Concept Note | Eco Friendly Automatic Clay Brick Manufacturing Project · 2017-06-13 · Concept Note | Eco Friendly Automatic Clay Brick Manufacturing Project . 2 | Page . Energy

Concept Note | Eco Friendly Automatic Clay Brick Manufacturing Project

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Energy Efficient, Eco Friendly Automatic Clay Brick Manufacturing Project

(Gas Fired Technology)

Fully Automatic Gas Fired Tunnel Kiln Fully Automatic Gas Fired Tunnel Kiln is the most advanced tunnel kiln in the clay brick manufacturing industry. It is highly energy efficient, environment friendly, low emission, full automatic firing system, more automatic production line compared to traditional kilns.

In general, brick making process divided to following phases:

1. Clay Preparation / Raw material treatment

2. Green Brick Forming

3. Brick Drying

4. Pre-Kilning

5. Brick Firing

Following are some key facts for a fully automatic brick production system:

Basic Info

Type of Bricks Clay Solid Bricks / Perforated Bricks (25% void max)

Other Products Facing Bricks, Pavement Bricks & Tiles

Optional Product Roof Tiles, Button Tiles etc.

Brick Size Solid Bricks: 9.5“ x 4.5“ x 2.75”

Pavers: 8” x 4” x 2”

Facing Bricks:8” x 2” x 0.6”

Production Capacity 120,000 bricks (Solid/Perforrated) / day, or

80,000 pavers / day, or

6000 sqm facing bricks / day, or (@ 100% utilization)

Firing Method Gas Fired

Energy Source Coal (Coal Gasification)

Coal Consumption 16 Tons / 100,000 bricks (@6500kCal/kg++)

Land Requirement 8 Acres +

Annual Cycle 330 days production

Operation Period Forming 16 hours /day


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Drying & Firing 24 hours / day

Number of Tunnels Two tunnel for drying

One tunnel for Pre-heating

One tunnel for firing

Housing Enclosed workshop

Open Shed for Clay and Coal Quarry

Brick Setting Double Stage Setting (semi-automatic)

Kiln Temperature 900° C ~ 1050° C

Fire Control Fully Automatic Via Programmable Console

No. of Production Labor 18~20 persons for 2 shifts

10 persons for 3 shifts

Financial Info Sl. Head Amount

1 Forming, Drying, Burning Machineries 216,090,739.20 2 Factory Shed 62,780,229.00 3 Administrative Building Construction 33,607,020.00 4 Generators 20,159,840.00 5 Substation, Cable 10,620,000.00 6 Support Vehicles 16,520,000.00 7 Local Expenses on Dryer and Pallet Making 20,047,000.00 8 Furniture & Fixture 1,022,000.00 9 Office Equipment and Supply 1,000,000.00

10 Pre-Project and Related Expenses 18,510,000.00 11 Customs Duty and Tax 19,084,046.40 12 Trial Run and Related Expenses 13,395,040.00

Total Cost 432,835,914.60 BDT Forty Three Crore Twenty Eight Lac Thirty Five Thousand

Nine Hundred Fourteen Only. Note: Above budget is estimated based on standard condition and excludes land, land

development, IDCP, IWC. Actual cost of the project will be calculated based on the project location, surrounding condition, soil profile, clay report, financing source(s) and so on.

Means of Finance

Source of finance Syndicating Finance: IDCOL/BIFFL

Rate of Interest 9% Debt-Equity Ratio Up to 70:30

Payback 5 years (Approx) Tenure 8 years + 1 years (Grace)


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Cost Analysis

Product A- Solid Bricks Yr1 Yr2 Sales

Clay cost per pc 0.66 0.66 Coal cost per pc 1.36 1.36 Electricity per pc 1.06 1.00 Diesel per pc 1.36 1.28 Direct Labor per pc 0.51 0.50 Total Cost per pc 4.94 4.79 9.00

Product B- Facing Bricks Clay cost per pc 0.09 0.09 Coal cost per pc 0.28 0.28 Electricity per pc 0.26 0.24 Diesel per pc 0.33 0.31 Direct Labor per pc 0.51 0.50 Total Cost per pc 1.46 1.42 16.00

Product C- Roof Tiles Clay cost per pc 0.57 0.57 Coal cost per pc 2.08 2.08 Electricity per pc 1.97 1.85 Generator Diesel per pc 2.52 2.37 Direct Labor per pc 0.51 0.50 Total Cost per pc 7.65 7.38 140

