Impact of Brickkiln Pollution on Dhaka City

Presented by: Ijaz Hossain Chemical Engineering Department BUET ijaz@bangla.net

Snapshot of the Brick Making Industry in Bangladesh

Parameter All Types of Coal-fired Kilns Natural Gas Fired Kilns Kilns Within 25 kilometers of Dhaka Kilns in the Dhaka North Cluster Annual Brick Production Value of Output in Taka Value of Output in US$ Contribution to GDP Coal Consumption Import Value of Coal Firewood Consumption GHG (CO2) Emission Clay Value (approximate) 5000 26 1200 550 15 Billion 450 Billion 640 Million 1% 2.2 Million Tons 140 Million US$ 1.9 Million Tons 8.75 Million Tons 45 Million Tons

Total Employment including supply of Close to 1 million clay/coal, transport of bricks and marketing

Database of Brick Kilns

Based on field surveys and interviews with random brick field owners

Database of Brick Kilns

Database of Brick Kilns

Database of Brick Kilns

Database of Brick Kilns

2005-2006 Brick-burning season

Total Number of Brick Kilns = 4140

This is the minimum number actual probably 10-15% higher

Source: GEF-UNDP Study (2006)

Modeling: Ground level particulate concentration as a result of emissions of 550 kilns in the North Dhaka Cluster were modeled Technical Options: Alternative cleaner technologies were identified and assessed

Main Data Requirement

Particulate emission from a typical kiln Exact position of each kiln in the

modeling domain
Chimney dimensions and flow of flue

gas (collected and/or assumed)

Gas properties (assumed) Meteorological data (WMO)

Stack Emissions Monitoring

Stack Emissions Monitoring

25'

Stack Emissions Monitoring

To improve understanding of the actual emissions from the industry

Stack Emissions Monitoring

550 THC Concentration 500

Total Hydro Carbon Concentration, (ppm)

500 ppm

450 400 350 300 250 200 150 100 50 0 1300 1303 1306 1309 1312 1315 1318 1321 1324 1327 1330 1333 1336 1339 1342 1345 1348 1351 1354 1357 1400

Time (Hours)

Figure1:Total Hydrocarbon Concentration Vs. Time (Hours)

Stack Emissions Monitoring

4000

CO Concentration

4000 ppm

3500

CO Concentration, (ppm)

3000

2500

2000

1500 1258 1301 1304 1307 1310 1313 1316 1319 1322 1325 1328 1331 1334 1337 1340 1343 1346 1349 1352 1355 1358 1401

Tim e (Hours)

Figure2: CO Concentration Vs. Tim e (Hours)

Stack Emissions Monitoring

Particulate Measurement

Stack Emissions Monitoring

Particulate Measurement

Sampling Date

Sampling Time

SPM (mg/m3)

March 18, 2006

2:30 PM-5:20 PM

663.94

March 23, 2006

3:16 PM-6:35 PM

1173.77

Stack Emissions Monitoring

Particulate Measurement

Bangladesh = 1000

Google Earth Dhaka North Cluster

Hand Held GIS Meters

Modeling Domain Dhaka North Cluster

Wind Direction In winter

(g/m3)

Four-month (December-March) Average Particulate Profile [in micrograms/cubic meter]

SEASONAL AVERAGE OF WORST CASE SCENARIO On a particular day/week, the pollution may be much more (g/m3)

December

January

February

March

Baseline

20% Less than Baseline

50% less than baseline

75% less than baseline

Particulate Concentration in g/m3 % More or Less Than Baseline LOCATION Baseline 20% more 20 % less 21 42 179 21 50 % less 13 27 112 13 75% less Baseline with wind at 170o 81 171 324 71

ZIA 1 AIRPORT 2 UTTARA 7 GABTOLI 1 CITY 1 CENTER

27 53 224 26

32 64 269 32

7 13 56 7

BAEC Apportionment Study

Found 15% of TSP to be from coal fired

brickkilns
This study: 26 53 g/m3 (except

Gabtoli)
BAEC: Total TSP = 150 200 g/m3 Therefore, 22% using BAECs total

1. Clamps Very old traditional technology 2. BTK Bulls Trench Kilns (less than 10%) 3. FCK Fixed Chimney Kilns (Baseline) 4. 5. 6. 7. 8. 9. Improved FCK (gravity settling chamber, etc.) Zigzag Kilns (less than 20% of existing kilns) Hoffman Kilns (natural gas only 26 kilns) VSBK Vertical Shaft Kilns Hoffman (coal) + Internal Fuel (UNOPS) [HHK] Tunnel Kilns

Clamps Does not exist in Bangladesh BTK Banned in Bangladesh

Market Share of the Four Types of Kilns (2005-06 season)

