Fly Ash Bricks

PROJECT DESIGN DOCUMENT FORM (CDM-SSC-PDD) - Version 03 CDM – Executive Board

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CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN DOCUMENT FORM (CDM-SSC-PDD)

Version 03 - in effect as of: 22 December 2006

CONTENTS A. General description of the small scale project activity B. Application of a baseline and monitoring methodology C. Duration of the project activity / crediting period D. Environmental impacts E. Stakeholders’ comments

Annexes Annex 1: Contact information on participants in the proposed small scale project activity Annex 2: Information regarding public funding Annex 3: Baseline information

Annex 4: Monitoring Information


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Revision history of this document Version Number

Date Description and reason of revision

01 21 January 2003

Initial adoption

02 8 July 2005 • The Board agreed to revise the CDM SSC PDD to reflect guidance and clarifications provided by the Board since version 01 of this document.

• As a consequence, the guidelines for completing CDM SSC PDD have been revised accordingly to version 2. The latest version can be found at <http://cdm.unfccc.int/Reference/Documents>.

03 22 December 2006

• The Board agreed to revise the CDM project design document for small-scale activities (CDM-SSC-PDD), taking into account CDM-PDD and CDM-NM.


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SECTION A. General description of small-scale project activity A.1 Title of the small-scale project activity: The title of project activity: Fly ash bricks project at UBMPL. The current version of the document: 01 The date when document was completed: 30/12/2009 A.2. Description of the small-scale project activity: Purpose of the Project activity: The fly ash which is a waste generated during generation of power in Indrajit Infrastructure Ltd and slag generated by Lloyds Steel Industries Ltd in steel manufacturing process are used to make blocks of bricks. These bricks are manufactured without using any fossil fuel. These bricks replace the fossil fuel burnt clay bricks. Hence the purpose of project activity is 1 To make bricks using fly ash and slag. 2 To avoid usage of fossil fuel. 3 To use waste products like fly ash and slag which cause air pollution and other kind of problems presently to produce fly ash bricks which are used as building material. Description of Project activity The project activity is to manufacture 300 tons/day (90000 number of bricks) of fly ash bricks. The chemistry of these bricks will be fly ash, waste slag, sand/stone and cement in fixed proportions mentioned below. The fly ash will be sourced from power plant of Indrajit Infrastructure Pvt Limited (IIPL) which is a waste product of power generation and slag from Lloyds Steel Industries Limited (LSIL) which is a waste product of steel manufacturing . both LSIL and IIPL are located within 2 km of the project location. The project activity will have 3 sets brick manufacturing equipment having capacity of 100 ton/day (30000 bricks per day). The machinery involved are listed below. Pre project scenario This is a green field project. At the moment there is no brick manufacturing facility in the project location using the waste fly ash from IIPL and Slag from LSIL . The fly ash and slag are dumped in the open and disposed of without using them. Explanation how the project activity reduces green house gas emission: The fly ash bricks replace the burnt clay bricks which are widely used and are manufactured using fossil fuel as energy source. The fly ash bricks do not use any fossil fuel. These fly ash bricks are used as building material instead of burnt clay bricks and hence achieve the reduction in CO2 emissions that would have been generated by replaced burnt clay bricks.


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What type of Technology is being employed? The technology employed is simple by mechanically mixing the fly ash, slag, cement, and aggregates in fixed proportions and fed into hydraulic press machine to make the blocks. Curing is done under sun shine without using any fuel. The composition of mixture is as follows on an average subject to variation as required by chemistry. Fly ash 64-68% Slag/Sand/stone 23-27% Cement 8- 9% The machinery installed is as follows: A Vibro compacting brick block making plants: 3 sets, Each set comprises of 1 Material mixing unit 2 Belt conveyor 3 Screw conveyors 4 no for feeding raw material from hopper to collecting belts for weighment 4 Raw material collecting belt 1 no 5 Weighing hoppers with load cell, gate and stands 4 no 6 Skip hoist for feeding material to pan mixer 1 no 7 Electrical control panel PLC Based

Present status of project:

1 One number brick making machine installed and commissioning activities will be started soon. 2 Second brick making machine expected to be installed and commissioned in January/February 2010. 3 Third brick making machine expected to be installed in and commissioned in March/April 2010. The base line scenario: As this is green field project the fly ash bricks will be replacing the burnt clay bricks which use fossil fuel. Hence the reduction in GHG emission from facility of the project arises from the replacement / displacement of fossil fuel which would have been otherwise used in the manufacture of burnt clay bricks. The Indian brick industry is unorganised with small production units clustered in rural and peri-urban areas. There are more than 100,000 brick kilns operating in the country. Brick making consumes about 24 million tonnes of coal and several million tonnes of biomass fuels per year. Coal consumption by the brick industry is approximately 8% of the total coal consumption in the country. Contribution of the project activity to sustainable development: The project activity will lead to sustainable development and promote sustainable Industrial growth by conserving natural resources and preventing the thermal pollution even though no such statutory requirement exists. Social benefit to state


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The project activity increases the employment within UBMPL for both skilled and non skilled persons. As the plant is not high tech type more unskilled labour will get employment from local area where manual handling and curing process involved. In the locality this provides employment opportunity to the people who are generally unemployed due to their lack of any skills and education. Skilled and unskilled labour will gain temporary employment while executing the project. The project activity uses the waste product like fly ash which is generated in large quantity and disposed in a very unhealthy way by dumping as there are no rules and regulations existing for disposal. This increases the dust content in the atmosphere leading to serious health hazards to people. This is avoided by the project activity leading to elimination of heath hazard to general public. Economical Benefits to State The project involves investment of around 22 million rupees and will involve more than 10 million rupees capital equipment purchase. Engineering industry will benefit and provide employment opportunity for professionals, skilled and unskilled people. The state will generate revenue out of the manufacturing activities supported by the power generation and due to purchase of equipment for execution of project by way of Sales Tax; Excise Duty; Entry Tax etc. Environmental Benefit The Project activity does not use fossil fuel in producing bricks and thus effectively saving environment of thermal and CO2 pollution. The project activity uses the waste product like fly ash which is generated in large quantity and disposed in a very unhealthy way by dumping as there are no rules and regulations existing for disposal. This increases the dust content in the atmosphere leading to serious health hazards to people. A.3. Project participants:

Name of the Party Involved (host) host party-

Private and/or Public entity (ies) Project Participant as applicable

Kindly indicate if the party involved wishes to be Considered as project participant (Yes/ No)

India (host) Ministry of Environment and Forest

Usha Building Materials Private Limited. Private entity.

No

A.4. Technical description of the small-scale project activity: A.4.1. Location of the small-scale project activity: >>


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A.4.1.1. Host Party(ies): India A.4.1.2. Region/State/Province etc.: Maharashtra A.4.1.3. City/Town/Community etc: Bhugaon. A.4.1.4. Details of physical location, including information allowing the unique identification of this small-scale project activity : Physical location The project activity located at Usha Building Materials Private Limited, Bhugaon village, Wardha Taluka & District, Maharashtra. Latitude 200 42’ 4.45” Longitude 780 37’ 15.24”. Nearest Railway station is Bhugaon. The plant is located approximately at 6 km from Wardha on Bhugaon link road near Lloyds Steel Industries Limited.


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A.4.2. Type and category(ies) and technology/measure of the small-scale project activity: Type and Category of the Project activity:

In line with paragraph 6I of decision 17/CP.7 on the modalities and procedures for the CDM, and ‘Appendix B’ of the simplified modalities and procedures for small-scale CDM project activities; “Indicative simplified base line and monitoring methodologies for small-scale CDM project activity categories” of Annexure II to decision 21/ CP.8 . The applicable type and category is:

Type-III Other Project Types Category III.Z. Fuel Switch, process improvement and energy efficiency in brick manufacture/ Version 02 Sectoral Scope 04 EB 47.


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Pre project scenario This is a green field project. At the moment there is no brick manufacturing facility in the project location using the waste fly ash from IIPL and Slag from LSIL. The fly ash and slag are dumped in the open and disposed of without using them. Description of Project activity The project activity is to manufacture 300 tons/day (90000 number of bricks) of fly ash bricks . the chemistry of these bricks will be fly ash, waste slag, sand/stone and cement in fixed proportions mentioned below. The fly ash will be sourced from power plant of Indrajit Infrastructure Pvt Limited (IIPL) which is a waste product of power generation and slag from Lloyds Steel Industries Limited (LSIL) which is a waste product of steel manufacturing. Both LSIL and IIPL are located within 2 km of the project location. The project activity will have 3 sets brick manufacturing equipment having capacity of 100 ton/day (30000 bricks per day). The machinery involved are listed below. Measures of small scale project activity: The project activity is to produce fly ash bricks using waste products like fly ash and slag. The project activity does not involve any high tech activity. 1 The slag is generated after reclamation of metal from slag generated by Lloyds Steel Industries Ltd in their steel plant. 2 The fly ash is generated in the power plant based on coal of M/S Indrajit Infrastructure Private Limited LSIL and IIPL are situated within 2 km of UBMPL. The manufacturing process involves the following process 1 Slag is crushed to the size of 0-20 mm and then separated by magnetic separator where the metal is separated from other materials. The slag is used as replacement of sand and aggregates. 2 Fly ash, cement, Sand, / Aggregates/ Slag and water are mixed mechanically and fed into hydraulic press machine to make blocks of bricks. Automatic Bricks making plant – 3 sets Make – Orbit Intelligent Engineering, Mehsana,India Description of Equipment 1 Vibro compacting brick block making plant Tonnage capacity-45 tonnes Structure material- IS 2062