Product D- Pavers Clay cost per pc 0.29 0.29 Coal cost per pc 0.92 0.92 Electricity per pc 1.06 1.00 Generator Diesel per pc 1.36 1.28 Direct Labor per pc 0.51 0.50 Total Cost per pc 4.13 3.98 14.00


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Product Images

Comparative Analysis on Hybrid Hoffman, Coal Fired Tunnel and Modern Gas Fired Tunnel Technology for

Brick Manufacturing

In this study we will analyze the difference between Hybrid Hoffman, Coal Fired Tunnel Technology and Modern Gas Fired Tunnel Technology. All the technologies originated in Europe nearly between 50 to 100 years ago and been developed gradually in course of time matching the evolution of newer type of machines as well as the development of basic science related to the ceramic industry. Compared to the FCK and ZigZag kiln system all these technologies are far more efficient, clean and environment friendly, while each of these technologies have their unique advantages and disadvantages.

Parameters Hoffman Kiln Coal Fired Tunnel Kiln

Modern Gas Fired Tunnel Kiln

Output Product 1. Clay Solid Bricks

2. Perforated Bricks

1. Clay Solid Bricks

2. Perforated Bricks

1. Clay Solid Bricks 2. Perforated Bricks

3. Facing Bricks 4. Roof Tiles 5. Pavement Tiles 6. Non-load

bearing pavement tiles

7. Cladding Tiles Product Quality Average quality;

cannot ensure uniform color.

Average quality; cannot ensure uniform color.

Very high with uniform color and strength; various color product; Close to ceramic bricks

Land Requirement

Approx. 5 to 6 Acres Approx. 5 to 6 Acres Approx. 5 to 6 Acres

Coal Consumption

18 to 20 tons / 100,000

14 to 16 tons / 100,000

Around 14 - 16 tons / 100,000

Combustion Method

Internal Internal Fully External

Clay Processing Usually Single Stage Single/Double Stage Triple Stage

Green Brick Making

Automatic Automatic Automatic

Setting Stages One One/Two Two

Brick Setting Manual/Robotic Manual/Robotic Semi-Automatic/ Fully Robotic

Dryer Type Low height multiple tunnel (16-20 tunnels) with no

Low and High height multiple tunnel (16 or Single tunnels)

Single tunnel with state-of-the-art measurement /


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measuring or controlling system

with no measuring or controlling system

monitoring and controlling system

Kiln Type Rectangular / Oval type multiple chamber (24~56 doors) kiln with no measuring or controlling system

Single Chamber Tunnel with some measuring or controlling system

Single Chamber Tunnel type kiln with state-of-the-art measurement / monitoring and controlling system

Fuel Pulverized Coal Dust

Pulverized Coal Dust

Coal Gas produced from small coal briquette

Fire control Fully Manual Fully Manual Fully Automatic by Programmable Console

Dependency on Firemen

Fully Dependent Fully Dependent No Dependency

Electronic Control

No electronic control in dryer and kiln

No electronic control in dryer and kiln

Fully electronic control in dryer and kiln

Loading and Unloading

Double Stage loading and unloading; one stage automatic; one stage manual

Double/Single Stage loading and unloading; one stage automatic; one stage manual

Double Stage loading and unloading; Semi-Automatic

Brick Separation in drying chamber

All bricks touch each other

All bricks touch each other

All bricks are separated; never touch each other

Pre-Kiln No Pre-Kiln No Pre-Kiln System consists a Pre-Kiln to ensure better drying before sintering

Housing Open Shed Open Shed Fully Enclosed Shed

Electricity Consumption

Low to Medium Medium to High Medium to High

Production Cycle per Year

Around 300 days Around 300 days Around 330 days or more

Human resource 70 to 120 and more 60 to 80 and more Around 50 to 70

Export Market None None Export market available for clay tiles, facing bricks, cladding tiles etc.

