Hybrid Hoffman Kiln - Instituto Nacional de Ecología y Cambio

Hybrid Hoffman Kiln - Instituto Nacional de Ecología y Cambio

Taller sobre Políticas Públicas para Mitigar
Impacto Ambiental de Ladrilleras Artesanales
Guanajuato, Guanajuato México
Septiembre 4 al 6, 2012.
Sesión IV. Experiencias y alternativas tecnológicas
"Hybrid Hoffmans and Improved Zig Zags"
I$ikhar
Hussain,
Clean
Energy
Alterna7ves,
Inc.
sabu.hussain@yahoo.com,
sabu.hussain@cleanenergyalt.com,
Citar como:
Hussain, I. (2012). Hybrid Hoffmans and Improved Zig Zags. En: INE Memorias del Taller sobre políticas
públicas para Mitigar Impacto Ambiental de Ladrilleras Artesanales (Sesión IV. Experiencias y alternativas
tecnológicas ). Guanajuato, México Septiembre 4-6, 2012. [diapositivas de PowerPoint-PDF]. Instituto Nacional
de Ecología. Disponible en:http://www.ine.gob.mx/cenica-memorias/1110-taller-ladrilleras-2012. Fecha de
acceso: Septiembre 17, 2012.
Hybrid Hoffmans
and
Improved Zig Zags
Iftikhar Hussain
CEA
Hybrid
Hoffman
Kiln
(HHK)
•  Developed
in
Germany,
modi1ied
in
China
•  Plant
combines
an
ef1icient
annular
kiln
with
waste
heat
recovery
mechanism
and
internal
fuelling
systems
•  Versatile,
Ef1icient
&
Clean:
*
Produces
high
quality
bricks
of
any
size,
shape
and
pigmentation
*
High
thermal
ef1iciency
*
Very
low
emitter
of
local
and
GHG
pollutants
Hybrid
Hoffman
Kiln
(HHK)
Design
Speci8ication
• 
Permanent
roof
and
brick
walls
insulated
with
clay
• 
Smallest
size
consists
of
22
1iring
chambers,
producing
15
million
pieces
annually
• 
Forced
draft
laminar
air1low
• 
8
Drying
chambers,
each
70m
long
Hybrid
Hoffman
Kiln
(HHK)
Production
Process
Three‐stage
interdependent
and
integrated
production
process:
•  Green
Brick
Production
Line
(Production
Phase)
•  Drying
of
Green
Brick
(Drying
Phase)
•  Firing
of
Green
Brick
(Firing
Phase)
Hybrid
Hoffman
Kiln
(HHK)
Green
Brick
Produc.on
Capacity
50,000
/day
Clay
&
Coal
being
mixed
Double
Shaft
Mixer
Hybrid
Hoffman
Kiln
(HHK)
Green
Brick
Produc.on
Phase
Vacuum
Extruder
in
Opera7on
Green
Brick
CuEng
Workers
arranging
green
bricks
on
trolleys
Hybrid
Hoffman
Kiln
(HHK)
Brick
Drying
• 
Hot
air
for
drying
is
forced
into
the
tunnel
from
the
annular
kiln.
The
drying
cycle
lasts
for
about
26
hours
at
about
120
o
C.
• 
Drying
Capacity
60,000/Day
Green
bricks
entering
drying
chamber
Dried
green
bricks
Hybrid
Hoffman
Kiln
(HHK)
Brick
Firing
The
dried
green
bricks
are
unloaded
manually
into
the
annular
HHK
kiln.
The
speed
of
the
firing
is
1.25
m/h
at
a
sintering
temperature
of
about
950oC–1050oC.
HHK
Firing
Chamber
Hybrid
Hoffman
Kiln
(HHK)
Bene8its
• 
Aesthetically
attractive
and
structurally
sound
• 
Compact,
less
land
than
FCK
and
yet
produces
6
times
more
bricks
• 
Weather
Proofed
:
production
is
for12
months
• 
Highly
energy
ef1icient,
uses
about
12‐14
Tons
per
100,000
bricks
• 
Very
low
pollution
• 
Economically
viable,
low
production
costs,
good
quality
products
Hybrid
Hoffman
Kiln
(HHK)
HHK
Emission
Monitoring
Results
Results
of
the
stack
monitoring
data
for
Universal
Bricks
:
Parameter
Value
Flue
gas
temperature
(°C)
37
(range
was
35‐38)
Velocity
(m/s)
3
(range
was
2‐4)
SPM*
(mg/
m3)
20.3
(range
was
15.8‐26.9)
*Stack sample (SPM) were collected for a period of 2 hours each
Source: Khan, A.H. (2008) “Energy and Stack Emission Monitoring In Hybrid Hoffmann Kiln (HHK) Type
Universal Kiln”, World Bank, Dhaka
Hybrid
Hoffman
Kiln
(HHK)
Air
Quality
Measurement
Comparison
of
ambient
air
quality
at
the
kiln
gate
and
national
standards
Parameter
Value
at
Kiln
Gate
SPM
(mg/m3)
20
National
Standards
1000
CO
(ppm)
1.20
9
Source: Khan, A.H. (2008) “Energy and Stack Emission Monitoring In Hybrid Hoffmann Kiln (HHK) Type
Universal Kiln”, World Bank, Dhaka
Improved
ZigZag
Kiln
ZigZag
Kiln
Salient
Features
of
Traditional
ZigZag
kiln
• 
Temporary
Roof
(300mm)
• 
Outside
wall
thickness
600mm
• 
Baf1led
,
ZigZag
air‐1low
• 
Underground
water
chamber
for
1lue
gas
passage
ZigZag
Kiln
Shortcomings
in
Traditional
ZigZag
Kilns
• 
Low
thermal
ef1iciency,
high
energy
consumption
• 
Low
quality
products
uneven
1iring
• 
High
levels
of
pollution,
local
and
GHGs
Improved
ZigZag
Kiln
Design
Changes
• 
Permanent
insulated
brick
walls
(2000mm)
and
roofs
(1000mm)
• 
Versatile
scale
size,
ranging
from
22
to
42
chambers
each
of
7,600
piece
daily
capacity
1000mm
Brick
Roof
Clay
2000mm
Side
Walls
Underground
pipe
Cross‐section
of
the
Improved
Zigzag
Kiln
Improved
ZigZag
Kiln
Design
Changes
• 
Updraft
with
straight
laminar
air1low
• 
Built
in
Heat
Recovery
mechanism
for
round
the
year
production
Improved
ZigZag
Kiln
Design
Changes
• 
Advanced
flue
gas
scrubbers
for
pollutant
removal
when
drying
chambers
not
installed
Improved
ZigZag
Kiln
The
Improved
Zigzag
Kiln
Improved
ZigZag
Kiln
Design
Bene8its
•  Aesthetically
attractive
and
structurally
sound
•  Design
capacity
of
9
million
bricks
per
year
–
4.5
times
the
capacity
of
Traditional
ZigZag
kiln
•  Flue
gas
desulphurization
and
dust
removal
system
•  Readily
adaptable
•  Low
capital
investment
suited
for
SME
application
Improved
ZigZag
Kiln
Environmental
Bene8its
•  Compact
and
Weather
Proofed
•  High
energy
ef1iciency:
coal
consumed
is
about
14
to
15
Tons
per
100,000
bricks
•  95%
Useable
products
THANK YOU