The Energy Sector Management Assistance Programme (ESMAP) grant supported the project with the objective to catalyse the adoption of sustainable environmental initiatives through energy efficiency measures in brick making industry with a focus on reducing air pollution, through pilot initiatives. The project involved a South collaboration between international VSBK Organisations i.e. Skat Consulting, Switzerland and Technology and Action for Rural Advancement (TARA) India. The project was managed locally by Practical Action, Bangladesh with overall coordination and management by Development Alternatives, India.

The objective of the assignment was to develop a complete package, including a demonstration kiln for the introduction and promotion of VSBK in Bangladesh. The assignment also focused on the appropriateness and operability of VSBK in Bangladesh context and also to show that the technology will result in reduced air emissions and energy use without compromising on the quality and production of bricks manufactured.

Earlier studies and an exposure visit of the Brick Association representatives (BBMOA) and the Government of Bangladesh (GoB) officials to India identified VSBK as one of the various options available for greening the brick industry in Bangladesh, in terms of improving the energy efficiency and drastically reducing the environmental emissions. Sceptic views were expressed since instances of failure was evident in Bangladesh through private initiatives. Thus "Operational Success" was expressed to be a major milestone towards investing in the same.

The project demonstrated the suitability and appropriateness of the Vertical Shaft Brick Kiln technology in Bangladesh.

From the technical point of view there are no issues in designing and constructing a VSBK in Bangladesh. All the materials required for construction, including high-quality refractory bricks are locally available. Expert masons are also available to do a quality construction. However during the initial couple of years, the design and construction of the VSBK needs to be under expert supervision. This is required for masons and engineers to absorb and practice the critical steps required for the VSBK.

The project demonstrated that some of the equipment can be manufactured in Bangladesh. Workshops have been identified for the same. The local skills available are sufficient to develop the same with technical back up support during the initial stages. However specialised equipment required needs to be imported from neighbouring countries.

In Bangladesh, the soil quality is extremely suitable for producing good quality bricks in a VSBK firing system. An added advantage is the mechanised processing of soil, which is also most appropriate to introduce the practice of internal fuel mixing for producing green bricks. It has been seen that a maximum of 3 per cent by weight of internal fuel can be mixed without compromising on the brick quality. More than 3 per cent internal fuel is not required from the total energy consumption issue. Moreover, any greater amount will create operational issues especially during the summer months in a VSBK.

The most critical factor for the acceptance of a VSBK is the demand of the high quality of bricks in the market. More than often, the VSBK-produced bricks are and will be notionally compared with those being produced through FCK and Hoffmann. The bricks produced from VSBK are of comparable, if not better quality, in technical terms of compressive strength and water absorption. They also fulfil all the required qualities as specified in the Bangladesh Standards (BDS 208:2002). The only negative issue was the visual colour of the bricks, which is commonly used by consumers as a yard stick for determining quality. Although the colour of the VSBK-produced bricks could not match with the best of the FCK or Hoffmann, they were comparable to the second- class being produced and sold. Thus it is recommended to devise and work upon an extensive marketing awareness campaign for the promotion of VSBK-produced bricks. A most appropriate starting point would be the promotion of "Eco Bricks" through government systems.

The pilot demonstration has shown that VSBK can be operated throughout the year, subject to the availability of green bricks stock and the absence of any water logging in and around the kiln site. During the rainy season, with the average moisture content of 7-8 per cent in the green bricks, the specific energy consumption was around 1.0 MJ/kg of fired bricks, giving a total fuel consumption (external and internal) of around 13 tonnes per lakh of fired bricks. With more dried bricks, this is expected to be around 0.8 MJ/kg with an average fuel consumption of between 8-10 tonnes per lakh of fired bricks. Thus, compared to the existing coal fired FCK there is a total energy savings of around 40 per cent through the VSBK firing technology.

The most important aspect of VSBK is that it can only be operated with coal or a combination of dense biomass briquettes. Under no circumstances can the woody biomass be used in VSBK. Thus adoption of VSBK will automatically arrest the deforestation caused by rampant use of wood in FCK firing.

