Study on Auto Bricks Bangladesh Perspect

PRE-INVESTMENT FEASIBILITY STUDY REPORT

(Fully Automatic Brick Plant with Tunnel Kiln & Tunnel Dryer)

Project Analysis Fully Automatic Machine Made Clay Brick Manufacturing Factory Based on Tunnel Kiln Firing System Production Capacity-150,000 Pcs/Day per day (45 Million per/Annum).

Annual 30 million common bricks production line

PROJECT SUMMERY 4. Product-mix and production Capacity: The project envisages setting up of a Auto Bricks Production Project at Mouza- Purbo Panch khati. JL no- 13 & 59, Goshairhat, Shariatepur, Bangladesh. After implementation of the project the product mix and the production capacity of the project based on the basis of 24 hours per day for kiln & Dryer operation and raw bricks production of 10 hours shift basis and 300 working days in a year at 100% capacity utilization will be as follows: Sl. No. 01

Items/products

Production Per Day

Standard Hollow Bricks (Pcs) Size 10’’ x 5’’ x 3’’ Total

Price Per Total Qnty Per Pcs Year Pcs

150000

9/=

45,000,000

Amount “000”

405,000 405,000

Section II Technical Aspect The project is for setting up a forming machine, tunnel dryer and Tunnel kiln brick factory with a new imported system machine. In this case, this factory has more competitive power with the operation has convenient and production lines design is simple and clean working conditions. The project has been designed to produce 1,50,000 PCs/day (raw material + forming machine + tunnel dryer + Tunnel kiln) with modern technology at Shariatepur district in Bangladesh. Quality of product meets Bangladesh’ s standards. It is expected that the project will go into commercial operation after Twelve months from the day of designing technology equipment supplying contract.

Additional Advantage Advantage of of Machine made Bricks

01. Machine made bricks: Fully automatic machine made bricks are more durable, stranger and good looking. These are uniformly burnt. Machine made bricks are getting favorite day by day in and around all municipal areas as this manufacturing plant is environment friendly. It is found that the demand of such bricks are growing faster for housing and industrial use. 02. Tunnel Dryer and Tunnel Kiln: Tunnel Dryer and Tunnel Kiln are Kiln are using for burnt and drying in ceramic tiles & sanitary ware factory. For uniformly & absolute burnt of bricks tunnel kiln and dryer are using in the machine made bricks plant to get 100% efficiency in bricks production at stimulated time. Tunnel kiln and dryer will be used for various types of bricks & tiles drying and burning. It ’ s ensure durable stranger and good Annual 30 million common bricks production line

looking bricks and there will be no wastage of bricks that with cost effective and environment friendly. Recently formed Government’ s industrial policy – to facilitate local industries Shariatepur will be the strategic location for any kind of industries and brick is one of the most essential items to build any kind of building either industries as well as residence and boundaries. 2.00

The proposal:

The proposal envisages setting up of Auto Bricks Production Project at Mouza- Purbo

Panch Khati. Jl no- 13 & 59, Goshairhat, Shariatepur, Bangladesh . under the name and style of SELF AUTO BRICKS LTD . Total fixed cost of the project has been estimated at Tk. 4088.99 lac. The project has been equipped with brand new China Origin machinery and equipment with some local machinery. The value of Foreign machinery is USD 23,71,989 equivalent to taka taka 1992.47 lac and the value of local machinery is taka 348.00 lac.

Technical knowhow: The technical knowhow required for the smooth operation of the project is locally available. Crash training and orientation program for both semi-skilled and unskilled persons will be conducted by a qualified and well experience production manager with a view to trained them into skilled hand as well as increase production efficiency.

Characteristic of Production Technology.

Generally production of brick and tiles is not very complicated. Howover, for producing the high-quality product as varioustypesof tiles, it requires skill of workers,especially when there are still a lot of manual production sections. Because this is a new production domain for the company, the factory expects to produce only constructing brick for local market in the first stage. In the second stage ( from the third year on words). when the worker’ s professional skill has been raised, the project will be investedin more ternacotta products. Thare fore we design of convenient factory systems here as most easy producing.

