LCA of Traditional Bricks in Western MH

Shridhar KumbharCentre for Technology Alternatives for Rural Areas

IIT BombayICAER

10-12th December 2013

Content•Clay Bricks•Types clay brick making•Study area•Need of LCA in Clay Bricks•Production process•Energy use and Impacts•Role of LCA•Objective and Scope of work•Material and Methods •LCA by SIMAPRO 7.3.3•Result and discussion•Conclusion

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Clay Bricks

• Oldest man-made technology• Discovery -Indus valley Civilization

• One of the major Building Construction Material• India- 2nd Largest producer of Bricks in world.• Production growth rate- 4% /year• 2001- 140 million• 2011- 250 million (UNDP, 2013 & Maithel et al, 2012)

• 2nd Largest consumer of coal after Steel Industry in India- 35 million tones coal consumption/year

(Lalchandani & Maithel, 2013)

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Types of brick kilnsType of kiln Specific Energy

Consumption ( MJ/kg of fi red brick )

Specific coal consumption ( tons/100,000 bricks )

Production Contribution

Continuous Kiln

VSBK (India, Nepal, Vietnam)

0.7-1.0 11-16 5-10%

Fixed chimney BTK (India)

1.1-1.5 17.5-24 20-25%

Movable chimney BTK (India)

1.2-1.75 19-28 5%

Tunnel Kiln (Vietnam) 1.4-1.6 22-25 5-10%

Modern Tunnel kiln (Germany)

1.1-2.5 17.5-40

Intermittent kilns

Clamp and other batch kiln (Asia)

2.0-4.5 32-71 50-55%

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Ref.- Teri, Brick by Brick, 2008

Study Area selection

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Data collection from Brick kiln site

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Production process

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Production process with emission

Life Cycle Energy use and Impacts

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-20%-60%-20%

Role of LCA

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• Provides A Scientific Approach• Detailed analysis –

• Raw material, • Process • Fuel consumption• Relative impact on environment

• LCA provides Holistic view of resource use and impacts of products/process by considering cradle to gate concept.

Objectives and Scope• Objectives• To study the energy consumption pattern

in traditional bricks• To study and analyze the natural resource

consumption• To study Socio-economic impacts of

traditional bricks in Western MH.• Scope• Traditional Bricks production in Western

Maharashtra

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Steps

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On-site data collection

• Interviews of Brick kiln owner, workers and stakeholders

• Sources of raw material• Distance travelled• Fuel required for brick kiln and transport• Emissions• Socio-Economic Impact

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Field dataConsumption per

1000 bricks (in terms of 3x4x9)

BK 1 BK 2 BH 6 BK 3 BK 4 BK 5 BK 6 BK 7 BK 8 BK 9 BK 10 BK 11

Soil ( in brass)

0.90 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

Foundry Sand ( in

brass)

0.06 0.04 0.03 0.06 0.03 0.02 0.06 0.08 0.03 0.13 0.13 0.03

Bagasse (in tons)

0.11 0.13 0.14 0.11 0.17 0.13 0.11 0.13 0.14 0.11 0.23 0.14

Coal powder (in tons)

0.06 0.08 0.08 0.08 0.08 0.09 0.06 0.08 0.08 0.08 0.10 0.08

Coal(tons)

0.04 0.035 0.04 0.03 0.02  0.03 0.040.03

50.04 0.03 0.02 0.04

Coal Powder(tons)

0.08 0.08 0.03 0.06 0.03  0.05 0.08 0.08 0.03 0.06 0.03 0.03

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Primary data

• Mining of soil is done manually and transported with tractors or truck

• Bagasse is taken from sugar factories nearby 50 km area.

• Coal and coal powder is imported from Chandrapur, Wani area- avg. transport distance 470 km

• Foundry sand is taken from nearby foundries about 15 km radius area

• Drying of green bricks by heat of natural solar energy

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LCA work

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Sr. No.

