1. International Conference on TIM, 2012, Nepal Viable Charring Technology to Meet the Industrial Demand of Brick Kilns Presented By: Sushim Man Amatya Venue: Technology and Innovation Management Conference Date: Oct 12, 2012 1

2. International Conference on TIM, 2012, Nepal Overview of Brick Industries 436 brick kilns registered with total production capacity of 872 million, Census of manufacturing establishments, Nepal 2006-2007 About 700 brick kilns in Nepal (Source: All Nepal Brick Kiln Entrepreneurs Association, 2011) Estimated total annual production capacity of about 1,423 million bricks Coal is the major fuel. 2

3. International Conference on TIM, 2012, Nepal Brick Kiln Technology Composition S. No.Type of KilnNo. of Kilns%Remarks 1Clamp426.0 2MCBTK39957.0 3FCBTK23333.0 4VSBK264.0

4. International Conference on TIM, 2012, Nepal Major Brick Kiln Technologies Clamp VSBK Fixed Chimney BTK (FCBTK) Moving Chimney BTK (MCBTK) 4

5. International Conference on TIM, 2012, Nepal 80,000 tones of coal is consumed annually by 120 brick kilns within Kathmandu valley out of 700 in Nepal. 1.12 billion Rupees are spent in India. Yet the quality and supply of coal is unreliable. Emission of 200,000 tones CO 2 annually by brick kilns in the valley. (1kg. Coal = 2.465 kg. CO 2 ) Case of Brick Industries in Kathmandu Valley 5

6. International Conference on TIM, 2012, Nepal Kathmandu Valley & FCBTKs Total No of Kilns:108 Source: 103 FCBTKs - All Nepal Brick Kiln Entrepreneurs Association, 2011. 3 VSBK units and 2 Hoffman Kilns. No of FCBTKs:103 Average brick production per year:720 million Average brick production per kiln is estimated to be 7 million per kiln Annual coal consumption in FCBTKs(Tons):68,500 Average coal consumption per brick in FCBTK in Kathmandu Valley is estimated to be 95gm per brick Annual expenditure in coal (NRs):1.23 billion Price of coal – Nrs 21,000 per ton, March 2012, Brick Entrepreneurs Annual CO2 emission (Tons):169,000 2.465 Kg of CO2 is emitted per Kg of coal fired, Project Design Document for VSBK Annual emission of dust particles (Tons):1800 2.51 Kg of SPM per 1000 fired bricks in FCBTKs, Stack and Energy Monitoring of Brick Kilns in Kathmandu Valley, IEM 2005 6

7. International Conference on TIM, 2012, Nepal Energy Coal is major fuel used in the brick production. Other non coal fuel such as agricultural residue, firewood, rice husk, saw dust etc Coal consumption per lakh bricks in the FCBTK is 15.45 tons and MCBTK 14.18 tons (CEN Baseline report, 2009). 7

8. International Conference on TIM, 2012, Nepal In 2008/09, Nepal imported about 293,000 tons of coal from India. KTM alone consumed about 40% of imported coal. It is mainly used in the industrial sector mainly in the brick kilns and cement factory Energy Dependency on imported coal Rising coal price is 200% increment in 6 years without considering inflation, (NRs 7.3 in 2006 and NRS 22 in 2012 per kg of coal ). 8

9. International Conference on TIM, 2012, Nepal In-depth into the issues Environmental issues Prime source of air pollution 2 nd largest air polluter in the valley 2.5kg dust emission per 1000 fired bricks (Average dry wt of bricks = 2.2 Kg) Serious occupational health hazards Emission of RPM-PM higher than prescribed limit, in some cases 7 times more than limit 1,600 die of air pollution every year in Kathmandu Valley, People’s Daily Online, Feb 2008 9

10. International Conference on TIM, 2012, Nepal Energy consumption in Brick

11. International Conference on TIM, 2012, Nepal In-depth into the issues Climate change issues One of the prime source of CO 2 and Black Carbon emission Burning a Kg of coal emits about 2.5 Kg CO 2 – major GHG Brick kilns have also been identified as one of the prime cause for BC emission – primary cause of melting Himalayan glaciers (ICCT 2009) 11

