7 Tunnel Kiln

1
FACTSHEETS ABOUT BRICK KILNS IN SOUTH AND SOUTH-EAST ASIA
TUNNEL KILN TECHNOLOGY
INTRODUCTION AND HISTORY1
GEOGRAPHICAL DISTRIBUTION
Tunnel kiln is a continuous moving ware kiln

in which the clay products to be fired are
passed on cars through a long horizontal
tunnel. The firing of products occurs at the
central part of the tunnel. The tunnel kiln is
considered to be the most advanced brick
making technology. The main advantages
of tunnel kiln technology lie its ability to
fire a wide variety of clay products, better
control over the firing process and high quality

of the the products.
The tunnel kiln technology was developed around
mid 19th century in Germany. However, the
application of the technology for brick firing took
place in the 20th century. After the Second World
War, the technology was widely adopted and led to
the transformation of the European brick industry
from several thousand small and scattered brick

making units into a few hundred large scale and
highly mechanised tunnel kiln units.
Indian Line
Chinese Line
In Asia, China and Vietnam started adopting

the technology during the 1970s and now have
several hundred tunnel kilns in operation. In India,
there are very few (~5) tunnel brick kiln units.
Chinese Line
Indian Line
PAKISTAN
NEPAL
BHUTAN
BANGLADESH
INDIA
BURMA
TUNNEL KILN IN VIETNAM
NUMBER OF OPERATIONAL ENTERPRISES AND TOTAL PRODUCTION*
ABOUT THE KILN

Kiln
ENTERPRISES USING THIS TECHNOLOGY

Nature of enterprise
Level of mechanization
Brick produced
Production capacity
Operational season
Country
Number of Total production

enterprises billion bricks/year
Vietnam2
~700
~10.5
India3
~5
~0.08
*Numbers are estimates only
% CONTRIBUTION TO THE TOTAL BRICK PRODUCTION IN INDIA AND VIETNAM
CONTINUOUS
MOVING WARE
INDUSTRIAL
MECHANIZED
SOLID AND
PERFORATED
LARGE
>10 million bricks
~4%
PERENNIAL
Out of the total annual production of around 280 billion bricks in

India and Vietnam only around 10.6 billion bricks are produced by
tunnel kiln technology
2
DESCRIPTION AND WORKING
In a tunnel kiln, a continuous moving ware

kiln, the clay products/bricks to be fired are
passed on cars (1.1) through a long horizontal tunnel (1.2). The firing of bricks occurs at
the central part of the tunnel. The length of
tunnel can vary from 60 m to 150 m.
Three distinct zones appear in an operating

tunnel kiln:
4.1 Brick firing zone where the fuel is fed and
combustion is happening,
4.2 Brick preheating zone (before the firing
zone) where the green bricks are being
pre-heated by the hot flue gases coming
from the firing zone and
4.3 Brick cooling zone (ahead of the firing
zone) where fired bricks are cooled by the
cold air flowing into the kiln.
Generally green bricks are produced by

mixing powdered fuel with clay. Green bricks
are then moved in the tunnel or chamber
dryers on cars for drying. Heat from the hot
flue gases coming out of the kiln is utilized
for the drying of bricks.
Fuel (granulated/pulverised coal) is fed into

the firing zone of the kiln through feed holes
provided in the kiln roof. The firing zone
usually extends up to 8 cars. The temperature in the firing zone is maintained at 900
10500C.
There is counter current heat transfer

between the bricks and the air. Cold air
enters the kiln from the car exit end (6.1) and
gets heated while cooling the fired bricks.
After combustion, the hot flue gases travel
towards the car entrance end losing a part of
the heat to the green bricks entering the kiln.
Hot air/gases are extracted from the tunnel

kiln at several points along the length of the
kiln and are supplied to the drying
tunnel/chamber. In some of the kilns, there is
also provision of a hot air generator to
supplement the requirement of hot air for
drying.
3
1.1
KILN
The cars loaded with dried green bricks are

pushed in the kiln. The cars are moved
inside the kiln intermittently at fixed time
intervals. The duration of the firing cycle can
range from 30 to 72 hours.
DRYER
1.2
4.2
4.1
8
4.3
The flue gases from the drying tunnel are

released in the atmosphere through a
chimney.
6.1
brick flow
air flow
3
AIR EMISSIONS AND IMPACTS
FUELS AND ENERGY
FINANCIAL PERFORMANCE
COMMONLY USED FUELS
PRODUCT QUALITY
Capital cost of kiln technology

for an annual production capacity of ~15
million bricks, excluding cost of land and
buildings
MEASURED EMISSION
FACTORS4,5
Product Quality
As per the local market perception
OCCUPATIONAL HEALTH AND SAFETY
Exposure to Respirable Suspended

Particulate Matter8
The concentration of air pollutants in the
surrounding environment of a tunnel kiln is low
Coal
~1,000,000 USD
g/kg of fired bricks

