Introduction of

Vertical Shaft Brick Kiln (VSBK) in Bangladesh

Project background As per earlier studies carried out, The World Bank identified the Vertical Shaft Brick Kiln (VSBK) to be the most promising energy efficient clean technology in the present context of Bangladesh. To promote cleaner technologies and practices in the brick sector, which is recognized to contribute substantively to the urban air pollution problem in Bangladesh, it was decided to introduce VSBK as a demonstration package to Bangladesh entrepreneurs to create awareness for alternate means of reducing air pollution. The ESMAP grant supported the project with the objective to catalyze the adoption of sustainable environmental initiatives through energy efficiency measures in brick making industry with a focus on reducing air pollution, through pilot initiatives. Objectives The objective of the assignment was to develop a complete package including a demonstration kiln for the introduction and promotion of VSBK in Bangladesh. The assignment also focused on the appropriateness and operability of VSBK in Bangladesh context and also to show that the technology will result in reduced air emissions & energy use without compromising on the quality and production of bricks manufactured. Achievements Earlier studies and exposure visit of Brick Association representatives (BBMOA) and GoB officials to India, identified VSBK as one of the various options available for greening the brick industry in Bangladesh in terms of improving the energy efficiency and drastically reducing the environmental emissions. Skeptic views were expressed since instances of failure was evident in Bangladesh through private initiatives. Thus Operational Success was expressed to be a major milestone towards investing in the same. The project demonstrated the suitability and appropriateness of the Vertical Shaft Brick Kiln technology in Bangladesh. Technical aspects From the technical viewpoint there are no issues for designing and construction of a VSBK in Bangladesh. All the materials required for construction, including high quality refractory bricks are locally available. Expert masons are also available to do a quality construction. However during the initial couple of years, the design and construction of the VSBK needs to be under expert supervision. This is required for masons and engineers to absorb and practice the critical steps required for the VSBK. The project demonstrated that some of the equipments can be manufactured in Bangladesh. Workshops have been identified for the same. The local skills available are sufficient to develop the same with technical back up support during the initial stages. However specialized equipment required needs to be imported from neighboring countries. Soil quality is extremely suitable for producing good quality bricks in a VSBK firing system. An added advantage in Bangladesh is the mechanized processing of soil which is also most appropriate to introduce the practice of internal fuel mixing for producing green bricks. It has been

seen that a maximum of 3% by weight of internal fuel can be mixed without compromising on the brick quality. More than 3% internal fuel is not required from the total energy consumption issue. Moreover any greater amount will create operational issues especially during the summer months in a VSBK. The most critical factor for the acceptance of a VSBK is the demand of the high quality of bricks in the market. More than often VSBK produced bricks are and will be notionally compared with those being produced through FCK and Hoffmann. The bricks produced from a VSBK are of comparable if not better quality in technical terms of compressive strength and water absorption. They also fulfill all the required qualities as specified in the Bangladesh Standards (BDS 208:2002). The only negative issue was the visual colour of the bricks which is commonly used by consumers as a yard stick for determining quality. Although the colour of the VSBK produced bricks could not match with the best of the FCK or Hoffmann, they were comparable to the 2nd. class being produced and saleable. Thus it is recommended to devise and work upon an extensive marketing awareness campaign for promotion of VSBK produced bricks. A most appropriate starting point would be promotion of Eco Bricks through Government systems. Energy and environmental aspects The pilot demonstration has shown that VSBK can be operated throughout the year subject to availability of green brick stock and absence of any water logging in and around the kiln site. During the rainy season with average moisture content of 7-8% in the green bricks the Specific Energy Consumption was around 1.0 MJ/kg of fired bricks giving a total fuel consumption (external and internal) of around 13 tonnes per lakh of fired bricks. With more dried bricks, this is expected to be around 0.8 MJ/kg with an average fuel consumption of between 8-10 tonnes per lakh of fired bricks. Thus compared to the existing coal fired FCK there is a total energy savings of around 40% through the VSBK firing technology. The most important aspect of VSBK is that it can only be operated with coal or a combination of dense biomass briquettes. Under no circumstances woody biomass can be used in VSBK. Thus adoption of VSBK will automatically arrest the deforestation caused by rampant use of wood in FCK firing. No environmental emissions were made to substantiate on the reduced environmental emissions. However no black smoke was visible during VSBK operation indicating the complete combustion of coal. It is estimated (from previous measurements in other countries), that stack and ambient emissions will be reduced by almost 70% compared to the operating FCK in the region. Financial aspects The economic and financial analysis of the VSBK technology shows that it can be an alternate option to FCK. However VSBK will have its own niche market amongst the medium to small brick producers looking at the per-shaft capacity. The attractiveness of the VSBK will be more to new entrants in the brick business since reluctance is expected amongst existing FCK owners until and unless forced by Government policies. Under the observations in this project it is expected that the probability of success and acceptance of a VSBK will be much higher in divisional cities and small towns. High volume brick technologies e.g. Hoffmann, HHK will continue to proliferate in metro cities of Dhaka and Chittagong. If the VSBK technology becomes popular in areas other than Dhaka, then it is expected to open up new avenues of opportunity. Since the land required and capital investment is less compared to FCK, financial institutions are expected to provide easy loans also. However this requires extensive support and policy changes.

