Workshop on

Energy Conservation Options in Brick Kilns31 May 2016, Lucknow

1

Mr O P BadlaniPrayag Clay Products Pvt Ltd, Varanasi

1937

( cladding)

( )

1937

1978

1999

2001

2003

2006 -08

2009-10

, -

2010-11

2013

Soft mud moulding machine

Dust pressing machine

Extruder Plant

Gasifier for power generation

Brick Drying shade

Experience with Natural Draught Zigzag Kiln

Modified brick setting and kiln design tooperate zigzag firing with the lowdraught created naturally by thechimney (without any requirement of afan).

Successfully converted my all threehigh draught zigzag kilns to naturaldraught zigzag kiln (2006-08).

Advantages of Natural Draught Zigzag Kiln Technology over FCBTK

As monitored by independent agencies

Energy Consumption

Percentage of Class-I bricks

NDZZ Nikasi, Varanasi

NDZZ Nikasi, Varanasi

SPM emisssion

Reduction in Air Pollution

Zigzag Natural Draught FCBTK

Advantages of Natural Draught Zigzag Kiln Technology over FCBTK

FCBTK NDZZAnnual Production 40 Lakh Bricks 40 Lakh BricksCoal Consumption per Lakh Bricks 16 ton 12 tonPercentage of 1st Class Bricks ~ 60% > 80%

Annual saving in coal consumption 160 tonAdditional 1st Class bricks per year 8 lakhCost of retrofitting existing FCBTK to natural draught zigzag kiln 10-20 Lakh Rs.

Cost of retrofitting can be earned back within one year because of savings in fuel cost and increase in revenue due to additional 1st class bricks

Key Differences in Operation of FCBTK & Natural Draught Zigzag Kiln

20

:

:

Zigzag Air Flow Straight Air flow

~ 36 ft ~ 3-6 ft

6

-

Single man continuous feeding smaller spoon

200 400 g 1 1.5 kg

1.5 kg x 8 spoon/min/person x 2 person = 24 kg/ min

0.4 kg x 8 spoon/min = 3.2 kg/ min

Double man feeding 6 8 minutes of feeding

followed by 20-30 minutes of rest

bigger spoon

Temperature Measurement & Control on Operation of Kiln

Benefits of zigzag firing/air flow

Zigzag movement of air Increases the air path and

turbulence Improves heat exchange

between bricks and air because of high turbulence.

Results in complete combustion of fuel because of better air-fuel mixing and increase in the retention time for volatile materials in the firing zone

Helps in uniform temperature across the kiln cross section

Efforts towards dissemination of Natural Draught Zigzag Kiln Technology

Established a training institute NeBriTA in collaboration with Dr Sameer Maithel and Mr Anand Damle. Training programmes for brick kiln owners, supervisors & workers Conducted around 10 training programmes/workshops in India, Nepal

and Bangladesh

Helped around 200 brick kiln owners to shift to this technology Customized design based on production capacity and brick

sizes Guidance in kiln construction Training of workers and staff in kiln operation Troubleshooting support

Spreaded this technology in the states of Uttar Pradesh, Bihar, Rajasthan, Punjab, Himachal Pradesh

Training Programme Varanasi

Training Programme - Varanasi

Training Programme - Nepal

Training Programme Bihar State Pollution Control Board

Kilns shifted to zigzag technology

Patna, Bihar

Varanasi, Uttar Pradesh

Kilns shifted to zigzag technology

Baghpat, Uttar Pradesh

Greater Noida, Uttar Pradesh

News Paper Reports

News Paper Reports