Production Line Description of production tecnology:


The clay exploited from the mine will be stored in the open air yard to be continuously weathered are reserved for the production at least in three months and it is better form 3 to 9 months ( Because Bangladesh has low terrain flooded during the monsoon rainy season)tare for the clayraw materials should be excauated and spread outon the groung for same time. The proess is known a weathering and has an important effect on the viscosily and strenght of the clay. the clay should be kept under open sky during the initial period. this weathering process is intensitied thanks to su ch measures as watering kneeding by means of machines like pay-roads and bulldozer. The weathered clay will be transported trailer.Wich is pulled by tractors from the reservation yard to the clay- containing house where the box feeder is installed. Here the clay is stoved for at least one wheek. The clay will be supplied to box feeder by the pay

loader.

Mixed raw materials after quantitalively determined in the box feeder will be transfered to rulling section by conveyar beside it a coat crusher will be installed and it is equipped with belt conveyar to delivery required quantity coat to box feeder. Than the clay will be passed through the roll crusher. the roll crusher has the slit betwen the two rollers around 3-5mm. than the clay will be moved to the double shaft mixer. Here the clay will be pugged and moisturs to reach the moisture of forming. This section also aims to sperate such esetraneous matter as grass, tree roots left inthe clay. She will mixed clay will come to pug sealer and de-airing extrusion. Here the clay pugged one more time. Watering if the moisture dose not reach the required level and comes to vacum chamber to such out the remained air bubbles.The forming mosture fluctuates with in the interval 18-21%. After that the clay will be extruded through the forming mould to get the desined shape and move to the auto cutting machine to cut the brick in to intended lenght. When changing the produced product, it is just needed to change the appropriate mould. The semi product of the green brick after cutting will be transferred by a horizantal type loading conveyar. Workers stay here will pick up the green brick and land on the kiln cart. The cart after being fully loaded will be moved to the drying chamber. The carts are pushed into the tunnel dryer thanks to the transfer car with pusher. The heat supplied to drying chamber is withdrawn party from the colling zone of tunnel kiln. The drying time is from 24 to 30 hours depending on product type. The dry cart with green products in the drying tunnel after finising drying will be moved to the loading line for kiln car where the dried green products will trunsfer loaded kiln cart. this kiln carts waiting move to sub-dryer and the kiln carts to pass enter the tunnel kiln thruogh a transfer line.


After going out of the dryer the cart, the carts holding dried products with the moisture of 10% will be move to the loading line for the kiln cart of tunnle kiln for arrangement. And dried brick loading conveyar section. The kiln car carried dried brick with moisture 10% and will be move to sub-dryer and pass here when this moisture are reduce about 6 – 7% and will be moved to tunnel kiln by kiln transfer car and pushed in to tunnel kiln by kiln hydraulic presher. this tunnel kiln is 140-150m of lanth with top firing or cool firing system and contonuously producing clay by kiln car with rail and running system. It can contain 52 kiln car, it composed three parts connection togather the pre-heating zone, firing zone and cooling zone. As to cooling zone, it was devided in to rapid cooling zone and cooling zone. highest firing temperature is 1000 C. firing time is 33 hours. the kiln car carrying 27,000 pcs /car after going out of the kiln will be moved to the rail road in order to wait for the brick to be cooled off and unload. the products should be classified and be bound and gather to the ware house or to storege yard so that delivering to customer.


Diagram Chart of Production line Raw materials from out side storage yard

Box Feeder

1st – 2nd Roll Crusher

Extrusion, Mixer / Double Shaft Filter Pug Mill

De – Airing Extruder

Slug Cutter, Colum Cutter

Green Brick Loading Seperator

Kiln Cart Loading Conveyar Belt

Drying Cart in to the Tunnel Dryer

Manual Unloading Dried Bricks

Dried Brick Loading to Tunnel Kiln

Tunnel Kiln

Manual Product Selection & Paking Warehouse


III. Auxiliary units : Including Mechanic and electric reparing workshops. Duties of the workshop : Small repairs for equipments, regular maintance and other repair on electricity and plumbing. Major repair will be implemented by the companys electromechanical workshop or by other factories workshop will be equipped with essential equipment and instrument.

IV. Selection of technology equipment Base of technology equipment selection: ·

process of balance the material of the factory.