Visual

Documents Require for Company Incorporation

1. Tax Identification Number of all Director 2. National ID/Voter Card of all Director 3. Non-Bangladeshi Director (Passport & National ID Card Copy) 4. Passport Size Photograph 12 copies/each Director 5. CV of all Directors 6. All Directors Educational Certificate photocopy 7. Company Registered office Address 8. All Directors Present & Permanent Address FOLLOWING DOCUMENTS ARE REQUIRED TO RUN THE COMPANY & APPLICATION FOR BANK LOAN 1. Incorporation Registration Certificate (JSC) 2. Company Bank Account 3. Trade License 4. Company TIN & VAT 5. Board of Investment (BOI) Registration 6. Site Clearance from DOE 7. Fire License (Fire Protection System) 8. Import Registration/Export Registration Certificate 9. Trade Organization Membership (BBMOA) 10. Company Seal, Pad, Voucher, Share Certificate 11. All Directors Asset List (Movable & Immovable) with 6 months Bank Statement 12. Project Profile & Project Feasibility Report 13. Net Worth Statement 14. Tax file / IT-10B Additional Documents Require for Auto Bricks Plant with CDM benefit 1. NOC from Local Union Parishad 2. Meeting on Auto Bricks with local people/neighbour (Meeting Invitation Letter,

Meeting Photograph, Meeting Minutes & Signature of meeting attendee 3. Electricity Assurance Letter from Local Palli Biddyut ( Rural Electrification

Board) 4. Transformer Quotation with layout plan 5. Details site plan of Proposed Project 6. Pro-forma Invoice of Machinery with Catalogue 7. Land-deed i.e. Mutation, Parcha, Non-encumbrance Certificate (from local AC

(Land) office) Up-to-date Land Tax Payment Receipts 8. Carbon Development Mechanism (CDM) Contract 9. Filling the Bank Prescribed Loan Application Form

Post Sanction / Pre Disbursement Phase

Pre-Project Expenses

Amount (Tk.) Sub Total (Tk.) Permission/Certificates Joint Stock Registration 275,000 Trade License 15,000 Company TIN 5,000 Company VAT Registration 55,000 BOI Registration 95,000 IRC Certificate 85,000 Trade Organizations Membership Certificate 100,000 Site Clearance from DoE 300,000 Brick Burning License from DC Office 150,000 NOC from Local Chairman 100,000 NOC from Agriculture Authority 25,000 Electric Board Permission (REB, PDB, PWD etc.) 20,000 Certificate from Local Fire Service and Civil Defense 25,000 (Approx.) 1,250,000 Baseline Clay Test (4 sample tests) 160,000 Soil Test (40 ~ 60 bore) 120,000 Feasibility Report 100,000 380,000 IDCOL Channel EIA (Environmental Impact Assessment) 300,000 IDCOL Processing Fee 300,000 Third Party Consultant Fee 300,000 Digital Survey 100,000 1,000,000 Other Financial Channels Arrangement fee for fund raising activities 800,000 Participation / signing fee for fund contribution 600,000 (*% of contribution)

1,400,000 Design Project layouts, plans, factorydesigns, drawings etc. 700,000 Other Civil Construction Designs 300,000 1,000,000 Others Engineering land survey 150,000 Land Pre-Vetting 200,000 350,000

Total

2,730,000 or 3,230,000

2,730,000 or 3,230,000

Remarks: Above total differs depending on the financing channel to be used for fund raising.

Vetting * - Land Name Transfer ** - Mortgage Fee *** - Other legal counsel and syndication charges **** - Equity Injection -

* Depends on total security size and nature ** Depends on value of property *** Depends on total security size ****Depends on total debt amount and syndication member

Approximate Total 30,000,000

Product Description

1. Solid Clay Brick (Our Primary Product): A brick is building material used to make walls, pavements and other elements in masonry construction. Traditionally, the term brick referred to a unit composed of clay, but it is now used to denote any rectangular units laid in mortar.

2. Perforated brick (Brit.): A brick or block in which holes passing through it exceed 25% of its volume, and in which the holes are not small (as defined under solid masonry unit, 2); up to three holes, not exceeding 5 sq in.

3. Paving Tile. : A glazed decorated tile used for floors, sidewalks, courtyards, and sometimes for walls.

4. Face brick. : Brick used in the face of a wall; usually: brick made especially for facing purposes by selecting clays to produce desired color or by special surface treatment.

5. Roof Tile: Roof tiles are designed mainly to keep out rain, and are traditionally made from locally available materials such as terracotta or slate. Modern materials such as concrete and plastic are also used and some clay tiles have a waterproof glaze.

6. Cladding Tile Brick: (architecture) A building construction technique in which an external, non-structural, brick wall conceals a structural wall of another material (such as timber or steel). Many home buyers like the low maintenance and quality look of a brick veneer home.