Vertical Shaft Brick Kiln Project: A Case Study Workshop on

Development AlternativesCDM Opportunities, New Delhi

Vertical Shaft Brick Kiln Project:

A Case Study

Workshop on

CDM: Opportunities in RajasthanJaipur

28-29 January, 2005


CONSTRUCTION SECTOR IS THE LARGEST CONTRIBUTOR TO

CO2 EMISSIONS IN INDIA


Cement Steel Bricks

60% of CO2 Emissions in Construction Sector

are contributed by


Demand Projections of Building Materials

47.52

92.5

202.3

136.05

45.31

61.2

89.1

72.9

23

8.114.99.6

3.3 5.12 8.3413.6

0

50

100

150

200

250

1990 2000 2010 2020

Cement (mt)

Brick billion

Steel (mt)

Lime (mt)

Building material demand

Year







Majority of current technologies for burnt bricks do not

meet environmental standards orSupreme Court of India directives

National Concern


CDM Project• Technology and Action for Rural

Advancement will facilitate installation of 100 VSBKs across 3 states

• TARA will provide the technology and existing kiln owners the finance


Technology Description Multiple Shaft VSBK with individual shafts upto 1.25m X 2m size

Operation Continuous mode

Production Capacity 10000 to 40,000 per day

Fuel Pulverized coal, lignite pellets

Greenhouse Gas Mitigation Drastic reduction in fossil fuel use (upto 60%)

CDM Project - Vertical Shaft Brick Kiln



Sche

mat

ic D

iagr

am o

f VSB

K





Baseline• Movable Chimney Bull Trench Kilns banned by the

Supreme Court• Fixed Chimney BTK is an option but involves

higher capital investments• Most MCBTKs still operating due to less

enforcement and lack of alternative options• Continuation with MCBTKs is therefore the

baseline scenario


Clamps = 4.5 to 8.0 MJ / Brick

Movable Chimney = 4.2 MJ / Brick(BTK)

VSBK = 1.80 MJ/ Brick

Energy Consumption in Brick Production


Baseline CalculationsEnergy baseline:• Specific Energy Consumption using MCBTK = 4.4 * 10-6 Tj/ brick• Total Number of bricks produced in 70 kilns = 70 kilns * 20,00,000 bricks/

kiln = 140,000,000• Total Energy Consumption = Specific Energy Consumption * Total Bricks

produced= 4.4 * 10-6 * 140,000,000

= 616 Tj

• Carbon Emission Factor (CEF) for bituminous coal = 25.8 tonnes of carbon per

TerajouleEmissions baseline = Total Energy Consumption * CEF

= 616 Tj * 25.8 t C/ Tj = 15892.8 t C


Additionality • Identification of alternatives

– Continue their existing operation with MCBTKs (not legal)

– Replace MCBTKs by Clamp Kilns (not profitable)– Replace MCBTKs by Fixed Chimney BTKs

– Replace MCBTKs by VSBK.


Additionality

• Investment Analysis– IRR for Fixed Chimney BTK: 34%

– IRR for VSBK: 24%


Additionality• Barrier Analysis

– Investment Barrier : Existing kiln owners used to cash requirements of Rs. 20 lakh per annum.In VSBK double is required

– Technological Barrier – Reluctance to adopt a new technology– Service infrastructure not yet in place– Require more trained manpower


Additionality• Impact of CDM Registration

– Increases IRR for entrepreneues to 29%

– Bridges the financing gap for TARA to undertake the project

– Helps alleviating other barriers


Sustainable DevelopmentS.D. Factors Indicators Impacts/Results

Economic Well-Being Employment Generation 300 more jobs created

Environmental Soundness

CO2 reduction 38000 tonnes per year

SO2 reduction 380 tonnes per year

NOX reduction 11 tonnes per year

SPM reduction 111µg/nm3

RPM reduction 86µg/nm3

Social wellbeing Community Development

Contribution to brick workers’ savings

Technological Adaptation

Resource requirements Less land requirementImproved brick quality


Documents

Vertical Shaft Brick Kiln Project: A Case Study Workshop on