best Practices in Available Available Coal Charging/ Being used in Widely used in Feeding varying capacities different Brick in multiple units Clusters all within the Cluster over India Available Induced Draft Fan Available Being used in Vendors four units within available for the cluster technology Implementatio Lack of Vendors n for technology Implementation Vertical Shaft Brick Not Available Available Kiln Currently not Operated in being operated varying within the cluster capacities along nationwide clusters Hoffman Kiln Not Available Available Not being Popular mode operated within of operation in the cluster Southern Indian Lack of Consultants and Vendors Process Change Available from straight line to Being used in 3 Zigzag Firing units in within the Cluster Manufacture of Available Perforated Bricks Currently operated in One unit within the Available Operated in varying capacities
Readily Available
Available Vendors available for technology Implementat ion Available Widely operated in brick manufacturi ng units worldwide Available Operated in brick manufacturi ng units in South East Asia and Oceania Available Popular mode of manufacture Page 46
Manual for Energy Conservation Measures in Brick Cluster, Varanasi S. No. Availability in Local Market cluster Availability in National Market multiple units in Brick Cluster providers who can Availability in International Market of bricks
Technology
3.4.3 Availability of local service abovementioned proposals
take
up
The following Local Service Providers were identified to implement the abovementioned proposals to reduce the energy consumption in the Varanasi brick cluster A. Technical Local Service Providers I. Bhagwat Technologies and Energy Conservation Pvt. Ltd Bhagwat Technologies and Energy Conservation is a leader in providing expert consultancy services in implementation of Vertical Shaft Brick kilns and technological step upgrades in the brick industry nationwide. They have a proven record of carrying out pollution control, and Energy Efficiency interventions in brick kilns. Company profile Bhagwat Technologies and Energy Conservation Private Limited (BTECON) is incorporated in 2002 as a Private Limited Company with registered and principal offices in Delhi. BTECONs aim it to promote new and innovative ideas in the field of renewable energy, energy conservation and to educate the general public and other stakeholders about the economic benefits of using energy efficient products and renewable energy systems. Awareness generation is an important prerequisite, however, much more needs to be also done at implementation level. Our motto is thus not only to spread the ideas but also to contribute in the practical implementation of the ideas and help in solving the problems faced in technical and commercial development of energy conservation devices and technologies. BTECON is an ISO- 9001: 2000 company working with following objectives and areas of operation: Energy conservation and management through energy planning in industrial, commercial, institutional, agricultural and domestic sectors. Page 47

