Zig-zag chimney Bhatta offers a 15-20% reduction in Specific Energy Consumption (SEC) and up to 75% reduction in SPM emissions over FC-BTK. A higher percentage of Class I bricks are produced as compared to FC-BTK (80-85% Class I bricks as compared to 55-60% in FC-BTK).
There is an option for easy retrofit of FC-BTK to natural draught Zig-zag kiln. Savings from reduced fuel consumption and an increase in revenue due to a higher percentage of Class I bricks.
The capital cost of retrofitting of existing FC-BTKs ranges from INR 10-25 lakhs and pays back in 3 months-2 years. However, for new construction, the capital cost ranges from INR 35-45 lakhs natural draught kiln and INR 40-45 lakh for a high draught kiln.
The payback period for the new construction of the Zig-zag chimney Bhatta is 2-3 years. Zig-zag Bhatta required skilled manpower for its operation. However, the same workforce working in FC-BTK can be easily trained for operating Zig-zag kilns. 4 persons are required for firing at a 6-hour shift.
Advantage of Zig Zag Chimney Bhatta
1- zig-zag kiln reduces 20-25% Specific Energy Consumption.
2-zig zag kiln reduction up to 75% in SPM emissions over FC-BTK.
3-Increase the percentage of the class 1st bricks.
4-zig zag kiln produces 85-90%, first-class bricks.
- The use of the down or cross draught system, with the fuel being burnt at regular intervals amongst the bricks, provides an even firing throughout the kiln.
- The firing is controllable by the use of the dampers and careful stoking.
- This is necessary when burning biomass fuels that have a higher mass and lower calorific value than other fuels, like coal or coke.
- their use of waste heat the bricks Efficiency figures for Hoffmann kilns using coal as a fuel, in England and China and ranging from 1,800 at best to 2,350 kJ per kg fired brick at worst.
- They have the capacity to fire very large quantities of bricks evenly and with minimal wastage.