·

Type of raw material will be used.

·

Product structure

·

Quality level of the product. According to offer of suppliers, analysis of parameters, the tecnology equipment of this project is selected as follow as per the enclosed table “List of equipment”


METHOD OF TECHNOLOGY Brick making is a very crucial and significant economic activity in Bangladesh since it is a developing country with a high construction sector growth. Despite being a crucial sector for the country, this sector is not formally recognized as an industry (Ministry of Industry'2010). The country's overwhelming dependence on bricks is due to scarcity of suitable alternative building materials to local climate at complete cost. Table 1.1 summarizes the main characteristics is tics of the brick sector in Bangladesh. Table 1.1 Snashot of Bangladesh's Brick sector 20122 Parameter Estimated total number of coal-fried kilns Number of natural gas fired kilns Annual brick production Value of output Coal Consumption Value of Coal Imported Fire Wood Consumption Emission CO2 Clay Consumption Total Employment Growth rate of the Construction Industry Estimated growth rate next ten year Contribution & GDP

Value

4,860d 20 17.24 billion Tk. 94.82 billion (US$ 1.35 billion) 4.03 million tons Tk. 26.18 billion (US$ 374 million) 1.9 million tons 9.81 million tons 58.38 million tons 1 million people 5.6% 2-3% 1%

In Bangladesh uses four main types of kiln technologies as presented as FCK (Fixed Chimney Kilns), Bull's Trench Kilns (BTKS). Which nearly 95 percent of the Kilns, are very Polluting and relatively inefficient. The substantially cleaner gas-based Hoffmann Kiln and the slightly better coal-based zigzag kilns are already available, but represent just a few percent of the total. Substantially cleaner technologies like VSBK, H.H.K. and most advanced TUNNEL KILN technology has just entered in to the Brick market. Existing Bricks Kiln Technologies in Bangladesh (2009)

Kiln type FCK BTK Zigzag Hofmann (gas) H.H.K. Others Total

Number Percent of Total Kiln 92.21% ≤ 4500 N/A 0.00% 3.07% ≤ 150 0.41% ≤ 20

Brick Production 24 (Bricks Billion) 15.75 0.60 0.24

Percent of Production 91.36% 0.00% 3.48%

≤

0.15 0.50 17.24

1.39% 0.87% 100%

10 < 200 ≤ 4880

0.20% 4.10% 100%


Some Brick Manufacturing Technologies in Bangladesh: 1. Fixed Chimney Kiln (FCK)

The chimney in a fixed chimney kiln (FCK) as the name suggest is fixed and is approximately 130 ft. high. This tall chimney creates a stronger draft improving the combustion process and releases the flue gas at a height 130 ft. above the ground thus providing faster and better dispersion. The kiln has under grounded piping to divert the flue gas from anywhere in the kiln to the fixed chimney. The length of the kiln is same as that of the BTK but its width is greater to accommodate the underground piping. The FCK also has better in solution in the side walls, which reduces heat loss to the surroundings. The cost of constructing the chimney is Taka 12,00,000 (US$ 20,700) which is nearly 50% of the local cost of FCK. Bull's Trench Kiln (BTK) The Bull's Trench Kiln is essentially an ellipetical shaped dug out area in as opened field. The kiln is about 250 ft. long and 57ft. wide and has two 32ft. high moveable chimneys. The bottom and the side walls of the kiln are bined with bricks with the top open. San dried bricks are stacked in the kiln in an orderly fasion learing enough room for fuel stoking and air circulation. After arranging the bricks in the kiln is covered with fired bricks and pebbles. The bricks are fired from the top and the fine moves forward-towards the chimney. The air entrance opening (air hole) and the chimney are located at the two ends in such a way that combustion air is preheated by taking heat from the fired bricks and the green bricks to be fired are preheated by the flue gas on its way out of the chimney. The bricks are fined all around the kiln, which means the chimney and the air hole must be progressively moved forward, until at bricks in the trench are fired. The chimney are made of iron sheets and during a typical season of five months these need to be replaced two to three times because the corrosive the gases eat away the kiln every year because of which BTK's need to be constructed almost from scratch every year. Hebla or ZigZag: The hebla or zigzag kiln is rectangular in shape and measures 250 ft. by 80 ft. It has a 55 ft. high fixed chimney located on one side of the kiln. At the bottom of the chimney these is a flower, which draws the flue gas from the kiln and discharges in to the atmosphere. The kiln is divided in to 44 to 52 chambers, which are at separated from each other in such a way that the hot gaseo move in a zigzag path through the kiln. The zigzag kiln is reported to be 10-15% more fuel-efficient than the FCK. This kiln is expensive to construct and cost approximately the same as a FCK. There are about 30 such kiln in operation mainly in the comilla region. Present FCK owners are keen to convert to the zigzag technology if the department approve it as an acceptable technology. The construction is not easily available and expertise has to be procured from neighboring states on India. Hoffman Kiln: H.H.K.

