Taller sobre Políticas Públicas para Mitigar Impacto Ambiental de Ladrilleras Artesanales

Transcription

1 Taller sobre Políticas Públicas para Mitigar Impacto Ambiental de Ladrilleras Artesanales Guanajuato, Guanajuato México Septiembre 4 al 6, Sesión IV. Experiencias y alternativas tecnológicas "Hybrid Hoffmans and Improved Zig Zags" I$ikhar Hussain, Clean Energy Alterna7ves, Inc. sabu.hussain@yahoo.com, sabu.hussain@cleanenergyalt.com, Citar como: Hussain, I. (2012). Hybrid Hoffmans and Improved Zig Zags. En: INE Memorias del Taller sobre políticas públicas para Mitigar Impacto Ambiental de Ladrilleras Artesanales (Sesión IV. Experiencias y alternativas tecnológicas ). Guanajuato, México Septiembre 4-6, [diapositivas de PowerPoint-PDF]. Instituto Nacional de Ecología. Disponible en: Fecha de acceso: Septiembre 17, 2012.

2 Hybrid Hoffmans and Improved Zig Zags Iftikhar Hussain CEA

3 Hybrid Hoffman Kiln (HHK) Developed in Germany, modi1ied in China Plant combines an ef1icient annular kiln with waste heat recovery mechanism and internal fuelling systems Versatile, Ef1icient & Clean: * Produces high quality bricks of any size, shape and pigmentation * High thermal ef1iciency * Very low emitter of local and GHG pollutants

4 Hybrid Hoffman Kiln (HHK) Design Speci8ication Permanent roof and brick walls insulated with clay Smallest size consists of 22 1iring chambers, producing 15 million pieces annually Forced draft laminar air1low 8 Drying chambers, each 70m long

5 Hybrid Hoffman Kiln (HHK) Production Process Three stage interdependent and integrated production process: Green Brick Production Line (Production Phase) Drying of Green Brick (Drying Phase) Firing of Green Brick (Firing Phase)

6 Hybrid Hoffman Kiln (HHK) Green Brick Produc.on Capacity 50,000 /day Clay & Coal being mixed Double Shaft Mixer

7 Hybrid Hoffman Kiln (HHK) Green Brick Produc.on Phase Vacuum Extruder in Opera7on Green Brick CuEng Workers arranging green bricks on trolleys

8 Hybrid Hoffman Kiln (HHK) Brick Drying Hot air for drying is forced into the tunnel from the annular kiln. The drying cycle lasts for about 26 hours at about 120 o C. Drying Capacity 60,000/Day Green bricks entering drying chamber Dried green bricks

9 Hybrid Hoffman Kiln (HHK) Brick Firing The dried green bricks are unloaded manually into the annular HHK kiln. The speed of the firing is 1.25 m/h at a sintering temperature of about 950 o C 1050 o C. HHK Firing Chamber

10 Hybrid Hoffman Kiln (HHK) Bene8its Aesthetically attractive and structurally sound Compact, less land than FCK and yet produces 6 times more bricks Weather Proofed : production is for12 months Highly energy ef1icient, uses about Tons per 100,000 bricks Very low pollution Economically viable, low production costs, good quality products

11 Hybrid Hoffman Kiln (HHK) HHK Emission Monitoring Results Results of the stack monitoring data for Universal Bricks : Parameter Flue gas temperature ( C) Velocity (m/s) SPM* (mg/ m 3 ) Value 37 (range was 35 38) 3 (range was 2 4) 20.3 (range was ) *Stack sample (SPM) were collected for a period of 2 hours each Source: Khan, A.H. (2008) Energy and Stack Emission Monitoring In Hybrid Hoffmann Kiln (HHK) Type Universal Kiln, World Bank, Dhaka

12 Hybrid Hoffman Kiln (HHK) Air Quality Measurement Comparison of ambient air quality at the kiln gate and national standards Parameter Value at Kiln Gate National Standards SPM (mg/m3) CO (ppm) Source: Khan, A.H. (2008) Energy and Stack Emission Monitoring In Hybrid Hoffmann Kiln (HHK) Type Universal Kiln, World Bank, Dhaka

13 Improved ZigZag Kiln

14 ZigZag Kiln Salient Features of Traditional ZigZag kiln Temporary Roof (300mm) Outside wall thickness 600mm Baf1led, ZigZag air 1low Underground water chamber for 1lue gas passage

15 ZigZag Kiln Shortcomings in Traditional ZigZag Kilns Low thermal ef1iciency, high energy consumption Low quality products uneven 1iring High levels of pollution, local and GHGs

16 Improved ZigZag Kiln Design Changes Permanent insulated brick walls (2000mm) and roofs (1000mm) Versatile scale size, ranging from 22 to 42 chambers each of 7,600 piece daily capacity 1000mm Brick Roof 2000mm Side Walls Clay Underground pipe Cross section of the Improved Zigzag Kiln

17 Improved ZigZag Kiln Design Changes Updraft with straight laminar air1low Built in Heat Recovery mechanism for round the year production

18 Improved ZigZag Kiln Design Changes Advanced flue gas scrubbers for pollutant removal when drying chambers not installed

19 Improved ZigZag Kiln The Improved Zigzag Kiln

20 Improved ZigZag Kiln Design Bene8its Aesthetically attractive and structurally sound Design capacity of 9 million bricks per year 4.5 times the capacity of Traditional ZigZag kiln Flue gas desulphurization and dust removal system Readily adaptable Low capital investment suited for SME application

21 Improved ZigZag Kiln Environmental Bene8its Compact and Weather Proofed High energy ef1iciency: coal consumed is about 14 to 15 Tons per 100,000 bricks 95% Useable products

22 THANK YOU