Material Database from Sima Pro 7.3.3

1 Soil Clay unspecified in ground

2 Water In water

3 Air In Air

4 Coal Hard coal mix, at regional storage/ UCTE

5 Land use Transformation, from arable , non irrigated

6 Transport Transport, combination of truck, diesel powered / US

7 Bagasse Bagasse from sugarcane, at sugar refinery Mh.

8 Foundry Sand Foundry sand, at mine / US – Waste generated from foundry

9 Air emissions Airborne emission

10 Heat waste Emission to soil

11 Particulate matter

Waste flow

User Interface to choose impact assessment

method

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Impact category Unit Total Bricks

Hard coal /UCTE U

Transport, /US Bagasse

Foundry sand, at mine/US

Disposal, /CHS

Carcinogens DALY 2.16E-10 0 1.76E-10 5.21E-16 4.01E-11 0 4.03E-13Resp. organics DALY 1.92E-11 0 1.47E-11 4.18E-17 4.35E-12 0 1.53E-13Resp. inorganics DALY 4.27E-07 4.22E-07 4.05E-09 4.67E-15 7.73E-10 0 1.59E-10Climate change DALY 2.07E-08 1.69E-08 3.35E-09 9.32E-15 4.14E-10 0 1.33E-11Radiation DALY 3.31E-12 0 1.92E-12 0 1.38E-12 0 4.28E-15Ozone layer DALY 1.32E-12 0 4.47E-13 1.31E-21 8.61E-13 0 1.28E-14

Ecotoxicity PDF*m2yr 4.34E-05 0 2.44E-05 1.23E-11 1.87E-05 0 1.96E-07Acidification/ Eutrophication PDF*m2yr 0.014984 0.014402 0.000496 1.8E-09 8.23E-05 0 3.66E-06Land use PDF*m2yr -0.10222 -0.10443 0.001165 0 0.001043 0 -1.9E-06

Minerals MJ surplus 0.000263 0 0.000114 0 0.000148 0 8.64E-07

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Result and DiscussionDamage assessment- Eco-indicator 99 (I)

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Damage assessment by Material

Impact category Unit Total Bricks

Hard coal mix, /UCTE U

Transport, /US Bagasse

Foundry sand, at mine/US

Disposal, /CH S

Total Pt0.04923

90.04789

80.00103

8 1.8E-090.00028

2 0 2.1E-05Carcinogens Pt 2.56E-05 0 2.08E-05 6.16E-11 4.74E-06 0 4.76E-08Resp. organics Pt 2.27E-06 0 1.74E-06 4.94E-12 5.15E-07 0 1.81E-08Resp. inorganics Pt

0.050503

0.049914

0.000479 5.52E-10 9.14E-05 0 1.88E-05

Climate change Pt

0.002445

0.001999

0.000396 1.1E-09 4.89E-05 0 1.57E-06

Radiation Pt 3.91E-07 0 2.27E-07 0 1.63E-07 0 5.06E-10Ozone layerPt 1.56E-07 0 5.28E-08 1.55E-16 1.02E-07 0 1.51E-09Ecotoxicity Pt 1.93E-06 0 1.09E-06 5.47E-13 8.35E-07 0 8.75E-09Acidification

Pt0.00066

80.00064

22.21E-05 8.04E-11 3.67E-06 0 1.63E-07

Land use Pt -0.00456 -0.00466 5.2E-05 0 4.65E-05 0 -8.6E-08

Minerals Pt0.00015

1 0 6.54E-05 0 8.54E-05 0 4.97E-0720

Single Score results - Eco-indicator 99 (I)

Comparison with Single Score

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Network - Eco-indicator 99 (I)

Impact Assessment Results

ImpactEco-indicator 99 (I)

Eco-indicator 99 (E)

Eco-indicator 99 (H)

Human Health

45% 30% 30%

Eco-system quality

35% 40% 50%

Resources 20% 30% 20%

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Conclusion• Environmental Impact depends upon

quantity and quality of coal used in kiln.

• High socio-economic impact• Easy Traditional technology• Movable technology• Low capital investment• Need to modify traditional technology to

reduce the pollution

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THANK YOU

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