CO2
Black
Carbon
GOOD ~ 95%
PM
CO
Capital cost breakdown
Petcoke
Average
166.3
negligible
0.24
3.31
57 %
Equipment
43%
LOSSES & BREAKAGES ~ 2%

INFERIOR ~ 3%
Energy consumed for firing 1 kg of fired brick
Range
NA
SPECIFIC ENERGY CONSUMPTION6,7
Construction Material + labour
NA
0.175 0.31
2.45 4.18
Average: 1.4 MJ/kg of fired bricks

(Range: 1.34 1.47 MJ/kg of fired brick)
Better heat distribution results in uniform

temperature across the kiln cross section in
the firing zone thereby resulting in a higher
percentage of good quality bricks.
MJ/kg of fired brick
MEASURED PM EMISSIONS
Average: 41 mg/Nm
(Range: 21 53 mg/Nm3)
Types of
product that
can be fired
in the kiln
maximum
Intermittent Kiln (2-4)
The workers have low risk of developing

respiratory tract infections and cardio
vascular diseases.
Solid bricks
Hollow/ Perforated bricks
Roof tiles
Exposure to Thermal Stress9

Exposure of workers to heat from the kiln
is quite low.
This reduces the thermal stress and

consequent risk of eye & skin diseases and
dehydration among workers.
Floor tiles
2
EMISSION STANDARDS
Notified for PM only
TUNNEL (1.34-1.47)
GOOD BRICK
minimum VSBK (0.6-1)
Country
PM (mg/Nm3)
India
No emission standard has been

notified for tunnel brick kilns
Vietnam
No emission standard has been

notified for tunnel brick kilns
COMMENTS ON EMISSIONS
Risk of accidents
In a well operated tunnel kiln, the risk of
accidents is low.
Note: Measured at firing temperature of

950-10000C
The specific energy consumption in a
tunnel kiln is slightly higher as compared to
other continuous kiln technologies. This is
mainly because the SEC also includes the
energy utilised for the drying of bricks in
the tunnel dryer.
Better fuel combustion results in lower

emissions from a tunnel kiln.
MAIN CAUSES FOR HEAT LOSS

Heat contained in the kiln cars and fired
bricks at the kiln exit and in hot flue gases are
the main sources of heat loss in tunnel kilns.
Low risk of injuries
Production
capacity
~50,000
bricks per day
Brick size
230 mm x 115 mm x 75 mm
Number of
Operators
required
~20
Payback
Period
Simple
Payback
~2
years
Discounted
Payback
(@ 6.5%)
~2.2
years
INFERIOR BRICK
under-fired and over- burnt
Compliance with ILO standards and remarks

on migratory labour and conditions of labour
Practices followed at tunnel kiln enterprises do
not always comply with the International Labour
Standards on occupational health and safety
drawn up by ILO.10
Because of mechanisation of the processes,
the working conditions of workers in tunnel kiln
enterprises are relatively better.
4

MARCH 2014
CONCLUSION
Performance of tunnel kiln is compared with the most commonly used continuous kiln technology in the region which is FCBTK.
PARAMETERS
AIR EMISSION
(g/kg FIRED BRICK)
FUEL & ENERGY
FINANCIAL PERFORMANCE
PRODUCT QUALITY
OHS
TUNNEL
FCBTK
CO2
166.3
131
Black Carbon
0.00
0.13
PM
0.24
1.18
CO
3.31
2.0
SEC (MJ/kg fired brick)
1.4
1.30
Capital Cost (USD)
~1,000,000
50,000-80,000
Production Capacity
~15 million bricks/year
3-8 million bricks/year
Simple Payback
~2 years
0.4 - 1.1 years
Types of product
All types of products
All types of products
Good Quality Product
95 %
60 %
Exposure to dust
COMMENTS
Tunnel kiln emits ~80% lower PM and negligible BC as
compared to FCBTK. This is mainly because of better
combustion and use of internal fuel. The emission of CO is
higher in case of tunnel kiln, probably due to incomplete
combustion of internal fuel.
Tunnel kiln consumes marginally higher energy as compared to FCBTK. It is to be noted that the SEC in tunnel
kilns also includes the energy utilised for the drying of
bricks in the tunnel dryer.
The capital cost of tunnel kiln is substantially higher as
compared to FCBTK mainly because of mechanisation of
brick production processes and considerably larger production.
The project team would like to acknowledge