Energy audit for load management. Technology/Industry/Market analysis of Renewable Energy Products and systems. Consultancy in designing, developing and implementing energy efficient measures. Adoption and promotion of alternative/ renewable energy sources. Organizing seminars and conservation campaigning for energy and resource thrift. Conducting training program on energy management for educating and motivating the end users. Demand Side Management for energy economics and environment improvements through retro-fittings and re-engineering. PDD for CDM project
Projects completed Training cum Orientation Programme on Energy and Environment Performance Monitoring of Brick Kilns, Semi-Mechanization and Zigzag Firing conducted at Varanasi in association with Green tech Knowledge Solutions Varanasi( 2009) Energy audit of Jindal Mechno Bricks , Badali, Jhajhar, Haryana (2008) Training program for brick kiln operator in eastern UP in association with TERI.(2007) Technical feasibility study of Thermact-BR and energy audit of brick Kiln in Gaziabad (2007) Baseline development for CDM implementation in SW pipe (Priya klay ) factory. (2006) Energy efficiency Improvements in the Indian Brick Industry (NCR and Eastern UP Cluster) prepared for TERI/ MOEF. (2005) Energy audit and study of emission in production of Fal-G brick and burnt brick production for CER computation Sponsored by Neptune Clean Technology, Mehsana Gujarat. (2005) R&D on suitability of mixing fly ash with clay available in Haryana State for brick making in association of Punjab State council for Science and Technology (2004). Energy and Environment Audit of Priya Brick Co, Raghavpur, West Bengal (2003) Priya Klay Products, Electrical and Thermal Energy Audit (2002) and energy conservation study.
Page 48
Manual for Energy Conservation Measures in Brick Cluster, Varanasi Contact Details: Anil Kumar Chief Operating Officer Bhagwat Technologies & Energy Conservation Pvt. Ltd. 5,Millenium Business Centre, 34 Corner Market Malviya Nagar, New Delhi-110017 Web: www.btecon.com E-mail : ak@btecon.com Tel: 26680036, 64513006 Mobile: 9891584175
II.
Neptune Engineering Neptune Engineering provides technical expertise and expert support in all aspects of Brick Manufacturing improvements in manufacturing processes. They offer retrofit and complete upheaval solutions in Energy Efficiency and Product management incorporating existing international technologies to the local industries. Company Overview Neptune Industries is a leading engineering and manufacturing company delivering Engineering Project Solutions to various industry segments. Neptune offers the world class designs, concepts & technologies with indigenous & economical proven solutions to provide client satisfaction through best quality service and timely delivery. Neptunes engineering and manufacturing solutions are known for performance, innovative and economical production technologies and high reliability. Neptune offers engineering project solutions along with Technical Services to diverse fields as: Ceramics Industry Fly Ash Technology Waste Recycling Agro-waste Panel Board Solar base Equipment Solutions Contract Manufacturing Services
Page 49
Manual for Energy Conservation Measures in Brick Cluster, Varanasi B. Managerial Local Service Providers I. Int Nirmata Parishad (Varanasi brick association) Int Nirmata Parishad is the local association of Brick Manufacturers in Varanasi with National associations and partnerships. Previously the Association has been a driving force to implement Energy Efficiency in the brick manufacturing industry with emphasis on socioenvironmental benefits. Organization Profile Int Nirmata Parishad (INP) is an association of brick makers of Varanasi district having its registered office at F-2(1), Ananta Colony, Nadesar, Varanasi. This association is formed by owner of brick kilns in Varanasi and has around 75 members. The association helps in facilitating its members with distribution of subsidized coal supplied under quota by the Government. The association act as a bridge between brick kiln owners and the government. INP played a major role in getting the Samadhan Yojana implemented which is a sale tax scheme only for brick kilns where the brick kiln owners pay a fixed amount of sales tax depending upon the capacity of their kilns. They also facilitate any Govt. / Non Govt. agency working for brick sector development. In past they assisted TERI in implementation of Vertical Shaft Brick Kiln (VSBK) in Varanasi and organized Training/Workshops for owners of kilns. Int Nirmata Parishad also organizes technical events and seminar for energy efficiency in brick kilns sector. The key members of the Int Narmata Parishad are: A. Shri Kamla Kant Pandey President B. Shri Om Prakash Badlani Vice President C. Shri Hira Lal Yadav Treasurer D. Shri Shiv Prakash Singh General Secretary E. Shri Hiranand Lacmani Secretary
II.
Prayag Bricks (Mr. O. P. Badlani) Prayag Bricks promoted by Shri O. P. Badlani is headquartered at S4/32, A-1, Orderly Bazar, Varanasi 221002, Uttar Pradesh. It is a 30 year old organization and has established it as one of Uttar Pradeshs leading manufacturers of high quality bricks (hand made & machine made) & decorative tiles. Prayag Bricks is the only company in the Page 50
Manual for Energy Conservation Measures in Brick Cluster, Varanasi Varanasi district which is producing perforated bricks and decorative tiles. Its products stand apart from rest in the states on account of different factors which are: Latest brick kiln technologies Exclusive firing techniques & practices. Quality maintenance & upgradation Latest manufacturing machinery Assurance of best services Prayag Bricks makes bricks with trade marks Prayag & Puja, which are now proven names in quality bricks. According to the market requirements and trends, Prayag Bricks has changed its manufacturing strategies & design to suit the needs of time as well as customers Prayag Bricks manufactures latest and wide range of decorative roofing and wall tiles of high quality. These tiles prove true to the expectation of the customers. Prayag Bricks makes use of best quality raw material and latest manufacturing technology. Prayag Bricks also manufactures extruded wire cut Sewer Bricks (IS Code: 4885) as per the Indian Standards specifications laid down by the government of India
Page 51
Manual for Energy Conservation Measures in Brick Cluster Cluster, Varanasi
3.5 Identification of technologies/equipments for DPR preparation 3.5.1 Justification (e.g. potential, replicability, etc. in the cluster) for technologies/equipments identified for DPR preparation : Justification and Replicability of identified Measures Table 28: S.No . 1 2 3 4 5 6 Technology Availability Potential for Cost of Energy Implementation Savings Medium Low Medium - Low - High Medium High - Medium Low Low - Medium Medium - High - High Medium - High Environmental Benefits Medium Medium Low- Medium High Medium - High High Implementati on Time Low Low Low Medium - High Medium - High Medium - High Replicability