Though, no environmental emissions were made to substantiate on the reduced environmental emissions there was no black smoke visible during VSBK operation, indicating the complete combustion of coal. It is estimated (from previous measurements in other countries), that stack and ambient emissions will be reduced by almost 70 per cent, compared to the operating FCK in the region.

The economic and financial analysis of the VSBK technology shows that it can be an alternate option to FCK. However, VSBK will have its own niche market amongst the medium to small brick producers, looking at the per-shaft capacity. The new entrants in the brick business will tend to get more attracted to the VSBK and reluctance is expected amongst existing FCK owners until and unless forced by Government policies. Under the observations in this project, it is expected that the probability of success and acceptance of a VSBK will be much higher in divisional cities and small towns. High volume brick technologies eg Hoffmann, HHK will continue to proliferate in the metro cities of Dhaka and Chittagong.

If the VSBK technology becomes popular in areas other than Dhaka, it may open up new avenues of opportunity. Since the land requirements and capital investments are less compared to FCK, financial institutions are expected to provide easy loans. However, this requires extensive support and policy changes.

The pilot demonstration of the VSBK technology has created a substantial interest amongst all the major stakeholders in the brick industry of Bangladesh. The Ministry of Environment and Forests, GoB has taken a keen interest in the VSBK technology with options of suggesting VSBK as an alternative for replacing the existing FCK. The results from the pilot demonstration initiatives have shown an enormous potential of replication. Apart from reduced emissions, an enhanced profitability of around 20 per cent from reduced coal and labour savings can also be achieved. Entrepreneurs will be interested in adopting the same due to enhanced profits and compliance with environmental standards. Regulatory agencies are interested in enforcing the same since environmental compliance will be maintained with.

In Bangladesh, there are around 4000 authorised FCKs. The annual coal consumption is around 2.2 million tonnes. If around 50 per cent of the existing units adopt improved technologies, then it would result in:

• Saving 480,000 tons of coal
annually

• Saving 1,500,000 tons of GHG emissions annually

• Saving 48 million USD foreign reserves annually

• Savings around 400,000 fully grown trees annually

This can arrest large scale deforestation. Wood also consists of nearly 50 per cent carbon. If burnt completely, one kg of wood releases around 1.8 kg CO2, the main greenhouse gas. Each tree cut down for fuel reduces the "CO2 sink"; the environments capacity to absorb this gas from the air. Thus savings in wood is expected to contribute further towards reducing the GHG emissions

The Government of Bangladesh has banned the use of firewood in brick kilns. Similar existing policies restrict the use of soil and high sulphur coal. The environment conservation rules for 1997 makes it compulsory for all new and operating brick kilns to get annual clearance from the Ministry of Environment and Forests (MoEF). Tougher laws are expected in the near future. However the enforcement of these laws remains almost non existent. In these conditions, VSBK is expected to solve the enforcement issues due to its inherent technology.

New approaches to operational practices require a paradigm shift from the conventional practices and the mentality amongst entrepreneurs of conducting regular business thereby integrating the whole process innovations with new technology process and re-engineering of existing methods. Change in mentality, technology innovations and trained human resources are the most valuable asset of improving the environment and benefiting the society in a business like manner. However the advantage of all this can only happen if the brick industry is ready to change its mind set and working habits. All this requires extensive awareness, widespread demonstration; intensive training and a long-term technology support; making both workers and entrepreneurs learn, practice and adopt improved technology options.

The above is the key to the success of the pilot initiatives and can only be achieved in time. In the absence of learning, the work force simply repeats the old practices and therefore, an on going process of learning and a commitment to re-learning are crucial for an overall improvement in the brick sector, especially with regards to energy conservation, minimising pollution and better quality of bricks.

Thus, it is recommended that the VSBK be seen as a compliment to improved FCK technology and not as a competitor with more attractive business opportunities and enhanced environmental benefits. q