Eco-Friendly, Energy Generating Brick Kiln

Abstract

Pakistan holds the 3rd largest share of brick production in the world, producing over 70 billion clay bricks per year which accounts for 3% of the global production. Half of the total coal extracted from Pakistan is used as fuel to burn bricks in highly inefficient Fixed Chimney Bull Trench kilns. These kilns are highly energy inefficient as they consume a lot of fuel but have low production, and at the same time, the quality of the bricks produced is generally not satisfactory. Moreover, they also release millions of tons of carbon emissions, extremely dangerous PM 2.5, carbon black, Sulphur oxides, nitrogen oxides, and heavy metals into the atmosphere. The problem not only lies in kiln design, the composition of the clay bricks also plays a huge role in adding to the inefficiency of the whole brick manufacturing process. This project adopts a comprehensive approach to address these challenges by designing and implementing mechanisms to make the whole clay brick manufacturing process eco-friendly, energy-efficient, and an economically viable source of energy production. In this project the traditional all-clay material composition of clay bricks was altered by adding 3 different waste materials; i.e. Fly Ash, Waste Glass Powder, and waste Cigarette Butts, to enhance their performance, manage the solid waste and minimize environmental impact. The bricks prepared by making these additions in the clay composition were baked quicker, were lighter in weight, had better insulation due to superior thermal conductivity, and had nearly a 10% lesser thermal mass relative to the conventional clay bricks. The strength and weather resistance capability of the bricks prepared were no less than the 1st class conventional clay bricks. Moreover, an efficient 3D kiln design equipped with a modern Waste Heat Recovery System is proposed. An elaborative 3D animation of the whole operational procedure of the proposed design is also made for a clearer explanation. The approach applied properly can lead to the production of up to 1 MW of electricity through a single kiln while protecting the environment as well. Additionally, the presented model of the kiln also includes a robust mechanism to further filter the highly toxic gases by directing the flue gases leaving the waste heat recovery system into a microalgae pond. This project aims to transform the clay brick manufacturing industry by developing sustainable and energy-efficient alternatives. The adoption of these cutting-edging strategies will not only improve the air quality and lessen the environmental footprint of brick production but also solve the energy crisis of Pakistan.