Process Change from straight High line to Zigzag Firing Best Practices Charging/ Feeding Induced Draft Fan in Coal High Medium High Medium Low Low
Medium High Medium Low Low Low - Medium
Vertical Shaft Brick Kiln ** Hoffman Kiln Manufacture Bricks of
Perforated Low Medium
**
Previously Implemented in Varanasi Cluster, operations shut down after 2 years of running in loss due to brick not having cha characteristic metallic sound and red color typical to bricks in the cluster
Page 52
Manual For Energy Conservation Measures in Brick Cluster, Varanasi 4. Environmental Benefits 4.1 Reduction in waste generation (if applicable) During the initial firing at the start of the season, there is usually 30% wastage in manufactured brick product. In the subsequent firing rounds of the kiln this wastage in 5% till the end of the season. This wasted brick products is largely made up of broken or melted bricks which are not fit for market sale. This broken brick waste can be crushed into fine particles and used for concrete construction by means of a Crusher. Additional waste from Bull trench kiln operation includes fly ash from incomplete combustion. This is recycled in the operation of Bull Trench Kilns by spreading and covering the top layer of the stacking arrangement in the trench for insulation purposes. There is also the issue of degradation of land by digging up of top soil making it unsuitable for agriculture after the kiln operations cease. This is a very a very important concern in India where poverty is widespread. Adoption of abovementioned proposals would reduce the amount of fly ash formed due to incomplete combustion and significant reduction in wasted fired bricks. Additional advantages are reduction in land degradation by reduction in un-usable brick wastage. 4.2 Reduction in GHG emission such as CO2, NOx, etc There are significant reductions to be achieved in Green House Gas emission by adoption of the above proposals. Reduction in coal consumption translates into GHG reductions roughly to the order of 1.4 tonnes of GHG per ton of coal. The other benefits include, decrease in particulate pollution levels in kiln and surrounding area.
Page 53
Manual For Energy Conservation Measures in Brick Cluster, Varanasi
5.
Conclusion
5.1 Summary of proposals for energy saving Table 29: : Summary of Proposals for Energy Savings
S. No. Proposal for Energy Savings Technology Gap Assessment Cost of Implement ation including Running Costs Costs(Clust er wide) (INR) 17,10 10,93,30 0 Techno - Economics Cluster Cluster Annual Energy Annual Savings Monetary (Thermal Savings Tera joules) (INR) Barriers in Implementation Simple Payback period (Years) Shortlist for DPR
Process Change from straight line to Zigzag Firing
Manually operated process can be upgraded to automated/ mechanized process
729.563
15,91,60,500
1.074
1. Change in Stacking arrangement Yes may not sit well with managers and labor used to traditional stacking methodology. 2. Bricks might remain too hot for handling at unloading point, due to fast firing of multiple chambers 3. Existing Brick kilns might have to be modified to accommodate a Zigzag firing operation. 4. Lack of Consultants and technical support for implementation 5. Lack of Control Measures from
Page 54
Best Practices in Coal Charging/ Feeding
Manually 2,37,30 30,000 Operated, can be upgraded to Automated/ Mechanized Process Induced Draft N/A 3,84,20,000 Fan
275.612
6,01,27,300
0.394
243.187
5,30,53,500
1.83
Vertical Shaft Capacity Brick Kiln ** Limitations
34,31 31,35,80 0
664.713
14,50,12,900
2.539
Managers 1. Savings may vary kiln to kiln. Yes 2. Lack of training at coal feeder / Manager level 3. Lack of awareness at Owner level 4. Lack of Training Facilities and Experts 1. Only suitable for kilns with low Yes draft 2. May cause increase in Air leakages 3. Chimney modifications may be required 1. Due to Fast Firing and Cooling, No bricks do not produce the signature metallic sound or red color, typical of the bricks manufactured in this area. This may lead to difficulties in marketing and sales 2. VSBK was previously adopted by one entrepreneur. The manufacturing unit subsequently shut down due to the above reason. 3. Due to fast firing and cooling, strength of fired bricks is typically
Page 55
lower than those fired from BTKs 5 Hoffman Kiln Mechanization 1,42,38 38,00,0 in Clay 00 Preparation, and Coal Feeding. 648.500 14,14,76,000 18.40 1. Lack of supporting regulation, fiscal incentives and standards to encourage energy efficient practices and technology 2. Lack of skilled manpower 3. Cluster Industry absorption capacity to new technology is low 4. Financial Barriers due to very high investment costs cost 5. Lack of Consultants and Agencies within the cluster Yes
Manufacture of Up-gradation to 97,29 29,30,00 Perforated Automated 0 Bricks Process Line
583.650
12,73,28,400
11.439
1. Under developed market for Yes perforated bricks 2. Present Technologies favor production of solid bricks 3. Lack of technical support for adoption of perforated bricks
Note: Proposals 1 & 2, and 4 & 5 are mutually exclusive. If one of them is implemented, the other cannot be implemented in the th same unit. 5.2 Summary of level of awareness on energy efficiency and energy efficient products in the cluster The level of awareness on Energy Efficiency and Energy Efficient products is very low within this cluster. Brick kiln owners have a traditional outlook in this industry, and have a short term view of operations. There is also a lack of technical support and knowledge base for the unit owners to broaden and keep them abreast of National and International technologies/ improvements in the Bri Brick industry.
Page 56
Page 57
Pictorial Acknowledgements Image 1: Varanasi District Overview: Image accessed from http://www.topnews.in/law/varanasi-s-pandit-channulal-mishra-elated-receivingpadma-bhushan-award-25011 on 31/05/10 Image 11: VSBK: Image Accessed from http://www.cosmile.org/images/inside/brick4.jpg Image 12: VSBK Schematic: Image Accessed from http://nzdl.sadl.uleth.ca/cgibin/library?e=d-00000-00---off-0hdl--00-0----0-10-0---0---0direct-10---4-------0-1l-11-en-50---20-about---00-0-1-00-0-0-11-1-0utfZz-800&a=d&c=hdl&cl=CL3.3&d=HASH01cf3c2f552f4f1812ac4ce9.2.4 Image 13: Side view of Hoffman Kiln: Image Accessed from http://www.lowtechmagazine.com/2009/10/hoffmannkilns-brick-and-tile-production.html Image 14: Layout of Hoffman kiln; Image accessed from http://www.cd3wd.com/cd3wd_40/GATE_DL/BUILDING/HK/EN/HK_FILES/FIGU RE2B.GIF
Annexure1: Detailed technology/equipment assessment report including the design technical specifications, in the format provided by BEE.