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Hydraulic System Hydraulic cylinders – precision machined and assembled, hydraulic cylinders Vibrating Table size -3.75 sq.ft Max Operating system -PLC Based automatic cycle Material feeding system – trolly type filling cavity Hydraulic power house Hydraulic pump –positive displacement type, 15 HP AC Direction control valve Oil sump/oil cooler Vibrating system Vibrating motor 1 HP X 2 No Oie Make Palletising system Pallet feeding system belt or chain type Operating system hydraulic Box feeder Storage capacity 950 kgs Feeding system under hopper type belt conveyor Capacity- 150 kgs/min Motor- 1.5 HP Reduction gear box- 3 inch NU Ratio- 50:1 2 material mixing unit Type – under driven pan type mixer Mixing capacity -600 kgs/batch Mixing arrangement –spring loaded arms 6 nos 3 belt conveyor Conveying capacity- 5 tonnes/hour Electrical motor- 3 HP 4 Screw conveyors 4 no for feeding raw material from hopper to collecting belts for weighment 5 Raw material collecting belt 1 no 6 Weighing hoppers with load cell gate and stands -4 no 7 Skip hoist for feeding material to pan mixer 1 no 8 Electrical control panel PLC Based


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Average age and life of each equipment above All the machineries are totally new and procured from manufacturers. The expected life is 15 years as assured by the manufacturers. The brick manufacturing follows the following steps 2.1 All the raw materials will be transferred to 4 silos manually using mechanical pan loaders 2.2 Each silo is provided with microprocessor controlled load chip. 2.3 Weighed quantities of each raw material is transferred to conveyor and conveyed to pan mixer 2.4 Weighed quantity of water controlled by microprocessor is added in the pan mixer where all raw materials are mixed to form homogenous mixture. 2.5 The homogenous material is taken by conveyor to hoppers provided on the press. 2.6 The hoppers feed this mixture into the mould through microprocessor 2.7 The press then compresses the mixture into bricks. 3 The wet bricks are shifted to curing area. Curing is done under sun shine without using any additional energy. The curing process takes about 10-21 days after which the bricks are ready. The composition of mixture is as follows on an average subject to variation as required by chemistry. Fly ash 64-68% Slag/Sand/stone 23-27% Cement 8- 9% The production of bricks Capacity: 300 tonnes/day No of bricks: 90000 per day Size of each brick: 9 inch x 4 1/2 inch x 3 inch (230x110x75 in mm) Density: 1800 kgs/m3 approximate Average Weight of each brick: 3.2-3.4 kgs How environmentally safe and Sound Technology: The project activity is totally environment friendly as manufacturing activity does not use any fossil fuel. The technology is simple, indigenous and proven .There is no technology transfer involved. The brick making machinery are run on electricity. The curing is done under sun shine. The power connected to the plant is 100 HP and this consumption is taken as project emission in line with approved methodology. The base line scenario: As this is green field project the fly ash bricks will be replacing the burnt clay bricks which use fossil fuel. Hence the reduction in GHG emission from facility of the project arises from the replacement /


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displacement of fossil fuel which would have been otherwise used in the manufacture of burnt clay bricks. The Indian brick industry is unorganised with small production units clustered in rural and peri-urban areas. There are more than 100,000 brick kilns operating in the country. Brick making consumes about 24 million tonnes of coal and several million tonnes of biomass fuels per year. Coal consumption by the brick industry is approximately 8% of the total coal consumption in the country. In the absence of project activity the requirement of the bricks is met by burnt clay bricks manufactured in the kilns using coal. Table 1: Summary of gases and sources included in the project boundary, justification explanation where gases and sources are not included.

Source Gas Included? Justification / Explanation

CO2 Included

CH4 Excluded Excluded for simplification This is conservative.

Baseline

Fossil fuel consumption in burnt clay brick kilns for thermal energy

N2O Excluded Excluded for simplification This is conservative.

CO2 Included

CH4 Excluded Excluded for simplification This is conservative.

Project activity

Supplemental electricity consumption at project plant

N2O Excluded Excluded for simplification This is conservative.


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A.4.3 Estimated amount of emission reductions over the chosen crediting period: Years Estimation of annual emission

reductions in tonnes of CO2eq

2010 12014 2011 12014 2012 12014 2013 12014 2014 12014 2015 12014 2016 12014 2017 12014 2018 12014 2019 12014 Total estimated reductions (tonnes CO2 e) 120140 Total number of crediting years 10 Annual average of the estimated reductions over the crediting period ( tonnes CO2 e)

12014

A.4.4. Public funding of the small-scale project activity:

No public funding from parties included in Annex-I is available for the project activity. A.4.5. Confirmation that the small-scale project activity is not a debundled component of a large scale project activity: As per appendix “C” and Annex 27 “Compendium of guidance on debundling for SSC Project

activities “ to the simplified modalities and procedures for small scale CDM project activities, debundling is defined as fragmentation of a large project activity in to smaller parts. A small scale project activity that is a party of large project activity is not eligible to use simplified modalities and procedures for small scale CDM project activities

A proposed small scale project activity shall be deemed to be a de-bundled component of large

project activity, if there is a registered small scale CDM project activity or an application to register another small scale CDM project activity.

* With the same project participants * In the same project category and technology / measure. * Registered within the previous 2 years; * Whose project boundary is within 1 KM of the project boundary of the proposed small-

scale project activity at the close point. This small scale project activity does not fall under the de-bundled category as:


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1 UBMPL is not having any other registered CDM activity any where and also they have not applied for Registration for CDM project activity as a party of any other large project activity for any other project activity.

2. There is no fly ash brick manufacturing unit within 1 kilometer of this small scale project activity.

3. This project activity is totally green field and UBMPL is established with the aim of producing fly ash bricks using fly ash generated in thermal power plant of IIPL and waste slag produced in steel plant of LSIL.

SECTION B. Application of a baseline and monitoring methodology B.1. Title and reference of the approved baseline and monitoring methodology applied to the small-scale project activity:

In line with paragraph 6I of decision 17/CP.7 on the modalities and procedures for the CDM, and ‘Appendix B’ of the simplified modalities and procedures for small-scale CDM project activities; “Indicative simplified base line and monitoring methodologies for small-scale CDM project activity categories” of Annexure II to decision 21/ CP.8 . The applicable type and category is : Type-III Fuel Switch, process improvement and energy efficiency in brick Manufacture.

Category III.Z. / Version 02, Sectoral Scope 04 EB 47. Tools referred in the methodology are: 1 Tool to calculate baseline, project and or leakage emissions from electricity consumption. Version 01 EB 39 2 Tool to calculate project or leakage CO2 emissions from fossil fuel combustion. Version 02 EB 41 B.2 Justification of the choice of the project category: Methodology applicability condition Project activity 1 The methodology comprises shift to alternative brick making process

Project activity is a new facility for manufacturing fly ash bricks which are alternative to burnt clay bricks as building material.

2 The methodology is applicable for A Bricks that are same in the project baseline case or B Bricks that are different in the project case versus the baseline due to change in raw materials, use of different additives and/or production processes resulting in reduced use or avoidance of fossil fuels for forming sintering or drying or other applications as long as it can be demonstrated that service level of the project brick is comparable to

1 The baseline bricks burnt clay bricks using fossil fuel. 2 Project activity is for fly ash bricks and manufacturing process does not use any fossil fuel. 3 The fly ash bricks is comparable to baseline burnt clay bricks in dry compressive strength, wet compressive strength and density.


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base line brick. Examples include pressed mud blocks with cement, lime stabilisation and other unburned bricks that attain strength due to fly ash, lime/cement, gypsum chemistry.

4 The composition of mixture is as follows on an average subject to variation as required by chemistry to attain strength and cured under sun shine. Fly ash 64-68% Slag/Sand/stone 23-27% cement 8-9%

3 The measures may replace, modify or retrofit in existing facility or be installed in a new facility.

The project activity is a new facility.

New facilities and project activities involving capacity additions compared to the baseline scenario are only eligible if they comply with related and relevant requirements in the general guidance for SSC Methodologies.

The project activity meets the requirements of general guidance for SSC methodologies. Type III project activities shall not exceed total direct emissions reduction of 60000 tonnes of C02e annually. The emission reduction calculated in section B.6.3 of the project activity is 12014 tonnes of CO2e annually.

The service level of project brick shall be comparable or better than the baseline brick i.e. the bricks produced in the brick production facility shall meet or exceed the performance requirements and specifications applicable to base line bricks ( e.g Dry compressive strength, wet compressive strength ,density).An appropriate national standard shall be use to identify the strength class of the bricks ,bricks that have compressive strengths lower than the lowest class of bricks in the standard are not eligible under this methodology. Project bricks are tested in nationally approved laboratories at 6 months interval (at a minimum) and test certificates on compressive strengths are made available for verification.

1 The fly ash bricks will be checked in accordance to IS 3495 Standard for burnt clay bricks for the following parameters. 1 Wet compression strength as per IS 3495 Part 1 2 Water absorption as per IS 3495 Part 3 3 Efflorescence test as per IS 3495 Part 2 The burnt clay bricks as per standard shall not be less than 7.5 N/sq.mm when tested as per IS 3495 Part 1.the compressive strength of any individual brick shall not fall below the minimum average compressive strength by more than 20%. In case locally manufactured clay bricks are of strength are less than 7.5 N/sq mm ,ash bricks of compressive strength less than 7.5 N/sq mm but not less than 5.0 N/sq mm can also be manufactured to compete with locally manufactured clay bricks. Water adsorption not more than 20% Efflorescence not more than moderate.