A Hoffman kiln is rectangular in shape and measures 300-400 ft by 60ft. Its construction and operation is very similar to the FCK. The pre dominant difference between the Hoffman kiln and the kiln described above is the fixed roof, which enables bricks to be fired throughout the year although during the rainy season, which is called off-season. The production decreases significantly because of rainy season; high humidity areas overproduce green bricks during the dry season and store them for the rainy season but to Annual 30 million common bricks production line

ad that adequate storage facility must be made available. Also for off-season production clay has to be stored, as harvesting of clay becomes impossible due to wide spread during the rainy season. The inside roof of the kiln is arched and has a fire brick lining on the inside surface. The thick walls of the kiln and good insulation heat loss to the surrounding. The chimney is 76 ft. high with a blower at the bottom. Green bricks are stacked in the kiln in more or loss the same fashion as that in the FCK. The bricks are fired from the top by introducing the fuel (Natural gas) in to the combustion zone through pipe-type burners. The burners are shifted for ward from section to section as the five progresses-fired bricks are unloaded at the back while greeb bricks are stacked in front of the firing zone. The flue gas is conveyed towards the chimney through a network of channels gust below the kiln. Five is controlled without the aid of any instrumentation or controllers by merely adjusting the gas flow rate and the opening and closing of dampers brated at selected point in the flue gas network. Opening and closing of dampers located at selected points in the flue gas network. Controlling the fine is the trickiest part of the whole operation. Since there is no in situational arrangement to learn the fining technique, several years of on the job training as an apprentice is needed to master the technique. Vertical Shaft Brick Kiln (VSBK)

The vertical shaft kiln (VSBK) was first developed in china (November 1992, November 1994). The VSBK is fuel-efficient consuming 20 to 30% less fuel in comparison to the BTK and FCK. In addition the kiln is simple to construct and operate, making it ideal for rural areas. The VSBK regnies has been tested and proven to be successful in china. In India and Nepal it has enjoyed limited success. There was one effort to construct a VSBK in Bangladesh, but that was unsuccessful due to the lack of adequate technical and financial support and poor brick quality considering the incremental investment. In a VSBK, Bricks are stacked in a shaft measuring 1X1 m3 up to a height of 6.0 m. Green bricks are loaded from the top in batcheo of unloaded every 1.5 hours. The fining occures around the middle of the shaft. The kiln uses pulverized coal, which is loaded from the top along with the green bricks. The combustion air gets preheated to about 750 oC by taking up heat from the fired bricks. After combustion the hot flue gases move up through the unfired bricks and in the process preheat the bricks to be fired. The VSBK is a permanent structure and can produce bricks throughout the year. It has a life of 8 to 10 years with minimum maintenance. One VSBK can have multiple shefts and can be very economical in utilizing space. A VSBK with six shafts can have the capacity as that of a FCK but needs only 13% of the space of a FCK.