Kiln Summary Report Heat balance MJ Sensible heat in Brick Energy in water vapor leaving the system Heat required for chemical reactions Dry flue gas loss Unaccounted (mainly structure + surface) Total heat input Total heat input Kiln Efficiency Coal CV Moisture in GB Specific Energy consumption (a)CALCULATION OF SENSIBLE HEAT LOSS IN FIRED BRICKS WITHDRAWN FROM THE KILN: Total weight of fired Bricks (Kg) 348 2630 6684 4205 17854.4 31722 31721.6 29.4 6012 6 1.525547 MJ % 25.2 % MJ/Brick % 1.1 8.3 21.1 13.3 56.3 100
20794
Specific heat of clay bricks 0.000836 Average temperature of the fired bricks when withdrawn 49.0 oC Average ambient temperature 29 oC total sensible heat loss in unloaded pipesin 347.7 MJ MJ/dayi.e(Mfp*Cp,fp*(Tfp-Ta)) % contribution 1.1 % (b)CALCULATION OF HEAT IN VAPOUR LEAVING THE SYSTEM: (I)Energy in water vapour due to mechanical moisture in green bricks: energy leaving with water vapour due to mechanical moisture=Weight of moisture* Cp,water *(100Tload)*4.18KJ/Kg]+[weight of moisture*Lvap ]+[Weight of moisture * Cp,steam(Tfluegas100)*4.18KJ/Kg] weight of mechanical moisture removed per day from the pipes :(moisture %present *weight of green pipes loaded in the kiln(Kg/day) Average % of moisture present 4 loss on ignition(%) 3.37 Weight of green Brick (Kg) 20794 kg weight of mechanical moisture removed per day from the pipes 831.74 Kg Average temperature of brick when loaded(Tload)(oC) 29 Average temperature of flue gas at the exhaust(oC) 197.0 Cp,water(1kcal/kg) 1 Lvap(latent heat of vap)KJ/Kg 2257 Cp,steam(Kcal/Kg) 1.5 Energy leaving with water vapour due to mechanical moisture(kJ/day) 2629949.6 kJ Energy leaving with water vapour due to mechanical moisturein MJ/day 2629.9496 MJ % contribution 8.2907196 % Heat required for reaction % of pure clay (^)=(Loss on ignition*100)/13.96 24.14 Specific heat of clay(Kcal/Kg) 0.502 specific heat of silica(Kcal/Kg) 0.264 Specific heat of green brick=[^ *0.502] +[(1-^)* 0.264] 0.321
kg MJ/kgoC

