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The VSBK technology outside
of China
Several attempts have been
made to transfer the VSBK technology from China to other
countries |
Beginnings in Nepal
IN 1991 under a GTZ_GATE project,
a twin-shaft VSBK was constructed at Kathmandu Brick Factory,
Lubhu, Nepal. One more VSBK was built in Biratnagar, Nepal.
With an energy consumption of 1 MJ per kg of fired bricks,
the energy saving potential of the VSBK technology was clearly
demonstrated.
However, both kilns ran into early technical problems that
the entrepreneurs could not solve unaided. In spite of strong
indications that the technology had a great potential, initial
enthusiasm was eventually replaced by disappointment and the
two Nepalese VSBKs were closed down. The lack of access to
reliable technical support was responsible for the failure.
An enthusiastic welcome in Bangladesh
With the assistance of SDC, a brick
kiln owner from Bangladesh visited the VSBK units in
Nepal. Inspired by what he saw, the entrepreneurs subsequently
built a VSBK near Dhaka. Unfortunately, the need for specialized
technical assistance was again overlooked. As a consequence,
this Bangladeshi pilot plant was never commissioned.
The attempt to transfer know-how to Bangladesh was a spontaneous,
private initiative. Unfortunately, the entrepreneur did not
know the finer aspects of the technology and without the requisite
technical back up; he made fundamental mistakes in the design
and construction of his kiln.
Production capacity becomes an issue in Pakistan
In 1993, a VSBK was demonstrated in Peshawar,
Pakistan; again under GTZ-GATE development projects.
This was followed by construction of several VSBK units in
the same region.
In Pakistan, the VSBK demonstration units (with twin shaft
design) were marketed as an alternative to Bull’s Trench
Kiln (BTK) technology. However, the typical production level
of a BTK varies between 15’000 to 50’000 bricks
per day in Pakistan. With only two shafts, the VSBK demonstration
units could not produce more than 3’000 bricks per day.
There was a clear imbalance between output capacity of these
dissimilar technologies.
This difference proved to be a major stumbling block in attracting
the attention of BTK owners toward VSBK. Inappropriate information
on the limits and potentials of VSBK technology resulted in
a misjudgment in its marketability. As a consequence of this
oversight, the VSBK technology made no significant break-through
in Pakistan beyond the early pilot project processes.
Alternative fuels tested in Sudan
A VSBK was adapted for the use in Sudan
during 1996. A pilot kiln was constructed by the Building
and Road Research Institute (BRRI) of the University of Khartoumin
in cooperation with GTZ-GATE. The fuel used was carbonized
agricultural waste from cotton stalks, sunflower stalks or
bagasse. The carbonized fuel, reduced to a granular size was
dispersed among the green bricks when loading the kiln from
the top. This VBSK was the first of its kind, which uses carbonized
agricultural waste. No recent updates on the operations of
the technology are available.
Large scale production in Afghanistan
In 1995, the Pakistan VSBK-GTZ project provided
training for engineers and kiln-crews from Herat, Afghanistan
in order to construct one 6-shaft VSBK for the Afghanistan
Rehabilitation & Energy Conservation Association. Private
entrepreneurs constructed three additional 6-shaft VSBK units
and a total of 4 such units (i.e. 24 shafts, each of 1m x
1m) were reported to be in operation in 1996. The status of
these kilns today is not known.
Commercial success in India - 1997
In 1996, SDC (Swiss Agency for Development
and Cooperation) supported an organized transfer of VSBK technology
to India through an elaborate Action Research Programme. The
process was initiated through a team of local and international
experts. This team was commissioned to analyze the mistakes
committed in earlier attempts to transfer the VSBK technology
beyond its native environment and to identify the success
factors responsible for its growth in China. Based on the
outcome of the study, a project was formulated for the transfer
of the VSBK technology to different geographical regions in
India.
The first VSBK kiln was set up in Central India at Datia in
Madhya Pradesh. The kiln was based on Chinese designs and
was set up in joint partnership with an experienced local
brick clamp owner. Initially, a team of experienced Chinese
specialists provided on-site operational support services.
Local support and key personnel were provided by Development
Alternatives to assist in the construction process and operation
of the kiln. This pilot kiln confirmed the potential energy
savings associated with VSBK and demonstrated the technical
feasibility of short cycle brick firing using indigenous soils
and fuels.
Buoyed by encouraging results, a second kiln using slightly
larger shafts was constructed in Orissa, Eastern India. This
was quickly followed by a third kiln for firing extruded bricks,
set up in association with (and at the behest of) a reputed
manufacturer of fired clay products — COMTRUST in Kerala,
South India. All of these early kilns assisted in the building
of local capacity for design, construction and operation while
demonstrating improved environmental performance. The performance
of the kilns was continuously upgraded with the assistance
of local partners, consultants and international back stoppers.
As of May 2003, more than forty commercial kilns are operational
throughout the whole country.
The technology dissemination phase has helped in paving the
way for a purely commercial multiplication process in India
through various agencies the prime being Development Alternatives.
Successful introduction in Vietnam - 2001
An UNDP project funded by “Small
Grant Programme of the Global Environment Fund” introduced
the first ever VSBK in Vietnam in 2001. The VSBK was constructed
under the supervision of Chinese experts and the VSBK became
operational in December, 2001.
After the successful operation of this VSBK, about one hundred
VSBKs were built across Vietnam in a short period of two years.
However, most of the VSBKs were self copied without proper
design and construction advice from experts, which resulted
into complication in operation, uneven shaft size and excess
flue gas on the top of the loading platform. However, the
Ministry of Science and Technology awarded a gold medal to
a VSBK company for energy saving and environmental performance
in December, 2003.
This clearly indicates that if the VSBK technology is properly
transferred, the VSBK technology know-how locally anchored,
there is an immense potential to transfer and bride the existing
traditional brick making system into an environmental cleaner
future.
Reintroduction of VSBK in Nepal - 2003
Technical problems faced during the initial introduction of
the VSBK technology in Nepal in 1991 were solved during a
nearly 10 yearlong technology development phase concentrated
mainly in India. Thus a global VSBK technology dissemination
potential was realized.
The growing concern of environmental pollution resulted from
brick production in Kathmandu Valley made it an urgent issue
to change the prevailing BTK firing process with an environmentally
accepted brick firing technology. The VSBK technology, after
a commercial success with more than 40 operating kilns in
India, was an obvious choice.
A feasibility study, conducted by Skat Consulting in 2002,
confirmed the commercial potential of VSBK with a general
positive impact on the environment. Thus a VSBK Technology
Transfer Programme in Nepal was signed between Swiss Development
Agency and HMG, Nepal in February 2003 for reintroducing it
in Kathmandu Valley.
The introduction strategy of the VSBK technology to Nepal
includes a demonstration phase that is presently being implemented.
During this phase two pilot kilns have already been constructed.
Brick quality, environmental and energy performance confirmed
previous efforts, notably from India. An economic study as
well as feed backs from entrepreneurs proof the economic viability
of the new technology in the Nepali context. The long term
technical support required by future entrepreneurs has been
ensured through a local network of commercially operating
support service providers trained by the VSBK programme.
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