TUNNEL KILN (B) Tunnel kiln technology was invented in Germany. This technology is most common in developed countries, since treit inventing tunnel kilns have now become highly automated and are for large production. Bricks move mechanically through a long stationary fine zone. They have minimal labour requirements but a very high capacity cost. They must be operated in continuous mode and require a guaranteed power supply through electricity or generator. Power supply through electricity or generator: Tunnel kiln is a long structure in which only the control portion is directly heated. Form the cool entrance. Brick is slowly transported through the kiln and its temperature is increased steadily as it approaches the control, hottest part of the kiln. From there, its transportation continues and the temperature is reduced until it exits the kiln at near room temperature. A continuous kiln is the most energy-efficient; beacous heat given off during cooling is recycled to pre-heat the incoming bricks. The Technology has the following advantages: 1. Continuous production, short production cycle 2. High jicled and superior quality brick production 3. Using counter-current principle of work, the high thermal efficiency, economical fuel consumption, it can save about 50%-60% energy compared to the old type kilns 4. The firing lime is relative by shorter. In other type kiln it require 3-5 days to complete the working cycle, while the tunnel kiln it takes about 30 hours to complete the working cycle 5. Save labour 50% - 60% less labour is required 6. The most of loading and unloading operation are outside the kiln with very convenient working was 7. Improved working condition and reduce labour intensity 8. Improve quality: The temperature of preheating zone, firing zone and cooling with three parts used to maintain a certain range, easy to grasp the firing rules, so the quality is better, less breakages. 9. Kilns and kiln structural are durable. It usually takes 5-7 years before repair. However the tunnel kiln construction materials and equipment needs a large investment 10. Generally applicable only to large volume production and the firing system which requires the same basic products, poor flexibility.


( Production Capacity 3 lac per day



COMPARATIVE ANALYSIS OF CLEANER BRICK TECHNOLOGIES A comprehensive Comparative Analysis on Alternative cleaner brick Kiln technologies in Bangladesh has been presented in Table 7.1. The comparative analysis was categorized based on the following key parameters: 1. 2. 3. 4. 5. Investment, Capital, Profitability Production, Raw material and Output quality Energy Consumption GHG and particulate Emission Social Cost Benefit Table 7.1 : Comparative Analysis on cleaner brick kiln technologies in Bangladesh12 Baseline Parameter

A. Investment,

Alternatives

Fixed Chimney Kiln

Improved Zigzag (SD+GM)'

2.5 acres, of which I acre used round the year

2.5 acres, of which I acre used round the year

VSBK (two shaft and Mechanized)

HHK` (50,000 bricks/day)

Tunnel Kiln (200,000 bricks/day)

3.96 Acre

3 acre

Capital, Profitability

1

Land

2

Initial Investment Outlay

3

IRR (%)

4

Pay back period

(in Tk million)

Years

, 1.32 Acre

5

5.5

10-15

146

40%

40%

30%

2

2

2

4

4

4

4

15

400

25%

25% 4

B. Production, Raw material and Output u alit

5

Rated Annual Production Capacity

6

Production Period

(Million brick/year)

November to A ril

November to April

Baseline

Raw Material

Tunnel Kiln (200,000 bricks/day

Improved Zigzag (SD+GM)

a) Clay

100,000 cft/million bricks

100,000 pelt/million bricks

100,000 cft/million Bricks

100,000 cft/million bricks

b) Labor

150 (15% skilled, 15% semiskilled)

150 (15% skilled, 15% semiskilled)

75(20% skilled Iabor,20%, semi skilled)

85 (27% skilled, 26°% semiskilled)

25

c) Electricity

Not essential

Needed for the ID fan

Not essential

180-250 kw

250-350 kw

VSBK (two shaft)

HHK (50,000 bricks/day)

Round the car

Fixed Chimney Kiln

Parameter

7

Round the Round the year year Alternatives

60+

12 Unless referenced otherwise data has to be considered taken from BUET (2007) 13 SD means Standard Design and GM means Good Management 14 HHK data has been sourced from Investment Feasibility Study, Investment Comparison Analysis 2010-2011, HHK CDM Project and from HHK entrepreneurs during Monitoring of the project. 15 Land requirements for different technologies: For a 2 shaft-VSBK 4 Bigha land is required. For HHK (50000 bricks/day) 12 bigha land is required and for HHK (100000 bricks/day) 15 Bigha land is required. 1 Acre=3.03 Bigha.