the financial support received from the Swiss
Agency for Development and Cooperation for
preparation of the fact-sheets.
Note: In the initial stage of this initiative
of developing factsheets on brick kiln
technologies, factsheets are developed for
South and South-East Asia and Latin America
regions. Factsheets on brick kiln technologies
of other regions will be developed over time.
Disclaimer: The country borders indicated on
the map do not necessarily reflect the FDFAs
official position. The red dotted line represents
approximately the Line of actual Control in
Jammu and Kashmir agreed upon by India
and Pakistan. The final status of Jammu and
Kashmir has not yet been agreed upon by the
parties.
Factsheet prepared by
Greentech Knowledge Solutions Pvt. Ltd., New
Delhi (Dr Sameer Maithel,
Sonal Kumar and Dheeraj Lalchandani)
Design & Illustration
Shoili Kanungo
CONTACT
Greentech Knowledge Solutions Pvt Ltd.
New Delhi, India
Both the kiln technologies are suitable for firing all types of
product. However, the quality of bricks fired in tunnel kilns
is better as compared to those from FCBTKs. Also while a
tunnel kiln can be used exclusively for production of hollow
bricks, in a FCBTK such exclusive production is not possible.
Tunnel kiln enterprise offers better OHS conditions as
compared to a FCBTK enterprise.
Exposure to Thermal
Risk of accidents
REFERENCES
ACKNOWLEDGEMENTS
1 Brick by Brick: The Herculean Task of Cleaning up the Asian Brick Industry written by Urs Heierly and Sameer Maithel available at www.gkspl.in/Brick_by_brick.pdf.
2 Report on Brick Kiln Performance Assessment available at http://www.unep.org/ccac/Portals/24183/docs/Brick_Kilns_Performance_Assessment.pdf
3 Based on interaction with tunnel kiln owners and professionals working in brick sector
4 Journal paper on Emissions from south Asian brick production published in Environmental Science & Technology, 2014, 48 (11), pp 6477-6483 available at http://pubs.acs.org/doi/abs/10.1021/es500186g?journalCode=esthag
5 Report on Performance of Brick Kilns in Nam Dinh Province in Vietnam, 2005, TERI (Project Report No. 2004BE31).
6 Ibid 2.
7 Ibid 5.
8 Report on Occupational health and safety study (OHSS) of brick industry in the Kathmandu valley by Department of Environmental Sciences and Engineering (DESE), Kathmandu University, Nepal
9 Ibid.
10 International Labour Standards are instruments drawn up by ILO in the form of conventions (the basic principles to be implemented) and recommendations (more detailed guidelines). Details on the standards for OHS can be found at http://www.ilo.org/global/%20standards/subjects-covered-byinternational-labour-standards/occupational-safety-and-health/lang--en/index.htm. A list of all such instruments on OHS with their status is available at http://www.ilo.org/dyn/normlex/en/f?p=NORMLEXPUB:12030:0::NO:::#Occupational_safety_and_health
TeleFax: +91 11 45535574

E-mail: [email protected]
Web: www.gkspl.in

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1

FACTSHEETS ABOUT BRICK KILNS IN SOUTH AND SOUTH-EAST ASIA

TUNNEL KILN TECHNOLOGY

INTRODUCTION AND HISTORY1

Tunnel kiln is a continuous moving ware kiln

control over the firing process and high quality

from several thousand small and scattered brick

In Asia, China and Vietnam started adopting

TUNNEL KILN IN VIETNAM

NUMBER OF OPERATIONAL ENTERPRISES AND TOTAL PRODUCTION*

ABOUT THE KILN

ENTERPRISES USING THIS TECHNOLOGY

Number of Total production

*Numbers are estimates only

% CONTRIBUTION TO THE TOTAL BRICK PRODUCTION IN INDIA AND VIETNAM

Out of the total annual production of around 280 billion bricks in

TUNNEL KILN TECHNOLOGY

DESCRIPTION AND WORKING

In a tunnel kiln, a continuous moving ware

Three distinct zones appear in an operating

Generally green bricks are produced by

Fuel (granulated/pulverised coal) is fed into

There is counter current heat transfer

Hot air/gases are extracted from the tunnel

The cars loaded with dried green bricks are

The flue gases from the drying tunnel are

TUNNEL KILN TECHNOLOGY

AIR EMISSIONS AND IMPACTS

FUELS AND ENERGY

COMMONLY USED FUELS

Capital cost of kiln technology

OCCUPATIONAL HEALTH AND SAFETY

Exposure to Respirable Suspended

g/kg of fired bricks

Capital cost breakdown

LOSSES & BREAKAGES ~ 2%

Energy consumed for firing 1 kg of fired brick

SPECIFIC ENERGY CONSUMPTION6,7

Construction Material + labour

Average: 1.4 MJ/kg of fired bricks

Better heat distribution results in uniform

MJ/kg of fired brick

The workers have low risk of developing

Exposure to Thermal Stress9

This reduces the thermal stress and

minimum VSBK (0.6-1)

No emission standard has been

No emission standard has been

Note: Measured at firing temperature of

Better fuel combustion results in lower

MAIN CAUSES FOR HEAT LOSS

Low risk of injuries

Compliance with ILO standards and remarks

TUNNEL KILN TECHNOLOGY

FUEL & ENERGY

SEC (MJ/kg fired brick)

Capital Cost (USD)

~15 million bricks/year

3-8 million bricks/year