Measures are limited to those that result in emission reductions of less than or equal to 60 kt of CO2e annually.

The project activity results in emission reductions Of 12014 tons of CO2e per year. Hence emission reductions are less than the maximum limit of


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60000 tonnes of CO2 emission reductions. Project will remain within the limits of SSC for the whole crediting period.

This methodology is not applicable if local regulations require the use of proposed technologies or raw materials for the manufacturing of bricks unless widespread non compliance of the local regulation evidenced.

There is no regulation to manufacture fly ash bricks. Hence normally fly ash is dumped unused by sponge iron plants and thermal power plants.

B.3. Description of the project boundary: As per methodology the project boundary is the physical and geographical where the brick production takes place during both the baseline and crediting periods. The project activity is green field project and hence covers the following brick making equipment covered in boundary area along with raw material storage area and curing area. The machinery installed is as follows and they fall in project boundary. Vibro compacting brick block making plants: 3 sets .Each set comprises of 1 Material mixing unit 2 Belt conveyors 3 Screw conveyors 4 no for feeding raw material from hopper to collecting belts for weighment 4 Raw material collecting belt 1 no 5 Weighing hoppers with load cell, gate and stands -4 no 6 Skip hoist for feeding material to pan mixer 1 no 7 Electrical control panel PLC Based


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Fly ash

Cement

Waste Slag from LSIL

Sand/Stone Dust

From IIPL Power

Plant

From Chemical

Plant

From Stone

Crushers/Sand Supplier

Storage of raw materials Fly ash : In open yard, duly wetted and covered by Plastic sheet. Sand/Stone dust: In open yard, duly wetted and covered by Plastic sheet. Slag: Dumped in open yard or stored in packets. Cement: In bags, stored in godowns.

Wet mixing in Pan Mixer

Raw materials are mixed via Pan mixer.

Fly ash : 64-68% Slag/Sand/Stone : 23-27% Cement : 8-9%

Project

Boundary

Project Boundar

y

Casting of bricks/blocks

The homogenous mortar taken out of pan mixer is put into the mould boxes. The product is compacted under hydraulic press

Drying & Curing

The green bricks are dried up under sun from 24 to 48 hours. The dried up bricks are stacked and subjected for water spray curing once or twice a day, for 10-21 days, depending on ambience.

DESPATCH TO THE MARKET


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B.4. Description of baseline and its development: As per AMS II.Z. “For projects involving installation of systems in a new facility, the average annual historical baseline fossil fuel consumption value and the baseline brick production rate shall be determined as that which would have been consumed and produced, respectively, under an appropriate baseline scenario. If the baseline scenario identified includes different technologies with different levels of energy consumption, a weighted average energy use of these technologies can be considered for determining the baseline emissions of the facility or facilities. The project involves setting up new facilities for production of bricks and blocks by using fly ash and waste slag which is energy efficient. The energy baseline is therefore the energy use of the facilities that would otherwise be built in the absence of the project in order to meet the demand for walling material, comparable in quality and utility to that of bricks and blocks produced by the project activity. In a paper presented by Sameer Maithel, N Vasudevan, Lt Col. Rakesh Johri (Retd) “Status report on VSBKs in India” on behalf of TERI who have done pioneering work on brick industry and have researched many papers on brick industry state as follows : The Indian brick industry is unorganised with small production units clustered in rural and peri-urban areas. There are more than 100,000 brick kilns operating in the country. Brick making consumes about 24 million tonnes of coal and several million tonnes of biomass fuels per year. Coal consumption by the brick industry is approximately 8% of the total coal consumption in the country. The brick-producing regions in India can be categorized into two major zones based on nature of soil availability. � Indo-Gangetic Plains, consisting of the north and north east part of India. Good quality alluvial soil is

available for brick making in this region and large capacity BTKs are found in this region. This region caters to about 65% of the total production.

� Peninsular and coastal India, consisting of the west, central and southern parts of India accounts for the

rest 35% of total production. This region has shortage of good quality soil for brick making. At present clamps and moving chimney BTKs are used for brick production. VSBK technology has higher potential in this region.

Another study ‘Small and Medium scale Industries in Asia: Energy and Environment ,Brick and Ceramic Sectors” by Regional Energy Resources Information Centre (RERIC) Asian Institute of Technology, Thailand also state as follows: In India, coal is used as main fuel for brick making and presently it consumes about 6.3 million tones of coal, which is more than 6% of the industrial coal consumption. Brick remains one of the most important building materials in India. Even though brick making has become more widespread in India, most units remain unorganised. This sector is utilising traditional technology. Brick making industries in India are generally confined to rural and peri urban areas. It is one of the largest employment generating industries with about 1.5 million workers compared to other developing countries. The Indian brick industry stands the second largest producer in the world, next to


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China, with more than 100,000 operating units, producing about 140 billion bricks. The estimated coal consumption for firing bricks is about 24 million tonnes annually (TERI, 2001). The fly ash bricks replace the burnt clay bricks which use fossil fuel like coal extensively. Production of burnt clay bricks is therefore considered the baseline scenario. The article by Sameer Maithel “Emission standards for brick kilns : An opportunity for technology up gradation” on www.brickindia.com on fly ash bricks give the fuel consumption in the Burnt clay brick manufacturing as follows :

The above discussion leads us to examine the energy use in brick kilns. Tata Energy Research Institute (TERI) has been monitoring energy consumption in brick kilns for the last four years. The results of these studies in terms of specific energy consumption can be summarised as follows :

Table 1 : Specific energy consumption of different types of brick kilns in India

Type of brick kiln Specific energy consumption (MJ/kg of

fired brick)

Specific fuel consumption (tons of coal/lakh brick)

Clamp 2-3 32-48

Moving Chimney Bull’s Tench Kiln (BTK)

1.25 – 1.75 20-28

Fixed Chimney BTK 1.0-1.5 16-24

High Draught Kiln 0.8-1.0 13-16

Vertical Shaft Brick Kiln (VSBK) 0.8-1.0 13-16

* Fellow Tata Energy Research Institute, India Habitat Centre, Lodhi Road, New Delhi.

Note : Specific fuel consumption is calculated, taking calorific value of coal as 4500 kcal/kg and fired brick weight as 3 kg per brick. Specific energy consumption figure for H.D. Kiln is based on the “Report on energy saving in the High Draught kiln developed by CBRI, 1982” and other references. Data for all other kilns is based on energy monitoring carried out by TERI.

More than 70% of the brick production in India comes from the two most inefficient kilns i.e. moving BTK and clamps. As per article by Sameer Maithel, N Vasudevan, Lt Col. Rakesh Johri (Retd) on “status report on VSBKs in India” for TERI the number of kilns operating in India have the following break up:


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Kiln type

Typical production capacity range (lakh bricks per year) Approximate Number of kilns

BTK–Fixed chimney§ 30 - 100 20000 BTK–Moving chimney 20 – 80 13000 High draft/zig-zag firing 30 - 50 200 Clamps 0.5 – 10 > 60000 Vertical shaft brick kiln (VSBK) 5 – 40 27 The specific energy consumption is worked as the weighted average by using the values given in above tables Kiln type Average

production lacs bricks per kiln A

Approximate no of kilns B

Average energy consumption MJ/kg C

A*B Energy consumed D=A*B*C

BTK–Fixed chimney§

65 20000 1.25 1300000 1625000

BTK–Moving chimney

50 13000 1.5 650000 975000

High draft/zig-zag firing

40 200 0.9 8000 7200

Clamps 5.25 60000 2.5 315000 787500 Vertical shaft brick kiln (VSBK)

22.5 27 0.9 607.5 546.75

Totals 2273607.5 3395246.75 Specific energy consumption: 3395246.75/2273607.5 =1.4933 MJ/Kg of brick considering weight of brick is uniform. The above energy is provided by coal and as the fly ash bricks do not use the energy, the emissions that would have occurred by burning coal would not be occurring when fly ash bricks are used instead of burnt clay bricks. As this is green field project the fly ash bricks will be replacing the burnt clay bricks which use fossil fuel. Hence the reduction in GHG emission from facility of the project arises from the replacement / displacement of fossil fuel which would have been otherwise used in the manufacture of burnt clay bricks. The production of bricks Capacity: 300 tonnes/day No of bricks: 90000 per day Size of each brick: 9 inch x 41/2 inch x 3 inches Density: 1800 kgs/m3 Average Weight of each brick: 3.2-3.4kgs