Kiln Type Number Percent of Kilns Brick Production (Billion) 9.4 2.0 0.7 0.3 12.4 Brick Production (%) 75.8 16.1 5.7 2.4 100

FCK BTK Zigzag Kiln Hoffmann Kiln Total

3123 794 197 26 4140

75.4 19.2 4.8 0.6 100

Source: GEF-UNDP Study (2006)

FCK

FCK Assessment
Simple and convenient technology Ideally suited to the level of the present

owners and workers

Is constructed in low lying land (cheap and

abundant)
Profitability High, IRR > 30% Pollution Very polluting

Zigzag Kiln

Zigzag Kiln Assessment

The construction technology is not readily

available, and expertise has to be procured from India

Scrubbing water is not changed regularly Operation procedure is more sophisticated than

FCK a badly operated kiln has the same energy consumption and hence pollution
Requires electricity and standby diesel generator Pollution 50% less assuming good design and

proper operation

HOFFMAN KILN
(30 Kilns use 5.5 MMcfd of Natural Gas )

Natural Gas Hoffman Kiln

Hoffman Assessment
Initial investment 10 times that of the FCK (50%

for land) Requires high land, natural gas connection, electricity and standby generator Requires more land compared to the FCK or Zigzag (at least 5 acres of high land close to a main road) Profitability low (IRR ~ 20%, 12-months operation needed to recover costs) Pollution 80-90% reduction compared to the FCK

FCK Modifications
Existing FCKs can be improved with one or all of the following Gravity settling chambers Improved coal feeding Internal fuel (up to 50%) Plugging air leakage All of these options will require technical assistance in the early

years. Once tried and tested, these can be easily replicated

Operation and maintenance aspect is not known Some Indian data is available for gravity settling chamber

modification along with improved coal feeding. The particulate emission can be reduced below 400 mg/m3 that would meet present and future emission standard

Coal Hoffman Hybrid Hoffman Kiln (HHK)

Coal Hoffman Hybrid Hoffman Kiln (HHK)

Permanent Roof and ID Fan

+

Internal Fuel (up to 80%)

Hoffman Coal (HHK) Assessment

The technology provider claims 80% coal can be

mixed with clay. This needs to be demonstrated

Operational and maintenance issues from

Bangladesh perspective is not known yet

Technology provider claims that the quality of

the brick is better than FCK 1st class brick (but using extruder and drying chamber)
It is claimed that Hoffman (coal) can reduce

pollution by 50% to 80% compared to the FCK

VSBK Assessment
According to available literature sources the bricks

are of good quality. But, Bangladeshi brick makers have the following perception problems:
Existence of cracks in bricks Bricks do not make a good ringing sound when banged

About 70-80% reduction in emission compared to the

FCK. Current standard is 1000 mg/m3 for 120-feet chimney. Emission is 200-300 mg/m3 for VSBK, but total height including chimney around 60 feet

Comparison of Particulate Emission of Different Kilns

1400

1200

Present Emission Standard 1000 Particulates (mg/m3)

800

600 Probable Future Emission Standard 400

200

0 FCK Zigzag (medium) NG Hoffman FCK (+GSC+IF) Coal Hoffman VSBK Zigzag (good)

Cement Block Plant

Summary Technology Options

1. Internal fuel This appears to be a very promising option for reducing pollution. Both the HHK and VSBK employ this practice + Gravity Settling Chamber FCK will be able to meet future emissions standard if it is set at 500 mg/m3 or more

2. Zigzag Kilns Many operating in Bangladesh have not been constructed according to the design standards. As a result these will not be able to meet the 500 mg/m3 standard. 3. Coal Hoffman (HHK) The HHK can meet future emissions standard. It will also lower coal consumption, but the exact amount will only be known after its commercial operation in Bangladesh.

5. VSBK In terms of emissions the VSBK is the best coal burning option. But this is totally new, and there appears to be some hesitation and resistance from existing FCK owners in shifting to this technology. 6. Cement Blocks In terms of service cement blocks are comparable to bricks, but there exists consumer resistance. Blocks use imported cement, while bricks use imported coal. However, the financial burden for importing Cement is 50 to 100% greater than that for importing coal from India.

 The DoE should use dispersion modeling

for Permitting industries. Compliance only with stack standards is not enough.
Significant

efforts are underway for transforming the brick industry. Many of these will yield positive results in the next 2-3 years. The DoE should initiate a study to update standards, and gradually introduce tighter standards, and not hastily ban technologies and practices.

 Undertake

project to determine the viability of using Gravity Settling Chambers and Internal Fuel in FCKs because if these options prove successful then FCKs may be able to meet future emission standards. Zigzag Kilns design and emission.

Undertake study to evaluate the popular Undertake pilot projects of new technology

(like VSBK) and assess operational (including product quality) and financial viability.