Maximim temperature(Tmax)(oC) Ambient temperature(Tamb)(oC) Cp of fired Bricks(kcal/Kg) Heat requited for reaction in MJ % contribution Flue gas lossess Approximate method (for O2%) O2% measured Exess air Amount of fuel burned Stociometric air equred Amount of air flow in the kiln Average exit flue gas temperature Specific heat of flue gas Dry flue gas loss % contribution 1020 29 0.2 6684.189 21.071 0.95 *O2/(21-O2) 16.3 329.47 % 1260 6 Kg/kg of coal 24907.787 Kg 197.0 C 1.005 kJ/kg-K 4205.43 MJ/day 13.26 %
Annexure 2: Details of technologies/services providers for the cluster
Details of Technology/ Service providers provided in Section 3.4.3 of Cluster Manual.
Annexure3: Quotations or techno-commercial service/technology providers (Sample)
bids
from

To, Mr. Sanjay Rawat Assistant Manager Energy Division Feedback Ventures (Pvt.) Ltd. Gurgaon. Date:- 27-05-2010
Please find the Quotation for conversion of brick kiln from straight firing line to ZigZag Firing.
Quotation
S.NO.
1. 2. a) b) c) d) e) 3.
Particulars
Cost of modification in Civil structure Cost of Equipments Feed hole covers 100 nos. @Rs. 550/Insulated Shunt 2 nos. @ Rs. 25000/Temperature gauge for Shunt 2 nos. @ Rs. 1500/Thermocouple 1 set (includes 1 small and 1 big) Temperature Indicator- 1 no. @3000/Cost of Consultancy and training to workers and supervisors Rupees Seven lack twenty one thousand only/only/-
Cost
Rs. 4.5 lack (Approx.) Rs. 55000/- (Approx.) Rs. 50000/- (Approx.) Rs. 3000/- (Approx.) Rs. 10000/- (Approx.) Rs. 3000/- (Approx.)
Rs. 150000/-
Total
Rs. 721000/721000/-
Note:1) Cost of modification in Civil structure may be vary , its depend on kiln condition. 2) If modification required in chimney thats cost will be extra.
Thanking you, Yours truly
O.P. Badlani Prayag Bricks S 4/32, A-1 Orderly Bazar Varanasi. Mob:- +91-993511095
Bureau of Energy Efficiency (BEE)

(Ministry of Power, Government of India) 4th Floor, Sewa Bhawan, R. K. Puram, New Delhi 110066 Ph.: +91 11 26179699 (5 Lines), Fax: +91 11 26178352 Websites: www.bee-india.nic.in, www.energymanagertraining.com

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What are the objectives and expected outcomes of the project?

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What are the main energy sources used in the brick cluster?

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MANUAL ON ENERGY CONSERVATION MEASURES IN BRICK CLUSTER VARANASI

Bureau of Energy Efficiency (BEE)

Feedback Ventures Pvt. Ltd., Gurgaon

Manual on Energy Conservation Measures in Brick Cluster, Varanasi

Manual on Energy Conservation Measures in Brick Cluster, Varanasi

Manual on Energy Conservation Measures in Brick Cluster, Varanasi LIST OF FIGURES

Manual on Energy Conservation Measures in Brick Cluster, Varanasi

Manual on Energy Conservation Measures in Brick Cluster, Varanasi

Types of fuel Specific Energy Consumption Manufactured Products

Manual for energy Conservation Measures in Brick Cluster, Varanasi

1.3 Project Duration

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

No. and name of Development Blocks

Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi

Cluster Products Manufactured

Annual Brick Production

Cost (Rs/ tonne)

Rate (Rs/ Ton)

Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi

60 50 40 30 20 10 0 Upto 15 Tonnes 15-18 Tonnes 18-21 Tonnes Above 21 Tonnes

Coal Consumption / lac Bricks

Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Firing / Combustion Zone

Pre heating zone

Pre Heating Zone Combustion Zone Cooling Zone

Manual for Energy nergy Conservation Measures in Brick Cluster, Varanasi

Image 5: : Combustion Zone with lines covered by metallic lids

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Identification of units for preliminary and detailed study

Information workshop for brick users

Technology Gap Assessment

Proposals for Energy Conservation

Site Visits to Identified units

Collection of General information about kilns

Measurement of kiln and fixed assest dimensions

Overview of Energy usage in manufacturing process

Documentation of raw materials used

Documentation and Measurement of manufactured product

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Collection of General information about kilns

Computation of Energy Losses

Documentation and Measurement of Fired Bricks

Measurement of kiln and fixed assest dimensions

Analysis of Combustion gases

Documentation of raw materials used

Weighed Determination of fuel consumption

Detailed documentation of Coal Feeding operation

Overview of Associated Processes

Manual for Energy Conservation Measures in Brick Cluster, Varanasi

Figure 12: Process Observations

Circular Brick Kilns

3.3.2 Process up-gradation

Table 14: Best Practices Cost of Implementation S.no 1. 2.