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B.5. Description of how the anthropogenic emissions of GHG by sources are reduced below those that would have occurred in the absence of the registered small-scale CDM project activity: A small scale CDM project activity is additional if anthropogenic emissions of greenhouse gases by sources are reduced below those that would occur in the absence of the registered project activity, and the project activity is facing one or more barriers as defined in Attachment A to Appendix B of the Simplified modalities and procedures for small scale CDM project activities. The project participants after studying the availability of fly ash from IIPL and slag from LSIL decided that making bricks from waste materials like fly ash and slag is a environmentally friendly project with no CO2 emissions and hence even after being handicapped of not having any experience in putting and running any type of industry, the international recognition of such project in terms of CDM registration And possible CER revenues enabled them to take decision in favour of project activity. The board meeting of 23/01/2009 considered all these aspects and decided to start the project activity. Timeline of activities of project activity 1 Board resolution: 23/01/2009 2 Ordering of equipment: 15/02/2009 3 Receipt of first set of equipment: September/October 2009. 4 Commissioning of fist brick making machine: November/December 2009. 5 Receipt of second set of equipment: December 2009. 6 Commissioning of second brick making machine: January/February 2010. 7 Receipt of third brick making equipment: February 2010. 8 Commissioning of third set of brick making equipment: March/April 2010. Time line of activities of CDM Process 1 Board resolution: 23/01/2009. 2 Appointment of CDM consultants: 15/02/2009 2 Notification to UNFCCC: 18/02/2009 3 Notification to NCDMA: 31/03/2009 4 Appointment of DOE for validation: 07/10/2009

When notification was done to UNFCCC on 18/02/2009 the notification indicated the approved methodology that will be followed as AMS II D as the fly ash bricks were registered under this methodology. However in EB 46 as Annex 20 on 25/03/2009 the methodology AMS III Z was issued for brick manufacture which was revised in EB 47 as Annex 25 on 28/05/2009. Hence we have followed approved methodology “Fuel Switch, process improvement and energy efficiency in brick Manufacture. Category III.Z. / Version 02, Sectoral Scope 04 EB 47” The analysis in the following paragraphs documents a number of barriers for the Fly ash brick project activity. It is expected that the burnt clay brick manufacturing using conventional technologies will continue to meet the walling material demand in the country resulting in substantial CO2 emissions, in the absence of the project activity. The project activity is therefore considered additional and would result in emission reductions below those that would have occurred if the equivalent amount of clay bricks were to be produced.


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As per Appendix B of the simplified modalities and procedures for small scale project activities and in accordance with paragraph 28 the project participant has to demonstrate that project activity would otherwise not be implemented due to existence of one or more barriers listed in Attachment A of this appendix. Hence the project participant proceeds to demonstrate additionality as required by Attachment A by doing barrier analysis as follows. a) Investment barrier The project participants approached the financial institutes like SIDBI and a nationalised bank but were refused the financial assistance to the project as the project participants were unable to provide the collateral securities for the entire amount of loan. This condition is not applied to established developers. As the project participants belonged to first generation promoter this rigid condition was put by institute and rejected the application. As the project participants were committed to put this project as green project they have gone ahead with finances from non institutional lenders who charge higher interest. The project participants after considering the CDM and possible income through CER sale decided to go ahead with project. This has acted as definite finance barrier. The capital cost of the project activity is Rs 22 Million compared to Burnt clay brick facility of similar capacity can be put within less than Rupees half Million. The financial parameters worked out are as follows: Cost of Raw materials per brick assuming weight of each brick as 3 kgs Raw Material Weight% Rate per kg

Rs/kg Required material kgs

Cost per brick Rs

cement 9 3.6 0.27 0.972 Slag/sand/stone 25 0.4 0.75 0.3 Fly ash 66 0.5 1.98 0.99 Total raw material cost 2.262 Labour per brick 0.45 Power per brick 0.07 Maintenance per brick 0.05 Total cost of brick 2.832 Overheads like administration,salaries,interest etc

0.1

Total cost per brick 2.932 Number of bricks per year 31.05 Million Selling price per brick 2.7 Total sales 83.84 Million Total production cost 91.039 Million Loss occurred 7.2 Million CDM CER sales at 10 euros per CER after deducting CDM expenses of 0.5 Million

7.55 Million

The calculations above demonstrate that project achieves break even only with CDM benefits.


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The sales realisation of fly ash brick has to be kept lower than burnt clay bricks due to the reasons of market resistance to fly ash bricks. Hence the fly ash bricks are priced at Rs 2.7 per brick compared to normal sales price of burnt clay brick Rs 3/brick. The project participant has actually taken higher sales price of brick at Rs 2.7 per brick even though presently he is getting Rs 2.6 only in the first order he is negotiating. The above financials of the project acts as financial barrier for the project participant. The CDM benefits enable the project participant to put the project with the hope that after some lapse of time the acceptability of fly ash bricks will improve and enable proper returns on the investment b) Technological Barriers Fly Ash Brick Project activity technology in particular, requires a recipe control of 3 main ingredients namely fly ash, cement and slag plus water at the mixing step. This is followed by manual/mechanical casting and lining up the bricks on the platform or casting yard for drying for one or two days. The dried up bricks are stacked and cured with water for one to three weeks, depending on the ambient temperature up on which the product is ready for despatching to the market. Fly Ash Brick Project activity is a proven technology and has superiority in terms of the strength as a walling material. However, it requires building the capacity of the entrepreneurs and training of artisans to start up and maintain the production. These requirements are perceived as barrier. c) Barrier due to prevailing practice Burnt clay bricks continue to be the most popular form of walling material in the country and have traditionally been believed to be the most suitable walling material for building construction. Although alternative building materials such as cement concrete block and fly ash bricks have been introduced in the recent past, burnt clay bricks account for most of the total market for walling material in larger parts of the country. This is supported by studies done by organisations like TERI etc and relevant papers are already referred in B.4 Clay brick production is a simple activity and is even practiced at the cottage sector level. Clay brick is a commonly used technological practice, which, even at the brink of 21st century, is practiced as a family trait that has been passed on from generation to generation. Small fired clay brick producers have no incentives to introduce alternate technologies, which require new investments, training to stabilize the operation, and a different business practice in long term perspective. Production and use of burnt clay bricks are therefore considered to be the most common practice at present and is expected to remain a common practice in the future unless significant regulatory mechanisms are evolved and enforced. d) Other barriers Two important aspects that have led to high risk perception of Fly Ash Brick Project activity are discussed below. d.1) Sourcing of raw material: In contrast to the clay brick industry, where the basic raw material is the soil available in and around the production sites, Fly Ash Brick Project activity technology and products require fly ash, cement and slag


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as key ingredients. These ingredients are required to be tested, selected and sourced from industrial facilities, where they are produced. Fly Ash Brick Project activity Plants are therefore required to be carefully located unlike the traditional clay brick plants, which require only the supply of adequate amount of soil. The project activity depends on fly ash availability on IIPL and slag on LSIL on whom the project participant has no control. If by any reason these materials are not available the project activity will come to halt and has to suffer financial losses. d.2) Operating within the specified limits for right chemistry: Fly Ash Brick Project activity technology, unlike the traditional clay brick making, requires recipe control of 3 main ingredients namely fly ash, slag/cement, plus water at the mixing step. In case there are changes to the sources of the raw materials, the chemistry and hence the recipe needs to be reworked. This is perceived as an interruption to plant operation leading to production loss. d.3) Market acceptance of Fly Ash Brick Project activity products In spite of the various superiorities of the Fly Ash Brick Project activity brick, the grey colour (imparted by the colour of fly ash) of Fly Ash Brick Project activity products creates a barrier in terms of low consumer acceptance. This is the common observation made by consumers during various market surveys conducted by different Fly Ash Brick Project activity brick promoters. In addition to the colour, the presence of ash in the product also creates negative perception d.4) Availability of Sand in rainy season Sand, one of the main raw materials used in the project activity, is collected from river bed. In rainy seasons, when water level goes up, the project participant faced problem in getting good quality of sand. The project participant has to bear extra expenditure in terms of making sufficient stock for 2-3 months for rainy season every year. d.5) No experience as first time entrepreneurs. The project participants are first time entrepreneurs having had no experience in running the industry as their present business activity is trading only in coal, steel etc. Industry running is complex activities to which they are not trained and are not experienced. Hence management of this industry will involve learn and practice for them as it is entirely different field and hence acts as a barrier. The above barriers are applicable only for project activity. The burnt clay bricks do not face the above barrier due to the following reasons: 1 Investment required is very low. Even cottage level industry can be established without much capital cost. The returns on burnt clay bricks are attractive as there is big demand for burnt clay bricks as walling material. 2 Technology used in making burnt clay bricks is very low kind and proven and widely practiced for many decades. 3 Raw materials is clay which is available to the brick manufacturer from his surroundings.