12. International Conference on TIM, 2012, Nepal More than 15300 CFUGs, 40% of total households of Nepal, own and manage community forests in 1,22,000 hectare of land. The potentials of economic return from the community forests are under-utilized mainly due to lack of knowledge, efficient technology and market linkage for forest-based products. The current demand for char is low and the income generated does not even cover the minimum wage or opportunity cost. 12

13. International Conference on TIM, 2012, Nepal Our experiences with internal fuel in VSBK 37 % less Environmental performance 18% less The results are based on the applied research carried out in a VSBK plant The research was carried out by firing 75,000 bricks with three different fuel composition in a VSBK shaft. Results are derived by scientific monitoring of stack emission and energy performance. 13

14. International Conference on TIM, 2012, Nepal Our experience with internal fuel in VSBK 16% less energy consumption Energy performance & brick quality 22% improvement in strength 14

15. International Conference on TIM, 2012, Nepal Potentials 10% improvement in energy efficiency can result into Reduction of 6900 tons of coal Annual saving of NRs 125 million in coal cost Reduction of 17000 tons of CO2 20% improvement in environmental performance can result into Reduction of 275 tons of mass emission load Improvements in occupational health and safety status Reduction in black carbon emission 15

16. International Conference on TIM, 2012, Nepal Potentials/Scope Kathmandu Valley & FCBTKs 15% savings25% savings Annual average brick production720 million Annual coal consumption in FCBTK (Tons) 68,50010,274 tons reductions 17,124 tons reduction Annual expenditure in coal (NRs)1.23 billion185 million saving 308 million saving Annual CO 2 emission (Tons)169,00025,326 tons saving 42,210 tons saving Annual emission of dust particles (Tons) 1800271 tons452 tons Improvements in occupational health and safety status Reduction in black carbon emission Viable for small-scale CDM 16

17. International Conference on TIM, 2012, Nepal Missing Links According to action research conducted, biomass based carbonized fuel (char) generated from non timber woody plants and forest waste can be used for brick firing instead of coal in brick industries 17

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19. International Conference on TIM, 2012, Nepal Field & laboratory works 19

20. International Conference on TIM, 2012, Nepal Summary of CV tests Average Top layer CV (Pit System)4096.665 kcal/kg 17.12406MJ/kg Average Middle layer CV (Pit System)6332.464 kcal/kg 26.4697MJ/kg Average Bottom layer CV (Pit System)5518.343 kcal/kg 23.06667MJ/kg Average Random CV5453.458kcal/kg22.79546MJ/kg 20

21. International Conference on TIM, 2012, Nepal Collection of Char and CV test (Coal and Char) (About 5 tons of char has been collected) Green Brick Making with Internal Fuel Baseline study to calculate the Specific Energy Consumption (SEC) SEC = 0.48 MJ/ kg of fired brick Calculation of char quantity in terms of energy value 40% coal substitution = 0.011 kg/brick 50% coal substitution = 0.014 kg/brick 60% coal substitution = 0.017 kg/brick 70% coal substitution = 0.020 kg/brick Green brick making with internal fuel as Char mixing Soil ageing Green Brick Making (on process)` 21

22. International Conference on TIM, 2012, Nepal Charring Retorts: Portable Type 22

23. International Conference on TIM, 2012, Nepal Fixed Type Charring Retort 23 Fig: Schematics of the fixed type charring retort

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29. International Conference on TIM, 2012, Nepal 29 Construction Phase of the Retort

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32. International Conference on TIM, 2012, Nepal Other Potentials Establishment of market links for industrial demand Efficiency of char production technology increased by at least 20% Increment of income from the increased efficiency is at least 40% Improved occupational health safety for char producers Increased income opportunity for disadvantaged members of CFUGs Potentials using char in other SMEs 32

33. International Conference on TIM, 2012, Nepal Thank You!! 33