Techno Green Associates

Islamabad Pakistan

A Presentation to Action Aid – July 2011

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 Presentation Sequence

Overview of TGA

Projects
o Energy Efficient Brick Production (EEBP)

o Compressed Stabilized Earth Blocks (CSEB) Construction

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 Overview of TGA

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 Overview of TGA

• A private firm established by the core team of Energy Efficient

Brick Production (EEBP Pakistan), project of Swiss Agency for
Development and Cooperation (SDC) and Swiss Resource
Center and Consultancies for Development (Skat-Switzerland)

•TGA is registered under Partnership Act of 1932 with Registrar

of Firms at Islamabad since 29th October 2010

•TGA-Pakistan works for development programmes related to

energy & environment, social, humanitarian aid and
construction sectors.

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 TGA’s Projects

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 Energy Efficient Brick Production (EEBP)
Project

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 Energy Efficient Brick Production (EEBP)

Vision

To minimize the impact of brick making industry on environment and

climate, whilst improving working and living conditions of kiln workers.

Goal

To introduce improved technologies in the brick sector, which are less

harmful for the environment, helping to mitigate climate change and
bring improvements for the involved work force

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 Outline of the EEBP Project

• Introduction of the Vertical Shaft Brick Kiln Technology

• Analysis of the Brick Kilns Sector of Pakistan

• Brick Kilns Sector Mapping (Sector Monitoring)

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 VSBK Technology - History

China

9 India Nepal Vietnam Afghanistan

 Earlier VSBK Experience in Pakistan

 GTZ (German Technical Cooperation)

made an attempt to introduce VSBK - 1st

generation
(Peshawar -1995)
 Failed introduction
 Short shaft
 Difficult unloading
 Improper Flue ducts
 No cooling chamber
 Reddish Colour and less output

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 Vertical Shaft Brick Kiln (VSBK)

VSBK Operation
Loading A continuous Kiln
with stationary fire
and moving
bricks arrangement

Burning out
and
vitrrification

Unloading

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 Bull’s Trench Kiln (BTK)
A continuous kiln with Figure 1: Top view- Schematic
diagram FCBTK
J

moving fire and

A

stationary Office B
26 sq. ft.

bricks arrangement C
Office Office

113 sq. ft. 113 sq. ft.

Office Office

26 sq. ft. 26 sq. ft.

Office Office

113 sq. ft. 113 sq. ft.

Office Office

26 sq. ft. 26 sq. ft.

Office Office

113 sq. ft. 113 sq. ft.

Office Office
G
26 sq. ft. 26 sq. ft.
2
H

Office Office
I
113 sq. ft. 113 sq. ft.

Office

26 sq. ft.

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 Construction of 3 Pilot Kilns (Sep 2008-Feb 2009)

Foundations Construction -VSBK at RWP

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 Construction of VSBK
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 Construction of Two Shaft VSBK
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 Construction of VSBK Arches
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 Two Shaft VSBK in Rawalpindi
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 VSBK in Operation at Rawalpindi
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 Four Shaft VSBK at Lohe Bher Islamabad
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 VSBK Operation

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 Loading of VSBK Shafts

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 Loading of VSBK Shafts

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 Loading Pattern of VSBK Shafts

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 Coal Weighing

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 Coal Charging

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 Initial Firing

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 Initial Firing

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 Temperature Monitoring

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 Record Keeping

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 Unloaded VSBK Bricks

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 Batch of VSBK Fired Bricks

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 Stock of VSBK Bricks

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 Ash Fusion Problems

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 Salient Features of VSBK Vs. BTK

Construction VSBK BTK

 
Total Construction cost (Rs) 2.8 Millions 1.0 Million

Type of Structure Engineered Design Non Engineered

Total Construction Period 4 Months 2 Months

Total Land Required (2 Shafts) 3 Kanals (16320 Sq ft) 5 Kanal (27200 Sqft)

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 Brick Production Capacity
Daily Production

Operation VSBK BTK

2 Shafts 8,000 Bricks

4 Shafts 16,000 Bricks 25,000 Bricks

(5,600,000 / Year) (6, 000,000 / Year)

Fuel Consumption 130 gms / Brick 180 - 210 gms / Brick

(38% Saving)

A-Grade Bricks 95 % 70 %

Labor for Operation

 
Fire Master 8 (Two Shifts) 5 (Two Shifts)

Coal Crusher 02 Nil

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 Brick Strength Comparison VSBK vs. BTK

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 Outputs of the EEBP - Inception Phase

o Initial Firing / Brick Production started in constructed VSBKs

o All the 3 VSBK units operational by April 2009

o Demonstration of Internal Fuel

o Successful Production of High Quality Bricks

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 Analysis of Brick Sector – Studies
o Legal review of the Brick Sector in Pakistan
>>Laws not specific to brick sector

o Economic analysis of the Brick Production Units

>>Up-front cost of BTK < VSBK

o Environmental analysis of Brick Kilns

>>Brick kiln emissions affecting population

o Social analysis of the Brick Kiln Units

>>60% workers below the poverty line

o Contemporary (Alternative) technologies for Brick Production

>>Alternate solution is VSBK or tunnel kiln
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 Brick Sector Mapping (Sector Monitoring)

o Research Study on Bricks Market

>>Less understanding on Greener bricks in the market

o Research Study on Construction Trends

>>Bricks market growth at 4% per annum

o Survey of Brick Kilns in Pakistan

>>Anthology of 110 Brick Kilns

o Model Business Plan of a Brick Kiln

>>Business Plans developed for VSBK and BTK

o Study on Bonded labour at Brick Kilns

>>Holistic approach needed to address the issue

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 Main Themes EEBP
Jan - Dec 2011

o VSBK Backstopping - Testing Gutka and Tiles (value addition)

o Introduction of Internal Fuel in BTKs

o Introducing Modified BTK in Pakistan, (Supporting BTK Alternatives)

o Analyzing Tunnel Kiln, (Supporting BTK Alternatives)

o Working with EPA to Establish Emissions Baselines for Brick Kilns

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 TGA’s Projects

Compressed Stabilized Earth

Blocks (CSEBs) Construction

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 Compressed Earth Blocks Project
Completed Activities
o Preparatory Activities on CEB

o Press Machines Selection and Fabrication

o Community Mobilization through Local NGO

o Trainings of Trainers

o CSEB Model Construction

o Coordination and Dissemination of Information

 Preparatory Activities on CSEBs

Team Selection Field Testing of Raw Material

Press Machines Selection and Fabrication
Local NGO “SHED” Training of Trainers
Selection of sites for Model Houses

Construction of Model Houses

Completion of Training Activities

Completion of Model Houses

o Coordination and Dissemination of Information to
Humanitarian Agencies

o Interest Shown by:-

o Danish Refugee Council (DRC)
o DFID
o ACTED
o Save the Children-UK
o UN Shelter Cluster
o Engro Foundation
 Q&A

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 THANK YOU

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