Baseline Fixed Chimney Kiln

Parameter

d) Fuel Coal

8

Brick types

9

Strength

PSI

10

Weight

Kg

11

Volume

1" class: 50%-55% Wastage: 3%-4% less than 2500 2.9 10 cubic cm

C. Energy Consumption Ton Fuel Per 12 consumptio 240 million n (Coal) Bricks 13

Alternatives Improved Zigzag (SD+GM)

Pulverized Coal 1st class : 60%-65% Wastage: 3%-4% less than 2500 2.9 10 cubic cm

160-180

Specific MJ/kgenergy 2.125 brick consumption

1.42'

VSBK HHK (two (50,000 shaft) bricks/day)

Pulverized Pulverized Coal Coal 1st class : 1" class: 80%% 90% Wastage: Wastage: 3%-4% 0%

Tunnel Kiln (200,000 bricks/day)

Pulverized Coal 1s' class 95% Wastage: 0%

4260

4500-6000'

4500-6000

2.9 10 cubic cm

3.5 12.5 cubic cm

3.5 12.5 cubic cm

100-120 3

120-130

100-120

1.06°

0.954

0.807

D. GHG and particulate Emission

14

15

Pollution

Particulate (mg/m3)

Severe Pollution

10-50% less than FCK depending on management

1000+

270-3 007

Least Least pollution pollution 500800

Least pollution

20.3"

< 50

17 Equivalent

to 300 Kg/ cm 2 as stated in the website: http:// w -u-w. vsbkindia.org //faq,htm is Based on BRTC, BUET Test report 19 Based on one pilot project in Savar, Dhaka and may not be representative of all VSBKs. z° Calculated by the Authors 21 SEC for Zigzag is reported as 0.8-1.10 MJ/kg- bricks in Maithel (2003). More improved technology can be imported from Vietnam. 22 SEC for VSBK is reported as 0.7- 1.00 MJ/kg- bricks in Maithel (2003) 23 Maithel et al. (2002) for high draft kilns in India 24 Energy and Stack Emission Monitoring in Hybrid Hoffman Kiln (HHK) Type, December, 2008


Baseline Alternatives Fixed HHK Tunnel Improved Chimne VSBK (50,000 Kiln Zigzag y (two shaft) bricks/da (200,000 (SD+GM) Kiln y) bricks/day)

Parameter

tco, emission 16 per million bricks

17

Emission Reduction in tCO, per million bricks''

E. Social Cost 18

No of workers employed

19

Nature of employment

21

582

388

291

315

291

180

291

372

421

Benefit Analysis

Working Condition

150

150

Seasonal

753

85

Round the

Round the

15-25 Round the

Seasonal year

Very poor

year year Highly Highly Very poor Satisfactory Satisfactory Satisfactory

25 Only emission due to coal consumption is considered. Calculation is made by the Authors 25

Calculated by the Authors

27

21 labors are directly employed in kiln production and rest of the labors are employed in green brick production through middlemen/labor contractors. Source: VSBK demonstration project in Sariatpur


Training work After signing the technology equipment contract, local and foreign specialist will teach some qualified workers to establish the technology process of production and machinery operation. Mechanical and electric engineers will taught by specialists both theory and practice before commodity delivery so that they can get basic knowledge on equipment installation, maintenance and operation. During the time putting the factory into operation, local and foreign specialists will guide and train the cadres and workers on production sections until they manipulate skillfully and can operate themselves.

SCHEDULE OF CONTRACT EXECUTION Description

Months 1

2

3

4

5

6

7

8

9

10

11

Dispatch of drawing Construction of Tunnel kiln Construction of drying chamber Factory building and foundation Forming machine delivery Packing, inspection and shipment Ocean transportation and C & F Foundation for machinery Installation Commissioning and test-run Making to utility Trial Production + “0” stands for the date of the contract come into force. + Drawings: - General layout - Machine foundation - Electricity, water, compressed air network - Drawings of gangways, support...under Buyer ’ s supply with cost estimate.


12

TECHNICAL SPECIFICATION AND CAPACITY 2.1

Capacity:

z

30,000,000 pieces of clay bricks based on brick size 240 x 120 X 70 mm.

z

Base product of the contract: 240 x 120 x 70 mm, void 30%.

2.2

Product range:

Item

Dimension, mm

Description

Fired W. kg

Void

01 02

240×120×70 240×120×70

Hollow brick Solid brick

2.6 3.7

30% 0%

03

240X120X240

Hollow block

6.2

50%

04

Other products to be defined.