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4 Acceptability of burnt clay bricks is 100% and faces no problem in selling the products. National policy on brick industry The fly ash brick industry does not get any favourable benefits from the government of India or states in terms of subsidy and loans. Institutional loans are not easily made available in view of the industry is mainly set up by small entrepreneurs. The rules of depreciation is same as applicable to all the industry under company act. B.6. Emission reductions:

B.6.1. Explanation of methodological choices: The applicability of approved methodology has been discussed in B.2 and project participant has arrived At the conclusion that ACM III Z Revision 2 EB 47 is applicable to this green field project activity as per clause 3 of approved methodology. The approved methodology covers the baseline under clause 10. Accordance with this clause As per AMS III.Z. “For projects involving installation of systems in a new facility, the average annual historical baseline fossil fuel consumption value and the baseline brick production rate shall be determined as that which would have been consumed and produced, respectively, under an appropriate baseline scenario. If the baseline scenario identified includes different technologies with different levels of energy consumption, a weighted average energy use of these technologies can be considered for determining the baseline emissions of the facility or facilities. In section B.4 under the description of baseline we followed the following steps: 1 Identified burnt clay bricks as base line. As this is green field project the fly ash bricks will be replacing the burnt clay bricks which use fossil fuel. Hence the reduction in GHG emission from facility of the project arises from the replacement / displacement of fossil fuel which would have been otherwise used in the manufacture of burnt clay bricks. 2 Identified various types of technologies with different levels of energy consumption and they were listed. The weighed average of energy use in burn clay brick manufacturing was calculated in B.4 and same was arrived at 1.4933 MJ/kg of brick. Section 10 of methodology provides the equations to calculate baseline emission reductions The emissions are calculated as below: BE y = EF BL* P PJ y , (1) BE y The annual baseline emissions from fossil fuels displaced by the project activity in t CO2e in year y (of the crediting period) EF BL The annual production specific emission factor for year y, in t CO2 / kg or m3


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P PJ y The annual net production of the facility in year y, in kg or m3 The annual production specific emission factor (EFy) can be calculated ex ante as follows: EF BL = Σ (FC BL i j j× NCV j× EF CO2, j ) / P Hy (2) j i Where: FC BL i j j Average annual baseline fossil fuel consumption value for fuel type j combusted in the process i, using volume or weight units NCV j Average net calorific value of fuel type j combusted, TJ per unit volume or mass unit EF CO2, j CO2 emission factor of fuel type j combusted in the in the process i in t CO2/ TJ P Hy Average annual historical baseline brick production rate in units of weight or volume, kg or m3 Leakage = 0 As per methodological conditions 11. Leakage emissions on account of diversion of biomass from other uses (competing uses) shall be calculated as per “General guidance on leakage in biomass project activities”. 12. In the case of project activities involving change in production process or a change in type or quantity of raw and/or additive materials as compared to the baseline, the incremental emissions associated with the production/consumption and transport of those raw and/or additive materials consumed as compared to baseline, shall be calculated as leakage. As the project is green field new project activity and does not involve change in production process Or change in quality of raw and/or additive materials or use of biomass, hence leakage is zero. Project activity emissions 13 Project activity emissions (PEy) consist of those emissions associated with the use of electricity or fossil fuel or both and are calculated in accordance with the “Tool to calculate baseline, project and/or leakage emissions from electricity consumption” Version 01 EB 39and/or “Tool to calculate project or leakage CO2 emissions from fossil fuel combustion” (tCO2e) Version 02 EB 41. Emission reductions 14 Emission reductions (ERy) achieved by the project activity will be calculated as the difference between the baseline emissions and the sum of project emissions and leakage as follows: ER y = BE y− PE y− Leakage (3) Where: ER y Emission reductions in year y (t CO2e/yr)


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BE y Baseline emissions in year y (t CO2e/yr) PE y Project emissions in year y (t CO2/yr) LE y Leakage emissions in year y (t CO2/yr) The values used in case of NCV j EF CO2, j EFy are not IPCC default values but are taken from Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in and as these values are lower than IPCC default values the emission reduction calculations are conservative.

B.6.2. Data and parameters that are available at validation: Data / Parameter: EF BL Data unit: Tons of CO2/Ton of brick Description: Specific emission factor Source of data used: PDD. Value applied: 0.12085893 Justification of the choice of data or description of measurement methods and procedures actually applied :

Calculated.

Any comment: Fixed for entire crediting period.

Data / Parameter: EF CO2, j

Data unit: tonnes of CO2/MJ Description: CO2 Emission factor per unit of energy of the fossil fuel used in the base line Source of data used: CEA CO2 Data base version 5.0 November 2009. Value applied: 0.0000958 Justification of the choice of data or description of measurement methods and procedures actually applied :

Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. The document gives the emission factor for fossil fuels considered. We have used these values.



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Data / Parameter: NCV j Data unit: MJ/Ton of coal Description: Net calorific value of coal. Source of data used: Calculated from GCV value given in CEA CO2 Data base version 5.0

November 2009. Value applied: 15179.881 Justification of the choice of data or description of measurement methods and procedures actually applied :

Calculated. Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. The document gives the emission factor for fossil fuels considered. We have used these values.


Data / Parameter: EFy

Data unit: tonnes of CO2/MWh Description: CO2 Emission factor per unit of energy of the fossil fuel used in the base line Source of data used: CEA CO2 Data base version 5.0 November 2009. Value applied: 0.8083 Justification of the choice of data or description of measurement methods and procedures actually applied :

Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. The document gives the emission factor for fossil fuels considered. We have used these values.



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B.6.3 Ex-ante calculation of emission reductions:

Based on the equations provided in section B.6.1 we calculate below the emission reductions, project emissions, baseline emissions and leakage in the following manner. Base line emissions Based on the data provided by As per article by Sameer Maithel, N Vasudevan, Lt Col. Rakesh Johri (Retd) on “status report on VSBKs in India” for TERI the number of kilns operating in India have the following break up :

Kiln type

Typical production capacity range (lakh bricks per year)

# Approximate Number of kilns

BTK–Fixed chimney§ 30 - 100 20000 BTK–Moving chimney 20 – 80 13000 High draft/zig-zag firing 30 - 50 200 Clamps 0.5 – 10 > 60000 Vertical shaft brick kiln (VSBK) 5 – 40 27

Note: Specific fuel consumption is calculated, taking calorific value of coal as 4500 kcal/kg and fired brick weight as 3 kg per brick. Specific energy consumption figure for H.D. Kiln is based on the “Report on energy saving in the High Draught kiln developed by CBRI, 1982” and other references. Data for all other kilns is based on energy monitoring carried out by TERI. The article by Sameer Maithel on www.brickindia.com on fly ash bricks give the fuel consumption in the Burnt clay brick manufacturing as follows:

The above discussion leads us to examine the energy use in brick kilns. Tata Energy Research Institute (TERI) has been monitoring energy consumption in brick kilns for the last four years. The results of these studies in terms of specific energy consumption can be summarised as follows:



fired brick)


Clamp 2-3 32-48


1.25 – 1.75 20-28





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Note: Specific fuel consumption is calculated, taking calorific value of coal as 4500 kcal/kg and fired brick weight as 3 kg per brick. Specific energy consumption figure for H.D. Kiln is based on the “Report on energy saving in the High Draught kiln developed by CBRI, 1982” and other references. Data for all other kilns is based on energy monitoring carried out by TERI. In an article “Energy Conservation and Pollution Control” in Brick Kilns by Sameer Maithel, R Uma, Anil Kumar and N Vasudevan 3.0 Energy performance of brick kilns Specific fuel consumption, in terms of tons of fuel consumed for firing one lakh bricks is the popular way of expressing performance brick kilns in India. The mode of expressing performance in this manner may be of interest to brick manufacturers; however, it is difficult to compare performance of brick kilns on this basis, because of: i) the varying weight of fired bricks which may vary from about 2 kg to 3.75 kg in India; ii) the difference in quality and hence calorific values of various fuel. Kiln type Average



Average coal consumption Tons of coal/lac of bricks C

Average production lacs of bricks A.B

Average coal consumption Tons A.B.C


65 20000 20 1300000 26 000 000


50 13000 24 650000 15600000


40 200 14.5 8000 116000

Clamps 5.25 60000 40 315000 12600000 Vertical shaft brick kiln (VSBK)

22.5 27 14.5 607.5 8808.75

Totals 2273607.5 54324808.75

Million bricks 227360.75 Average weight of brick

2.875 kg=.002875 ton

Total weight of bricks

653.662116 million tonnes

54.3248075 Million tonnes

Calculation of specific emission factor EF BL EF BL = Σ (FC BL i j j× NCV j× EF CO2, j ) / P Hy (2) j i


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= 54.3248075*15179.881*0.0000958/653.662116 =0.12085893 Tons of CO2/Ton of brick Where: FC BL i j j Average annual baseline fossil fuel consumption value for fuel type j combusted in the process i, using volume or weight units = 54.3248075 Million tonnes of coal NCV j Average net calorific value of fuel type j combusted, TJ per unit volume or mass Unit = 3625.6524 kcals/kg = 15179.881 MJ/Ton of coal EF CO2, j CO2 emission factor of fuel type j combusted in the in the process i in t CO2/ TJ = 95.8 gms of CO2/MJ = 0.0000958 Tons of CO2/MJ P Hy Average annual historical baseline brick production rate in units of weight or volume, kg or m3= 653.662116 Million tonnes Conservativeness followed in base line calculations. As indicated above Specific Energy Consumption worked out by TERI takes into consideration 4500 kcals/kg as net calorific value of coal. Project participant has followed the caloric value data available in “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in . These guidelines give 3755 kcals/kg as gross calorific value and Net calorific value corrected with the available data in baseline data base is 3525.65 kcals/kg which is lower than 4500 kcals/kg calorific value taken by TERI. Hence calculated base line emissions are very conservative. Instead coal consumption in kilns is used to calculate baseline emission factor in line with approved methodology with lower calorific value given in CO2 Data base for Calorific value of coal. Hence the calculated baseline emissions are conservative. Base line emission factor will be constant as Ex ante based and fixed for the entire credit period. The base line emissions are calculated as below: BE y= EF BL* P PJ y , =103500*.12085893 =12508.9 Tonnes of CO2/year Rounded to 12509 tonnes of CO2/year. (1) BE y The annual baseline emissions from fossil fuels displaced by the project activity in t CO2e in year y (of the crediting period) EFBL The annual production specific emission factor for year y, in t CO2 / kg or m3 = 0.12085893 Tons of CO2/Ton of brick


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PPJ,y The annual net production of the facility in year y, in kg or m3 = 300 tonnes/day * 345 days/year = 103500 tonnes/year Source of the following data used in the above equations for coal. 1 EF CO2, j CO2 emission factor 2 NCV j Net calorific value Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. Project emissions The grid electricity is connected to the plant. Load connected = 100 HP Electricity consumed/year = 100 HPh *.0007457 MWh/HPh*24 hours/day*345 days/year*0.95 pf = 586.57 MWh Grid electricity emission factor EF y =0.8433 ton of CO2/MWh Project activity emissions: 586.57 *0.8433 =494.65 Rounded to 495 tons of CO2/year Source of grid electricity emission factor The MSEDCL grid power is being used by UBMPL at the moment. We select NEWNE grid electricity of which MSEDCL is a part and hence NEWNE grid electricity emission factor used to calculate baseline emission reductions which will give conservative reduction in base line emissions as grid power is mainly coal based but also comprises of diesel, hydel and nuclear power which will give lower emission factor for grid compared to coal based power plant. Government of India, Ministry of Power, Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year.


