1 FACTSHEET ABOUT BRICK/TILES KILN

TECHNOLOGIES IN LATIN AMERICA

2 CEDAN KILN (SEMI-CONTINUOUS)

INTRODUCTION AND HISTORY GEOGRAPHICAL DISTRIBUTION:

This kiln is an alternative version of the
traditional Hoffman model and consists in
a set of chambers (usually twelve to sixteen
chambers) built in pairs to facilitate the flue
gases transfer.
The heat produced in a chamber is deflected
to the dome (roof ), then the hot gases move
down heating the bricks and leave the This kiln produces homogeneous products
chamber through the openings on the floor, due to the constant temperature of the heat Guyana
move across the openings in the floor and to that moves from one chamber to another, with Surinán
Guyana Francesa
the next chamber through holes at the bottom a low level of losses. Venezuela
zone in the fixed walls which are connected to The draft can be natural or forced. The fuels
the next chamber, producing a preheating of commonly used are logs, branches and pieces
Colombia
this chamber. of wood.

Ecuador

Brasil
Perú

Bolivia

Paraguay
Chile

Uruguay

Argentina

ESTIMATED N° OF OPERATIONAL ENTERPRISES AND TOTAL PRODUCTION

(USING CEDAN KILN)

Total Production
Country N° of enterprises
TYPE OF KILN CHARACTERISTICS OF ENTERPRISES USING THIS TECHNOLOGY: (billion bricks/tiles/year)

Brazil ~ 150 ~ 1,5

kiln Nature of Organisation Level of Type of bricks/ tiles Annual production capacity Operational period
mechanisation produced of the enterprise
% CONTRIBUTION TO THE TOTAL BRICK PRODUCTION IN BRAZIL

Out of the total annual production of around 430 million

~ 3,5% bricks in Brazil, around 150 million bricks are produced in
cedan kilns.
Hollow/perforated
Semi-Continuous
Industrial Semi-mechanised bricks - Tiles > 1 & < 10 million bricks Round the year
Moving Fire
(medium scale)
2 FACTSHEET ABOUT BRICK/TILES KILN
TECHNOLOGIES IN LATIN AMERICA

2 CEDAN KILN (SEMI-CONTINUOUS)

DESCRIPTION & WORKING:

Cedan Kiln is a semi continuous moving fire model in which the heat moves forward in the
direction of air flow due to the draught provided by a chimney. This kiln has a rectangular shape
The process is repeated from one chamber
and dimensions are: 25 to 30 meters in the front for 12 chambers (6 on each side), sidewall around to the next
8 meters (covering two chambers) and height between 2,8 to 3,0 meters. The whole cycle takes between 55 to 65
hours, reaching temperatures in the range
of 800 to 930°C. The burning takes 16 hours.

2
1
Hot gases produced by
the burning process in the
chamber moves to the next
The process starts with the chambers, where the green
burning of the first chamber products are preheated

3
Cooling The hot gases are
chamber Firing chamber conducted through
the duct to the stack.
Openings for fuel
feeding

Dome
ceiling
Pre heating
chambers

Hot gases Hot gases

Duct for gases

Door for Floor with

loading the openings
material Flue gases to the chimney
 3 FACTSHEET ABOUT BRICK/TILES KILN
TECHNOLOGIES IN LATIN AMERICA

2 CEDAN KILN (SEMI-CONTINUOUS)

AIR EMISSIONS AND IMPACTS: FUEL AND ENERGY: FINANCIAL PERFORMANCE: PRODUCT QUALITY: OCCUPATIONAL HEALTH AND SAFETY (OHS):