The Supplier s scope of supply does include also an unit (for beautifying the bricks unit please refer to Appendix 1.) which makes the decoration on three surfaces of chamfering treatment 2.3

Raw materials

z

Clay laboratory tests are to be carried out.

z

Project data and supply can vary according to the test results.

z

In the case if another type of clay or sand is needed, the Purchaser has to check and solve the problem.

2.4 Electric voltage 380 Volts - 50 Hz

z

2.5

Fuel used

z

Natural gas with P.C.I. 8,500 Kcal/m 3.

z

Coal with P.C.I. 6,500 Kcal/kg, size of the coal has to be less than 50 mm.

z

The project is designed to adopt by coal which is to be mixed together with clay or natural gas

z

The quantity of the supply of the burner system for natural gas shall be enough in the case that if the kiln has to be arranged 100% by natural gas.

2.6

Work organization


Description

Preparation

Production

Drying

Firing

330 7 1 10 10

330 7 1 10 10

330 7 3 8 24

330 7 3 8 24

Working days a year Working days a week Working shift/day Working hours/shift Working hours/day

2.7 Compressed air: Pressure: 0.7 Mpa 2.8 Main economic data

Item

Description

Unit

Index

01

Production capacity

Piece/year

30,000,000

02

Clay consumption

Cft/year

Max. 2,100,000

03

Installed power

KW

about 1000

04

Production manpower

Total

about 55

2.9 Technological calculation Please kindly refer to attached Appendix.2.1 for detail, final data and supply can be adjusted at the final design.

2.10 List of installed power of the plant equipment Please kindly refer to attached Appendix.2.2 for detail, final data can be adjusted at the final design.


TECHNICAL SERVICE

1. In order to realize the smooth installation, commissioning and normal operation of the Contract equipment, the Supplier shall send their skilled, healthy and competent technical personnel and installation team to the Purchaser s site for the technical service. 2. The Supplier s personnel shall be responsible for technical instruction of the equipment s installation, commissioning, operation and maintenance, etc. The Supplier s technical personnel shall also explain in detail to the Purchaser s personnel of the equipment s speciality, operation rules, maintenance ways and other points concerned, explain and solve the technical problems raised by the Purchaser s personnel. 3. The Purchaser shall provide the Supplier s technical personnel with convenient working conditions and skilled workers to assist the site works. The Purchaser shall, before the arrival of the Supplier s technical personnel, make all arrangement ready. 4. The starting date of the technical service by the Supplier s technical personnel shall be fixed by both sides through consultation according to the actual situation of the project. 5. The working time of the Supplier s technical personnel shall be 48 hours, per man, per week, i.e. 6 days per week and 8 hours per day. 6. The Purchaser shall bear all expenses for round trip air tickets for Supplier s personnel; the Purchaser shall bear also lodging, food and local transportation for all the Supplier s technical personnel during their stay at the project site. 7. The Supplier s technical personnel shall observe the laws of Bangladesh and the regulations of the Purchaser. 8. The Purchaser shall prepare 2 competent Chinese/English interpreters for finishing the cooperative work with the project-site technicians from supplier. 9. The Purchaser shall arrange 30 days in advance all qualified invitations to the Supplier s personnel and make sure that with the above mentioned invitation the Supplier shall have no problem to get the visa; and in case of prolongation of visa is needed, it will be the Purchaser s expenses and responsibility. 10. Extra works and overtime works at the site will be charged, detailed standard are to be agreed by both parties. When overtime work is needed, the Purchaser shall make accordingly his people and means t o follow and coordinate.


NSTALLATION, COMMISSIONING AND ACCEPTANCE

1.

Installation

Installation m ea ns t h e i n s t a l l a t i o n w o r k s , i n c l u d i n g a s s e m b l y , i n s t a l l a t i o n a n d connection of all equipment and materials of the Contracted Equipment. 2.

Test-run

Test-run means to check the readiness for operatio n, adjustment, trial operation without load and with load on the individual units and the whole system after completion of the installation of the Contracted Equipment. 3.