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The calculations cover all five regional grids. The document follows Tool to calculate the emission factor for an electricity system version 1.1 version 01.1 EB 35 formulae for calculation of emission factor for each grid. UBMPL has selected NEWNE grid as base line and in line with “Tool to calculate the emission factor for an electricity system version 1.1 EB 35” we have to consider available vintage data for 3 years. We give below data available from the CO2 Base line Data base for the Indian Power Sector referred above. Emission factor 2006-07 2007-08 2008-09 EF OM, Simple tCO2/MWh 1.01 1.00 1.01 EF BM Build Margin tCO2/MWh 0.68 Weighted average EF OM, Simple tCO2/MWh

1.0067

EF y Combined Margin tCO2/MWh 0.8433 Net Generation in operating margin GWh 379471 406142 421843 Net Generation in Build Margin GWh 102589 EF y considered for base line calculation is 0.8433 t CO2/MWh Calculations Weighted average of EF OM, Simple tCO2/MWh = (379471*1.01+406142*1+421843*1.01) / (379471+406142+421843) = 1.0067 Build Margin based on 20% of the generation For the latest year 2008-09 EF BM Build Margin tCO2/MWh = 0.68 Combined Margin EF y Combined Margin tCO2/MWh = 0.5 *1.0067+0.5*0.68 = 0.8433 Base line emission factor will be constant as ex ante based and fixed for the entire credit period.

Leakage =0 As the project is green field new project activity and does not involve change in production process or change in quality of raw and/or additive materials or use of biomass ,hence leakage is zero. Emission reductions. Emission reductions (ERy) achieved by the project activity will be calculated as the difference between the baseline emissions and the sum of project emissions and leakage as follows: ER y= BE y− PE y− Leakage = 12508.9 -494.65-0 = 12014.25 Tons of CO2/year = 12014 rounded to Tons of CO2/year (3)


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Where: ER y Emission reductions in year y (t CO2e/yr) BE y Baseline emissions in year y (t CO2e/yr) PE y Project emissions in year y (t CO2/yr) LE y Leakage emissions in year y (t CO2/yr) The values used in case of NCV j EF CO2, j EFy are not IPCC default values but are taken from Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in and as these values are lower than IPCC default values the emission reduction calculations are conservative

B.6.4 Summary of the ex-ante estimation of emission reductions:

year

Estimation of project activity emissions

Estimation of base line emissions

Estimation of leakage

Estimation of overall emission reductions

(tonnes of CO2 e) (tonnes of CO2 e) (tonnes of CO2 e)

(tonnes of CO2 e)

2010 495 12509 0 12014 2011 495 12509 0 12014 2012 495 12509 0 12014 2013 495 12509 0 12014 2014 495 12509 0 12014 2015 495 12509 0 12014 2016 495 12509 0 12014 2017 495 12509 0 12014 2018 495 12509 0 12014 2019 495 12509 0 12014 Total (tonnes CO2e) 120140

B.7 Application of a monitoring methodology and description of the monitoring plan:

B.7.1 Data and parameters monitored: (Copy this table for each data and parameter) Data / Parameter: P PJ y , Data unit: Tons Description: Production output Source of data to be used:

Plant records. Log book maintained for every day.


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Value of data 300 tons/day / actual production data Description of measurement methods and procedures to be applied:

Weighing load cell data available on PLC. Accuracy of measurement: +/- 0.5%

QA/QC procedures to be applied:

Load cell to be calibrated once a year. The calibration will be carried out by government accredited laboratory.

Any comment: Nil.

Data / Parameter: Q fly ash Data unit: tonnes Description: Fly ash consumed Source of data to be used:


Value of data 200 tonnes/day/actual. Description of measurement methods and procedures to be applied:

Load cell data on PLC and Plant records. Accuracy of measurement: +/- 0.5%


Calibration of load cell every year. The calibration will be carried out by government accredited laboratory

Any comment: Nil. Data / Parameter: Q cement Data unit: tonnes Description: Cement consumed in Fly ash bricks out put Source of data to be used:


Value of data 27 tonnes/day/ actual. Description of measurement methods and procedures to be applied:

Load cell data and plant records. Accuracy of measurement: +/- 0.5%



Any comment: Record will be maintained for 12 years

Data / Parameter: Q slag Data unit: tonnes Description: Slag consumed in Fly ash bricks out put Source of data to be used:


Value of data 39 tonnes/day./actual. Description of measurement methods and procedures to be applied:



35




Data / Parameter: Q sand ,aggregates Data unit: tonnes Description: sand consumed in Fly ash bricks out put Source of data to be used:


Value of data tonnes/year Description of measurement methods and procedures to be applied:





Data / Parameter: EG Data unit: MWh Description: Electricity consumed by the project activity. Source of data to be used:

MSEDCL bills/plant records

Value of data 617.44 MWh /year Description of measurement methods and procedures to be applied:

MSEDCL Meter/plant records/MSEB Bill .Accuracy of measurement: class 0.2


MSEDCL calibrates the meter as per their schedule.

Any comment: Record will be maintained for 12 years.

Data / Parameter: QCD Data unit: tonnes Description: Wet compressive strength of Fly ash bricks Source of data to be used:

Recognised laboratory data

Value of data 7.5 N/sq.mm Description of measurement methods and procedures to be applied:

Samples drawn every six months.


Involvement of third party for sampling as per IS 3594 1992. The testing will be carried out by government accredited laboratory

Any comment: Records will be maintained for 12 years.


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Data / Parameter: WA Data unit: % Description: Water absorption Source of data to be used:


Value of data Not more than 20% Description of measurement methods and procedures to be applied:



Involvement of third party for sampling and testing as per IS 3594 1992. The testing will be carried out by government accredited laboratory

Any comment: Record will be maintained for 12 years.

Data / Parameter: Ef Data unit: Not applicable. Description: Efflorescence. Source of data to be used:


Value of data Moderate. Description of measurement methods and procedures to be applied:



Involvement of third party for sampling and testing as per IS 3594 1992. The testing will be carried out by government accredited laboratory

Any comment: Record will be maintained for 12 years. B.7.2 Description of the monitoring plan:

>> As per the methodology, monitoring shall consist of 1 Metering of electrical energy consumption monthly by the project activity. 2 Monitoring of the weight of bricks produced in the project activity. 3 Tests to validate the project bricks meet the performance requirements and specifications at six month intervals 4 Principle raw material purchases on monthly basis. Monitoring plan: A Monitoring plan has been developed by the project participant for monitoring and verification of actual emission reduction. The Monitoring plan defines a project-specific standard against which the project's performance (i.e. GHG reductions) and conformance with all relevant criteria will be monitored and verified. The aim of this monitoring plan is to enable the project have a clear, credible, and accurate set of monitoring, evaluation and verification procedures to determine project outcomes i.e. greenhouse gas (GHG) emission reductions.


37

The above meters used for monitoring of the project activity will comprise microprocessor-based instruments of reputed make with desired level of accuracy. All instruments will be calibrated and marked at regular intervals so that the accuracy of measurement can be ensured all the time. Monitoring Approach The general monitoring principles are based on: _ Frequency _ Reliability _ Registration and reporting _ Frequency of monitoring. The project participant has installed energy meter and load cells to monitor and record the monitored data in the log book of the project activity . Responsibilities of plant officers. We define below the responsibilities of the professionals involved in running the project activity. Shift in charge (Operations): Responsible for proper operation of the mechanical equipment and reporting hourly and eight hourly data. Shift in charge (maintenance): Responsible for proper maintenance management. The report is then sent to the Manager (plant) for his review on a daily basis Manager (Plant): Responsible for operation, maintenance and management of plant will be reviewing the monitored parameters shift-wise and presenting a daily executive summary report. He will be in charge of all CDM related matters and CDM officer will be directly reporting to him CDM officer: He will be reporting to the Plant manager/ Director and will be responsible for preparing required documentation and reviewing the accuracy of various reports with counter checks along with project developer. He will be responsible for internal audit every month regarding CDM project matter. B.8 Date of completion of the application of the baseline and monitoring methodology and the name of the responsible person(s)/entity(ies) Preparation of this document has been done by “Lloyds Steel Industries Ltd, Engineering division.” Who is project CDM consultant and is not project participant. Date of completion of baseline study: 27/11/2009 Plant Manager of UBMPL will be responsible for execution of monitoring methodology. UBMPL is the project participant and a private entity. Responsible person for baseline and monitoring methodology covered in this PDD and LSIL is not project participant.