MEASURED EMISSION COMMONLY USED FUELS Capital Cost of the kiln technology Product quality:
Exposure to Respirable Suspended Particulate
FACTORS 1 Matter3
(for annual production capacity of 4-9 million (As per the local market perception)
Biomass Description about the exposure: some dust in the
bricks) surrounding environment. Workers are exposed
Biomass (e.g. firewood, biomass (excluding land and working capital cost)
briquettes, sawdust). to high concentration of suspended particulate
matter.
(in g/kg fired bricks)
200.000 to 260.000 USD (depending of the
Black Particulate SPECIFIC ENERGY CONSUMPTION2 number of chambers) GOOD 75 - 85%
(SEC) Impacts: This can result in a few cases
CO2 Carbon Matter CO
(measured at firing temperature of 900-1100 0C) of respiratory diseases among workers
(BC) (PM)
Capital Cost Breakdown
Average: 1,85 MJ/kg fired bricks or tiles
175 Not Not Not (Range: 1,75 – 1,95 MJ/kg fired/brick or tile)
(165-195) available available available Capital Cost Break-up Exposure to Thermal Stress 4
Description about the exposure: The workers
Material Cost 65% INFERIOR 15 - 25% that are engaged in kiln activities (discharging
products and fueling) are exposed directly to heat
COMPARISON WITH OTHER KILN Labour Cost 33% LOSSES AND BREAKAGES < 1%
and some radiation.
MEASURED PM EMISSION
TECHNOLOGIES Equipment Cost 2%
Average: Not available Total 100%
Cedan Kiln reports a SEC value under the range Description on product quality
for traditional kilns (SEC – 2 to 4 MJ/kg fired Homogenous and very high quality.
brick), but the value is slightly above compared
Impacts: This can result in dehydration
to the reported SEC values for continuous kilns
among workers
EMISSION STANDARDS (tunnel model).
Types of Solid bricks
MJ/kg fired bricks product Hollow/ Perforated bricks
6 that can
Country PM (mg/Nm3) be fired in Roof Tiles Risk of accidents
5 the kiln Others Description about the exposure: danger of falling
730 (< 10 MW) maximum (3,85 - 5,35)
Brazil off during the bricks assembly in the kiln and/or
520 (between 10 and 30 MW) 4 burn.
3
COMMENTS ON EMISSIONS GOOD BRICK
(1,75 - 1,95)
2
The values of the emission standards of fixed
sources depend on the thermal power rating 1 Impacts: Risk of injuries
(MW) of the sources (kilns). minimum (1,34-1,77)
0
Tunnel6 Cedan Intermitent
Soot emissions are very low because the internal (campaña)7 Compliance with ILO standards and remarks
200,000 bricks or tiles per week
design of the kiln that acts like a filter. Even Production on migratory labour and conditions of labour:
Main brick size: 180 x 180 x 85 mm
though the kiln can use a continuous biomass Capacity Practices followed at CEDAN kiln enterprises
DESCRIPTION ON ENERGY Main tile size: 490 x 130 mm
feeding process (sawdust or chopped firewood) INFERIOR BRICK do not comply with the International Labour
reducing or eliminating the soot completely. CONSUMPTION AND MAIN CAUSES OF No of Under-fired and over-burnt Standards on occupational health and safety
HEAT LOSS Operators 6-8 drawn up by ILO, majority of the workers are
required usually exposed to thermal stress and significant
The fuel consumption is low and there is : is low Simple Payback 2,5 – 3,5 years risk of accidents.
Payback
PM in the flue gas. Discounted
Period 2,7 – 3,8 years No migratory labour issues have been identified.
Payback (@ 6,5%)
4 FACTSHEET ABOUT BRICK/TILES KILN
TECHNOLOGIES IN LATIN AMERICA

2 CEDAN KILN (SEMI-CONTINUOUS)

CONCLUSION & REFERENCES:

Conclusion: ACKNOWLEDGEMENT:
The project team would like to acknowledge the financial support received
Parameters Cedan Kiln Comments
from the Swiss Agency for Development and Cooperation for the preparation
CO2 175 of these fact-sheets.

Black Carbon NA Note:

AIR EMISSION (G/KG FIRED BRICK) Cedan Kiln is a good technological option for batch production. In the initial stage of this initiative of developing factsheet on brick kiln
PM NA technologies, factsheet are developed for South and South-East Asia and Latin
CO NA America regions. Factsheet on brick kiln technologies of other regions will be
developed over time.
SEC (MJ/kg fired
FUEL & ENERGY 1,85 Energy performance is good in this kiln. Factsheet prepared by:
brick)
National Institute of Technology – INT5 , Rio de Janeiro, Brazil
(Dr Mauricio Henriques Jr.)
Capital Cost (USD) 200.000-260.000 Swisscontact, Lima, Peru
(EELA Program staff members)
FINANCIAL PERFORMANCE Production Capacity 7-8 million bricks or tiles / year High capital cost is one of the difficulties.

Simple Payback 2,5 – 3,5 years Design & Illustration:

Luis Enrique Caycho Gutiérrez
Types of product All types of product Non-uniform temperature distribution across the kiln (cross-section) can
PRODUCT QUALITY CONTACT
Good Quality Product 80% result in variation in product quality.

Exposure to dust yes

National Institute of Technology Swisscontact
Exposure to Thermal Cedan Kiln has some poor OHS conditions, mainly related to work exposition Rio de Janeiro, Brazil Lima, Peru
OHS yes
stress to heat during discharching products. Telephone: +55 21 21231256 Telephone: +51 1 2641707
E-mail: energia@int.gov.br E-mail: eela@swisscontact.org.pe
Risk of accidents yes
Web: www.int.gov.br Web: www.redladrilleras.net
FOR MORE INFORMATION:

REFERENCES:
(1)Report on ‘Brick Kiln Performance Assessment’ available at
http://www.unep.org/ccac/Portals/24183/docs/Brick_Kilns_Performance_Assessment.pdf
(2)Ibid.
(3) Field observation.
(4)Ibid.
(5)By its initials in Portuguese
(6)Tunnel Kiln: EELA. Manual de hornos eficientes para la industria de cerámica roja. Feb, 2015. / Greentech, SDC. Factsheets about brick kilns in South and South-East Asia. Dec, 2013.
(7)Intermitent (campaña): EELA. Diagnóstico inicial del sector ladrillero, Región del Seridó en el Nordeste de Brasil. Marzo, 2011