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Vertical Shaft Brick Kiln |
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A Vertical
Shaft Brick Kiln (VSBK) is an energy efficient technology for fired clay
brick production. This technology originated in China and has about 10,000
kilns running at present. In India, the VSBK technology has introduced at a
pilot scale in 1996 and presently 20 kilns are operational. It essentially
consists of one or more rectangular, vertical shafts within the kiln
structure. Rectangular arrays of dried green bricks and crushed fuel (coal)
are carefully stacked into batches, which are loaded into the shaft from the
top and finally batches of fired clay bricks are removed from the bottom
end. During this process, the batches of bricks pass through the preheating,
firing and cooling zones before they reach the shaft exit.
This
technology relies on the principle of counter correct heat exchanger in
order to achieve high thermal efficiency. When the shaft lid is in the
closed position, the entire kiln functions as a chimney. The heating cycle
for the green bricks is between 22-24 hours. A kiln with 2 shaft of 1.25m x
2m - produce upto 10,000 bricks in a day, which equals to the annual brick
production of around 2.5 million.
The VSBK
technology considerably economizes on fuel cost, with savings of between 30
to 50% when compared with other common firing technologies such as clamps or
Bull’s Trench Kilns. Pollution levels are extremely reduced compared to
other prevalent methods of brick firing.
Areas of application
VSBK bricks are suitable for all fired brick applications. Well-designed
loading and unloading mechanism ensure uniform size, sharp edges and corners
and less breakage during the production. These qualities make these bricks
more suitable for exposed brick masonry and high strength load bearing
applications. Wire cut extruded VSBK bricks with compressive strength upto
300 kg/cm2 are ideal for such applications.
Advantages
| ● |
Energy
efficient Save 30% to 50% on fuel cost when compared to other brick
firing technologies |
| ● |
Economically
viable A profitable business opportunity, with 50% recovery on
investment made, within 1st year of operation. |
| ● |
Requires
low initial investment Required relatively less capital for
infrastructure and construction |
| ● |
Requires
extremely low working capital Production cycle can start with 50,000
hands on stock of green bricks, whereas fixed chimney BTK’s requires
around 5 lakhs of green bricks. Secondly, the working capital required
in case of VSBK is considerably low. This is because the saleable
product (fired bricks) is obtained in 22-24 hrs, compared to 20- 24 days
which is required in any other conventional brick firing system. |
| ● |
Low
gestation period Construction of kilns can be completed within 60 days
with immediate start of production |
| ● |
Environment
friendly Much lower emissions (e.g. SPM – 22 to 37 mg/nm3) |
| ● |
Requires
less land for kiln construction Unlike the horizontally spread in the
BTK, VSBK requires vertical firing concept reduces the land requirement
considerably |
| ● |
Flexibility
in production The batch type firing system gives an unmatched
flexibility in production. It allows you to plan a precise production
schedule with exact amount of bricks to be produced, depending upon
the market demand. |
| ● |
High
quality and less breakage More than 90% of the bricks produced belong
to 1st grade, where as in a BTK 2nd and 3rd
grade brick are produced in significant quantity. Well designed
loading and unloading system controls the breakage within 2-3% of the
production. |
Development
Status
Commercialized
Technical Data
| Annual
production |
2,000,000
(With 2-shaft kiln of size 2mx1m) Based on 220 days of operation |
| Land
requirement |
2000m2(excluding
area required for moulding of bricks) |
| Electricity |
7.5
KVA, only while using mechanised lifting |
|
Nos.
of jobs created (workforce) |
44
(1 Supervisor, 30 skilled, 13 unskilled) |
Economic Data
Cost
benefit analysis of Biogas with different fuels
| Infrastructure |
Rs
500,000/- (For Kiln and office space) |
| Equipment |
Rs
200,000 (For Kiln accessories, vertical hoist, generator) |
| Training
and commissioni |
Rs
65,000/- |
| Total |
Rs
765,000/- (US$ 15,300) |
| (These
cost do not include cost of land, as it varies considerably from
place to place) |
Business
VSBK is highly profitable for
small and medium scale building material producers. A capital investment of
about Rs. 8 lakh can yield a production value of Rs. 20 lakhs. The gestation
time for kiln construction and commissioning is only 60 days. The technology
is provided by TARA Nirman Kendra, an associate of Development Alternative
Group.
Transfer forms
Turnkey basis
For further
information, please contact :
Mr.
Subroto Roy
Senior Business Development Executive
Development Alternatives
B-32, TARA Crescent
Qutab Institutional Area
New Delhi – 110016
Tel : 91+ 11+
696-7938, 685-1158
Fax : 91+ 11+ 6866031
Email : tara@devalt.org
sroy@devalt.org
URL : www.devalt.org
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