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Mr R.M.Alegavi Vice President (Technology) Lloyds Steel Industries Ltd Engineering division 21-B Modern Centre Sane Guruji Marg. Mahalaxmi. Mumbai 400011 Tel No 91-22-30418111, 30418221 Fax No 91-22-30418260 [email protected], [email protected] SECTION C. Duration of the project activity / crediting period C.1 Duration of the project activity: C.1.1. Starting date of the project activity: 15/02/2009, starting date considered is date of issue of purchase order. C.1.2. Expected operational lifetime of the project activity: 15 years 0 months . C.2 Choice of the crediting period and related information: C.2.1. Renewable crediting period Project participant has opted for fixed period. C.2.1.1. Starting date of the first crediting period: Not applicable. C.2.1.2. Length of the first crediting period: Not applicable. C.2.2. Fixed crediting period: Fixed crediting period is selected by project participant. C.2.2.1. Starting date: 01/02/2010/From the date of registration whichever is later. C.2.2.2. Length: 10 years 0 months.


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SECTION D. Environmental impacts >> D.1. If required by the host Party, documentation on the analysis of the environmental impacts of the project activity: As the facility does not produce any pollution in manufacturing process but proposes to use the waste products like fly ash and slag which create environmental pollution by increasing dust levels of atmosphere thus leading to respiratory problems in general public. The project activity does not use any fossil fuel in the manufacturing and produces no pollution. Hence there is positive impact on the environment due to this small scale project activity of reducing the pollution caused by fly ash and slag. Consent to establish from MPCB has been received for the first stage of the project activity and mentions no fuel being used in the process. The only conditions set out are: 1 There shall be no nuisance due to industrial activity to surroundings. 2 The handling of fly ash i.e transport, loading and storage shall be done in a scientific manner so as to avoid fugitive emissions and nuisance. 3 Water shall be sprinkled on stored fly ash to avoid fugitive emissions. There is no condition that EIA has to be conducted in the consent to establish as Ministry of Environment and Forests notification dated 14th September 2006 does not include this industry under environment clearance requirements. UBMPL is committed to meet the above conditions D.2. If environmental impacts are considered significant by the project participants or the host Party, please provide conclusions and all references to support documentation of an environmental impact assessment undertaken in accordance with the procedures as required by the host Party: There is no negative impact due to project activity as it produces no pollution during manufacturing of fly ash bricks. Hence no environmental impact study is required. As required by regulations the environment clearance has been received from MPCB. SECTION E. Stakeholders’ comments E.1. Brief description how comments by local stakeholders have been invited and compiled: UBMPL recognises the following as stake holders in the project activity: 1 Bhugaon Village Panchayat


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UBMPL management apprised the representatives of village Panchayat of village Bhugaon about the project activity personally by the officers of UBMPL and called for a meeting of villagers. The Sarpanch who is the head of local governing body panchayat with representative villagers attended the meeting. 2 Maharastra Pollution Control Board (MPCB) UBMPL applied for clearances in proper formats and clearances from MPCB has been received. 3 District Industrial Centres. UBMPL applied for small scale registration and Small Scale Industry (SSI) Registration has been received 4 Indrajit Infrastructure Private Limited. (IIPL) The fly ash is being sourced from IIPL. UBMPL and IIPL have the agreements duly signed. 5 Lloyds Steel Industries Ltd (LSIL) The slag is being sourced from LSIL. UBMPL and LSIL have the agreements duly signed. E.2. Summary of the comments received: UBMPL management apprised the representatives of village Panchayat of village Bhugaon about the project activity personally by the officers of UBMPL and called for a meeting of villagers. The Sarpanch who is the head of local governing body panchayat with representative villagers attended the meeting on 29/01/2009. The members of Panchayat appreciated and had expressed their no objection for project activity. Bhugaon Gram Panchayat has issued no objection certificate. We give below queries raised during meeting held. Bhugaon village sarpanch is the elected head of Panchayat body created for looking after interests of the village. Persons attended from village Persons attended from UBMPL Mr Raju.N.Nakhale Sarpanch Mr Sanjay Choudhary. Mr G.B.Kshirsagar Mr O.G.Dastidar. Mr Sukhadeo.Punwatkar. Mr R.P.Gupta. Mr Ritish Darode Mr Kishor Sarate MrRishan Bulkunde Question Reply by UBMPL 1 How the village is benefited This was asked by Mr Raju.N.Nakhale Sarpanch of Ghugus Village

1 The manufactures fly ash sourced from Indrajit Infrastructure Limited and slag from Lloyds Steel Industries Limited and can be considered as land mark project in the district. 2 Direct and indirect jobs are created at many levels


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like fly ash collection and transportation to plant. This will lead to income rise for the local people as commercial activities around the plant area and unskilled people get benefited in various levels of collection points. 3 Direct effect of reduction in dust pollution as fly ash will now be used for brick making and not dumped.

2 Criteria for local people employment This was asked by Mr G.B. Kshirsagar and Mr Darode.

1Plant: Project will require qualified technicians, professionals, skilled and unskilled labour. Local people will be given preference if qualified technicians who have required qualification and experience are available. In case of commercial jobs where specific professional qualification is not required all efforts will be made to employ only local people. 2 Fly ash collection: company will employ local people for collecting, transporting of fly ash from local area.

3 Dust emission problem This was asked by sarpanch on behalf of every body present.

The project activity does not create any polluting dust.In fact project is using the fly ash being dumped presently and causing pollution to make bricks. Hence the dust levels of air will definitely be reduced due to the project activity.

4 Plans for village development This was asked by Sarapanch of Bhugaon Mr Nakhale after discussing with other villagers present.

Company informed that they will be pleased to contribute to sustained development of the village. The company will make efforts to coordinate with gram panchayat in any manner that will help the villagers.

Sarapanch, village Bhugaon raised the points of activities required to be carried out by company for benefiting the village. The company will work with panchayat so that the progress of the village people and facilities are addressed. The village panchayat has issued the letter expressing their happiness as the project activity proposes to Use pollution causing fly ash and also provide employment opportunity to unskilled workers. E.3. Report on how due account was taken of any comments received: Project participant will make all efforts to employ local people and provide employment opportunity to the unskilled and train them to be able to work in manufacturing set up. Necessary clearances from MPCB and SSI Registration have been received.


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Annex 1

CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY

Organization: Usha Building Materials Private Limited Street/P.O.Box: Bhugaon link road Building: Lloyds Nagar City: Wardha State/Region: Maharashtra Postfix/ZIP: 442001 Country: India Telephone: 07152 305000,040 66488208 FAX: 07152 305 050,040 23777917 E-Mail: [email protected] URL: Represented by: Title: Director Salutation: Mr Last Name: Gupta Middle Name: First Name: Ravi Department: Mobile: 09391031223 Direct FAX: 040 65458208 Direct tel: 04023777917 Personal E-Mail: [email protected]


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Annex 2

INFORMATION REGARDING PUBLIC FUNDING UBMPL have not received any ODA funds and any public funds for the project activity.


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Annex 3

BASELINE INFORMATION

The base line scenario: As this is green field project the fly ash bricks will be replacing the burnt clay bricks which use fossil fuel. Hence the reduction in GHG emission from facility of the project arises from the replacement / displacement of fossil fuel which would have been otherwise used in the manufacture of burnt clay bricks. Base line emissions Based on the data provided by As per article by Sameer Maithel, N Vasudevan, Lt Col. Rakesh Johri (Retd) on “status report on VSBKs in India” for TERI the number of kilns operating in India have the following break up :

Kiln type

Typical production capacity range (lakh bricks per year)

# Approximate Number of kilns

BTK–Fixed chimney§ 30 - 100 20000 BTK–Moving chimney 20 – 80 13000 High draft/zig-zag firing 30 - 50 200 Clamps 0.5 – 10 > 60000 Vertical shaft brick kiln (VSBK) 5 – 40 27 The article by Sameer Maithel on www.brickindia.com on fly ash bricks give the fuel consumption in the Burnt clay brick manufacturing as follows:

The above discussion leads us to examine the energy use in brick kilns. Tata Energy Research Institute (TERI) has been monitoring energy consumption in brick kilns for the last four years. The results of these studies in terms of specific energy consumption can be summarised as follows:



fired brick)


Clamp 2-3 32-48


1.25 – 1.75 20-28


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Note : Specific fuel consumption is calculated, taking calorific value of coal as 4500 kcal/kg and fired brick weight as 3 kg per brick. Specific energy consumption figure for H.D. Kiln is based on the “Report on energy saving in the High Draught kiln developed by CBRI, 1982” and other references. Data for all other kilns is based on energy monitoring carried out by TERI. In an article “Energy Conservation and Pollution Control” in Brick Kilns by Sameer Maithel, R Uma, Anil Kumar and N Vasudevan 3.0 Energy performance of brick kilns Specific fuel consumption, in terms of tons of fuel consumed for firing one lakh bricks is the popular way of expressing performance brick kilns in India. The mode of expressing performance in this manner may be of interest to brick manufacturers, however, it is difficult to compare performance of brick kilns on this basis, because of: i) the varying weight of fired bricks which may vary from about 2 kg to 3.75 kg in India; ii) the difference in quality and hence calorific values of various fuels used for firing bricks. Kiln type Average