Impact The pilot demonstration of the VSBK technology has created a substantial interest amongst all the major stakeholders in the brick industry of Bangladesh. The Ministry of Environment and Forests, GoB has taken a keen interest in the VSBK technology with options of suggesting VSBK as an alternative to replacing the existing FCK. Results from the pilot demonstration initiatives have shown an enormous potential of replication. Apart from reduced emissions, an enhanced profitability of around 20% from reduced coal and labour savings can also be achieved. Entrepreneurs will be interested in adopting the same due to enhanced profits and compliance with environmental standards. Regulatory agencies are interested in enforcing the same since environmental compliance will be maintained with. In Bangladesh there are around 4000 authorized FCK. The annual coal consumption is around 2.2 million tonnes. If around 50% of the existing units adopt improved technologies, then it would result in: Saving of 480,000 tons of coal annually Saving of 1,500,000 tons of GHG emissions annually Saving of 48 million USD foreign reserves annually Savings of around 400,000 full grown trees annually This is expected to result in arrestation of large scale deforestation. Wood also consists of nearly 50% carbon. If burnt completely, one kg of wood releases around 1.8 kg CO2, the main greenhouse gas. Each tree cut down for fuel reduces the CO2 sink; the environments capacity to absorb this gas from the air. Thus savings in wood is expected to contribute further towards reducing GHG emissions Challenges The Government has banned the use of firewood in brick kilns. Similar policies also exists restricting use of soil and high sulphur coal. The environment conservation rules for 1997 makes it compulsory for all new and operating brick kilns to get annual clearance from MoEF. Tougher laws are expected in the near future. However the enforcement of these laws remains almost non existent and effectiveness is grounded. In these conditions VSBK is expected to solve the enforcement issues due to its inherent technology. New approaches to operational practices requires a paradigm shift from the conventional practices and the mentality amongst entrepreneurs of conducting regular business thereby integrating the whole process innovations with new technology process and re-engineering of existing methods. Change in mentality, technology innovations and trained human resources are the most valuable asset of improving the environment and benefiting the society in a business like manner. However the advantage of all this can only happen if the brick industry is ready to change its mind set and working habit. All this requires extensive awareness, widespread demonstration; intensive training and long term technology support; making both workers and entrepreneurs learn, practice and adopt improved technology options. The above is the key to the success of the pilot initiatives and can only be achieved in time. In the absence of learning, the work force simply repeats the old practices and therefore, continuing learning and commitment to re-learning are crucial for overall improvement in the brick sector especially with regards to energy conservation, minimizing pollution and better quality of brick. Thus it recommended that the VSBK be seen as a compliment to improved FCK technology and not as a competitor with more attractive business opportunities and enhanced environmental benefits.