March 10,2011

Energy efficiency improvements in

Indian brick industry

Girish SethiDirector, Industrial Energy Efficiency Division

TERI

10 March 2011

March 10,2011

About TERI

• An independent, not-for-profit research organization established in 1974

• Pursuing activities related to energy, environment, and sustainable development

• Staff strength of over 900 drawn from multidisciplinary and highly specialized fields

• Great emphasis on capacity building and education. Set up TERI university in 1999 offering doctoral and master programmes

• Based in New Delhi; regional centres in southern; western and north-eastern India; and staff presence in Japan and Brussels

• Affiliate: TERI-NA in Washington DC, TERI-Europe in London, TERI-Gulf in Dubai

March 10,2011

Indian Brick Sector: Salient features

� Construction sector– Important contributor of GDP; annual growth rate of around 9%

� Solid clay fired bricks – Most popular building material – Annual production ~ 140 billion bricks (2000 – 01 data)– Per capita consumption ~ 100 bricks/capita/year

� Decentralized unorganized production– Decentralized Production: No. of units > 0.1 million – Seasonal operation (Dec to Jun)– Employment for about 10 million workers directly

� Resource Intensive process:– 3rd largest coal consumer (about 24 million tonnes/year)– Large consumption of good quality top soil (400 million tonnes/year)

March 10,2011

Brick making in India

Clamps

BTK

No Bricks

March 10,2011

BTKs - Characteristics

� Production capacity - From few millions to more than 10 millions/ annum

� Market:– Caters to both local and regional markets (up to a distance of 200 km) – Segregation based on quality (generally 5 classes)

� Fuel – Coal transported from larger distances or even imported (e.g

Indonesian/Australian coal).– Agricultural residue

� Production process: Continuous� Workforce:

– Different categories: moulders, loaders/unloaders, firemen

– Migratory labour from far-off regions : Workers contracted through labour contractors by paying advance money

March 10,2011

Key issues facing brick industry

� Technological obsolescence� Increasing fuel prices� Labour shortage – seasonal industry� Unskilled manpower� Increasing demand for quality

products – Niche market for new products

March 10,2011

UNDP-GEF project

� Project objective:To make India’s major brick producing clusters more energy efficient

� Executing Agency – UNDP; Implementing Agency –MoEF; Responsible Partner –TERI

� Project focusing major brick producing clusters in different regions – East, West, North, South and North-East

� Project being implemented through 5 Local Resource Centres

� Project duration – 4 years (2009-13)

Local Resource Centres (LRCs)

PSCST

Varanasi

INP

Bangalore

TERI

Agartala

TSCST

Chandigarh

Ahmedabad

CEPT

March 10,2011

Project focus

� Promote manufacturing of REB products in different parts of the country

� Facilitate market creation of such products� Capacity building of stakeholders� Develop linkage with banks and financial

institutions

March 10,2011

Need for technology upgradation

� Switching over from manual moulding to mechanization e.g. use of extrusion for brick making

� Adoption of better firing technologies e.g. tunnel kiln, Hoffman kiln etc.

� Better control on raw material and product characteristics

� Changes in product profile – Hollow blocks and perforated bricks

� Use of alternate material for brick making e.g. Fal-G bricks with curing instead of baking

� Brick industry to operate round the year

March 10,2011

Challenges

� Technology transfer and adaptation to local needs

� Financing

� Capacity building and awareness generation of large end-users

� Implementation of ECBC guidelines to promote green construction practices

Transformation of brick industry into an organisedindustry set up

March 10,2011

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