Average coal consumption Tons of coal/lac of bricks C

Average production lacs of bricks A.B

Average coal consumption Tons A.B.C


65 20000 20 1300000 26 000 000


50 13000 24 650000 15600000


40 200 14.5 8000 116000

Clamps 5.25 60000 40 315000 12600000 Vertical shaft brick kiln (VSBK)

22.5 27 14.5 607.5 8808.75

Totals 2273607.5 54324808.75

Million bricks 227360.75 Average 2.875


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weight of brick

kg=.002875 ton

Total weight of bricks

653.662116 million tonnes

54.3248075 Million tonnes

Calculation of specific emission factor EF BL EF BL = Σ (FC BL i j j× NCV j× EF CO2, j ) / P Hy (2) j i = 54.3248075*15179.881*0.0000958/653.662116 =0.12085893 Tons of CO2/Ton of brick. Where: FC BL i j j Average annual baseline fossil fuel consumption value for fuel type j combusted in the process i, using volume or weight units = 54.3248075 Million tonnes of coal NCV j Average net calorific value of fuel type j combusted, TJ per unit volume or mass Unit = 3625.6524 kcals/kg = 15179.881 MJ/Ton of coal EF CO2, j CO2 emission factor of fuel type j combusted in the in the process i in t CO2/ TJ = 95.8 gms of CO2/MJ = 0.0000958 Tons of CO2/MJ P Hy Average annual historical baseline brick production rate in units of weight or volume, kg or m3= 653.662116 Million tonnes Conservativeness followed in base line calculations. As indicated above Specific Energy Consumption worked out by TERI takes into consideration 4500 kcals/kg as net calorific value of coal. Project participant has followed the caloric value data available in “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in . These guidelines give 3755 kcals/kg as gross calorific value and Net calorific value corrected with the available data in baseline data base is 3525.65 kcals/kg which is lower than 4500 kcals/kg calorific value taken by TERI. Hence calculated base line emissions are very conservative. Instead coal consumption in kilns is used to calculate baseline emission factor in line with approved methodology with lower calorific value given in CO2 Data base for Calorific value of coal. Hence the calculated baseline emissions are conservative. Base line emission factor will be constant as ex ante based and fixed for the entire credit period. The base line emissions are calculated as below: BE y= EF BL* P PJ y ,


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=103500*.12085893 =12508.9 Tonnes of CO2/year (1) BE y The annual baseline emissions from fossil fuels displaced by the project activity in t CO2e in year y (of the crediting period) EFBL The annual production specific emission factor for year y, in t CO2 / kg or m3 = 0.12085893 Tons of CO2/Ton of brick PPJ,y The annual net production of the facility in year y, in kg or m3 = 300 tonnes/day * 345 days/year = 103500 tonnes/year Source of the following data used in the above equations for coal. 1 EF CO2, j CO2 emission factor 2 NCV j Net calorific value Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. Project emissions The grid electricity is connected to the plant. Load connected = 100 HP Electricity consumed/year = 100 HPh *.0007457 MWh/HPh*24 hours/day*345 days/year*0.95 pf = 586.57 MWh Grid electricity emission factor EF y =0.8433 ton of CO2/MWh Project activity emissions: 586.57 *0.8433 =494.65 Rounded tons of CO2 Source of grid electricity emission factor The MSEDCL grid power is being used by UBMPL at the moment. We select NEWNE grid electricity of which MSEDCL is a part and hence NEWNE grid electricity emission factor used to calculate baseline emission reductions which will give conservative reduction in base line emissions as grid power is mainly coal based but also comprises of diesel, hydel and nuclear power which will give lower emission factor for grid compared to coal based power plant.


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Government of India, Ministry of Power, Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in The objective is to facilitate adoption of authentic baseline emission data and also to ensure uniformity in the calculation of CO2 emission reductions by CDM Project developers, the Central Electric Authority in cooperation with GTZ CDM-India has compiled a data base containing the necessary data on CO2 emissions for all grid connected power stations in India. The data base currently covers the five fiscal years 2005-06 to 2008-09.CEA intends to update data base at the end of each financial year. The calculations cover all five regional grids. The document follows Tool to calculate the emission factor for an electricity system version 01.1 EB 35 formulae for calculation of emission factor for each grid. UBMPL has selected NEWNE grid as base line and in line with “Tool to calculate the emission factor for an electricity system version 1.1 EB 35” we have to consider available vintage data for 3 years. We give below data available from the CO2 Base line Data base for the Indian Power Sector referred above. Emission factor 2006-07 2007-08 2008-09 EF OM, Simple tCO2/MWh 1.01 1.00 1.01 EF BM Build Margin tCO2/MWh 0.68 Weighted average EF OM, Simple tCO2/MWh

1.0067

EF y Combined Margin tCO2/MWh 0.8433 Net Generation in operating margin GWh 379471 406142 421843 Net Generation in Build Margin GWh 102589 EF y considered for base line calculation is 0.8433 t CO2/MWh Calculations Weighted average of EF OM, Simple tCO2/MWh = (379471*1.01+406142*1+421843*1.01) / (379471+406142+421843) = 1.0067 Build Margin based on 20% of the generation For the latest year 2008-09 EF BM Build Margin tCO2/MWh = 0.68 Combined Margin EF y Combined Margin tCO2/MWh = 0.5 *1.0067+0.5*0.68 = 0.8433 Base line emission factor will be constant as Ex ante based and fixed for the entire credit period.

Leakage =0 As the project is green field new project activity and does not involve change in production process or change in quality of raw and/or additive materials or use of biomass ,hence leakage is zero. Emission reductions


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Emission reductions (ERy) achieved by the project activity will be calculated as the difference between the baseline emissions and the sum of project emissions and leakage as follows: ER y= BE y− PE y− Leakage = 12508.9 -495.07643-0 = 12009.824 Tons of CO2/year = 12014 rounded tons of CO2/year (3) Where: ER y Emission reductions in year y (t CO2e/yr) BE y Baseline emissions in year y (t CO2e/yr) PE y Project emissions in year y (t CO2/yr) LE y Leakage emissions in year y (t CO2/yr)

The values used in case of NCV j EF CO2, j EFy are not IPCC default values but are taken from Government of India, Ministry of Power, and Central Electricity Authority in technical cooperation with Indo-German Energy Programme have issued “CO2 Baseline Data base for the Indian Power Sector’ User Guide Version 5.0 November 2009. This document along with CO2 Data base excel calculations are available on web site www.cea.nic.in and as these values are lower than IPCC default values the emission reduction calculations are conservative


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Annex 4

MONITORING INFORMATION

As per the methodology, monitoring shall consist of 1 Metering of electrical energy consumption monthly by the project activity. 2 Monitoring of the weight of bricks produced in the project activity. 3 Tests to validate the project bricks meet the performance requirements and specifications at six month intervals 4 Principle raw material purchases on monthly basis. Monitoring plan: A Monitoring plan has been developed by the project participant for monitoring and verification of actual emission reduction. The Monitoring plan define a project-specific standard against which the project's performance (i.e. GHG reductions) and conformance with all relevant criteria will be monitored and verified. The aim of this monitoring plan is to enable the project have a clear, credible, and accurate set of monitoring, evaluation and verification procedures. to determine project outcomes i.e. greenhouse gas (GHG) emission reductions. The above meters used for monitoring of the project activity will comprise microprocessor-based Instruments of reputed make with desired level of accuracy. All instruments will be calibrated and marked at regular intervals so that the accuracy of measurement can be ensured all the time. Monitoring Approach The general monitoring principles are based on: _ Frequency _ Reliability _ Registration and reporting _ Frequency of monitoring The project participant has installed energy meter and load cells to monitor and record the monitored data in the log book for the project activity. Responsibilities of plant officers. We define below the responsibilities of the professionals involved in running the project activity. Shift in charge (Operations): Responsible for proper operation of the mechanical equipment and reporting hourly and eight hourly data. Shift in charge (maintenance): Responsible for proper maintenance management. The report is then sent to the Manager (plant) for his review on a daily basis


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Manager (Plant): Responsible for operation, maintenance and management of plant will be reviewing the monitored parameters shift-wise and presenting a daily executive summary report. He will be in charge of all CDM related matters and CDM officer will be directly reporting to him CDM officer: He will be reporting to the Plant manager/ Director and will be responsible for preparing required documentation and reviewing the accuracy of various reports with counter checks along with project developer. He will be responsible for internal audit every month regarding CDM project matter.


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Appendix

The economic analysis of the project activity to show financial barrier is summarised as follows

The capital cost of the project activity is Rs 22 Million compared to Burnt clay brick facility of similar capacity can be put within less than Rupees half Million. The financial parameters worked out are as follows: Cost of Raw materials per brick assuming weight of each brick as 3 kgs Raw Material Weight% Rate per kg

Rs/kg Required material kgs

Cost per brick Rs

cement 9 3.6 0.27 0.972 Slag/sand/stone 25 0.4 0.75 0.3 Fly ash 66 0.5 1.98 0.99 Total raw material cost 2.262 Labour per brick 0.45 Power per brick 0.07 Maintenance per brick 0.05 Total cost of brick 2.832 Overheads like administration,salary,interest etc

0.1

Total cost per brick 2.932 Number of bricks per year 31.05 Million Selling price per brick 2.7 Total sales 83.84 Million Total production cost 91.039 Million Loss occurred 7.2 Million CDM CER sales at 10 euros per CER after deducting CDM expenses of 0.5 Million

7.55 Million

Excel spread sheet for the above will be made available to DOE during validation and spread sheet print screen given below.


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Fly Ash Bricks

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