CLEANER BRICK PRODUCTION FEASIBILITY STUDY MALAWI. 12 th June 2012

Transcription

1 CLEANER BRICK PRODUCTION FEASIBILITY STUDY MALAWI 12 th June 2012

2 Implemented by: Supported by:

3 CLIMATE Green brick making May October Low humidity and temperature Firing process June October Assessment Quicker drying time, more production Efficient drying Extended firing season Conducive to brick production in VSBK system

4 SOIL Soil quality Soil Quality is inconsistent Varied type ranging from lateritic to black Presence of sand and granular materials High FeO content Higher vitrification temperature Sufficient reserve Assessment Detailed analysis required for optimization of production process Suitable for brick making in VSBK with modifications Improved strength Consistent colour Lower breakage

5 BRICK MAKING PROCESS Green brick Cutting of soil, watering and ageing for 24 hours Moulding with double / four moulds Slop moulding process followed Shape, size and finish not satisfactory and uniform Very high water content and shrinkage Proper moulding process not followed Assessment Room for sufficient improvement Mixing and moulding training Use of sand moulding Improved cutting devices Introduction of mechanization in mixing..will lead to vastly improved quality

6 FIRING PROCESS Observations Traditional method scoved clamps Fixed chimney BTK Assessment Reduced energy consumption Improved and consistent quality Extended brick production Lower emission levels

7 PRODUCT QUALITY Observations High breakage No consistent colour and strength Different sizes of fired bricks Poor shape and finish Various fired brick qualities Assessment Introduction of VSBK technology as a system and not only as a firing technology

8 KILN CONSTRUCTION Observations Availability of construction materials e.g. cement, lime, bricks, sand etc. Expert masons available Refractory materials available Steel materials available Availability of mechanical workshops Assessment Training and capacity building of masons for specialized kiln construction Capacity building of local mechanical workshops in producing VSBK equipments and accessories

9 ENERGY CONSUMPTION Observations Sufficient quantity of coal available Coal is of high calorific value and high volatility Fire wood consumption 15 t / 40,000 bricks SEC : MJ/kg increased deforestation Assessment Potential to explore a lower CV and low volatile coal lower price Introduction of internal fuel extremely reduced energy consumption Introduction of VSBK (SEC : 0.8 MJ/kg) energy reduction by 75%

10 ENVIRONMENT SCENARIO Observations Extremely high consumption of energy Incomplete and inefficient combustion of fuel Inefficient firing process and habit Absence of any pollution control measures Absence of E&E monitoring agencies Assessment Introduction of VSBK.. potential to reduce SPM by 90% Training of firemen in benchmark firing process Creation of awareness on health hazards due to high emission levels

11 MARKET SCENARIO

12 PRODUCTION COST Raw Material Internal Fuel : 2650 MK Others : 100 MK Green Brick making Charges : 700 MK Maintenance : 450 MK Green Brick Lifting : 400 MK Firing Expenses : Coal : 1660 MK Labour : 720 MK Overheads : 570 MK Wastage : 250 MK Total : 7500 MK

13 Per Brick Lilongwe Blantyre Mzuzu Producti on Cost If waste used 7.5 MK 4.85 MK 7.75 MK 5 MK 5.3 MK 3.8 MK

14 ECONOMICS Parameter 1 Shaft 2 Shaft Investment Production (300 days) Production Cost Entrepreneurs' Share Selling Price Turnover Annual Profit RoR 8 million 1.2 million 7.5 MK / brick 1.5 MK / brick 12 MK / brick 14.4 million 3.6 million ~3 years 15 million 2.4 million 7 MK / brick 1.5 MK / brick 12 MK / brick 28.8 million 8.4 million ~2 years

15 SOCIAL AND INSTITUTIONAL ASPECTS

16 WORKING CONDITIONS Number of Workers varies from 1 to 15 Only men are engaged in the brick industry Age profile : young 12 hours per day / 6-7 days week Relatively unstable work force No division of labour Salaries uniformly paid at 250 MK per day Current skills of kiln workers are sub-standard or un-skilled Mainly on-the-job training

17 ASSESSMENT Improvement of working conditions : Safety & Health Job creation for local workers Through training Leads to improved output of workers Leads to lower labour costs

18 INSTITUTIONAL Stakeholders: Private sector (willingness to invest) Governmental bodies (room for improvements; green growth strategy) End-consumers (ability to pay more depending on quality) Mainly small-scale enterprises No licensing observed New SME promotion policy Standards for brick quality not enforced

19 POTENTIAL To strengthen private entrepreneurs economic development approach (small enterprise support) To improve Governmental services and enforcement of laws (private business is protected by the State, and in turn Government gets more taxpayer money) To develop and execute regulations for improved working conditions, standards, and quality of bricks for higher productivity

20 THANKS