Acceptance Test

Acceptance Test means to examine if the performance of the Contracted Machines can reach 90% of the guaranteed parameters as stipulated in APPENDIX 2 to the Contract. If the results of the test show that 90% of the guaranteed parameters can be reached, the machinery shall then be accepted by the Purchaser. If all the guaranteed figures specified in Appendix 2 to the Contract are fulfilled, a certificate of acceptance shall be signed by the representatives of both parties after the test in 4 (four) copies, 2 (two) copies per each party. During the acceptance test the working log shall be made and signed by representatives of both parties. This record shall be part of the evidences used for the acceptance. The content of this record should include the following: - Type of products - Quantity of the shift production - Quality data of the products The acceptance test will last for 4 continuous working days i.e. it will work 48 + 48 hour for each product. At the work start the MACHINES has to be ready and full of good materials. Any stop not due to the reason caused by the Supplier s machines, the time of stoppage will be deducted and the quantity of production will be reduced in proportion. In detail, the type A) of product 240X120X70 mm (Void: 30%) to be tested for 48 hours (two working days, 2 shifts per workday for preparation and production); In detail, the type B) of product 240X120X70 mm (Void: 0%) to be tested for 48 hours (two working days, 2 shifts per workday for preparation and production);

After completion of above procedure and the signing of the acceptance certificate, the product of hollow block with size 240X120X240 mm (Void: 50%) could be tested.

In the case that for delays due to the Purchaser for more than 3 months, then the plant equipment shall be regarded as has already been accepted by the Purchaser.

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MARKETING ASPECTS An Overview : Modern development process has come to produce rapid urban growth. Hence one of the objectives of planned development is to improve the physical conditioning of living such as housing and water supply. But as people aspire for comfort, rural community also needs to have access to such basic facilities of life. In fact poor countries have come to be regarded as rural slums and the rural urban migration is as attempt to escape it. The program of development of physical infrastructure covers both urban and rural communities in public and private sectors. The program consists of development of housing, office and commercial buildings, site development for private housing, office & commercial buildings, city roads etc. In the middle of the second plan rather a comprehensive approach was for the first time taken to bring development to the door of people and steam urban migration. This consisted of the Government policy decentralization of administration and acceleration of development activities at upzilla level. This policy will require creation of necessary physical infrastructures there within the framework of national physical plan and the demand for construction materials like bricks etc. 02. The Project: The Products of the project will be automatic bricks to be produced from local day. Automatic bricks have comparative advantage over hand made bricks in respect of unit price, size/ specification, quality etc. Automatic bricks having standard in size, smoothness in surface, bright in colour, hardness in strength and cheaper as compared to hand made bricks being produced by the brick fields situated in the rural areas. The initial cost of the type of the project, though high but the overhead working cost is less. As such, this type of project can supply bricks at relatively cheaper price. Furthermore, it can cater to the large volume of demand for bricks at a time when various government/private institutions/ organizations place orders. It may be mentioned here that some times various public works are interrupted due to shortage of bricks. This type of project of implemented may be able to solve this problem. 03. Uses and User of Bricks : Bricks are mainly used in constructing houses, roads and bridges. Bangladesh is a developing economy and from 1976 onwards the economy is striving forwards, in both public and private sectors, with the development of trade and industry and overall expansion of the economy, construction sector has also exhibition considerable growth. It has already been mentioned here that bricks are mostly used in the construction of houses apartments, roads and bridges, beside the private housing sector, the major users of bricks are the various Government, Semi-Government and autonomous organization of which the following deserve special mention. a) Public Work Department; b) Roads and Highways; c) Water and Power Development; d) Public Health Engineering; e) Rural Electrification Board; f) Pourashavas and Others; g) Zilla Parlshad (1) Thanas h) Titas Gas etc.

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04. Demand analysis at Micro Level: Bricks are heavy in weight and cannot be transported easily and cheaply to any long distance; therefore, bricks are mostly locally produced and locally used. Only special bricks, like designed ceramic bricks are sometimes brought in from distant place. The Plant under consideration will be located at Goshairhat, Shariatepur, Bangladesh and is expected t o supply bricks to various parts of Dhaka, Barisal, Faridpur, Narayangonj, Shariatepur District. The demand for bricks depends on the number on additional brick built houses and the requirement of bricks in each additional brick built house. As per census 1991 total household in Dhaka Division Stood at 1404,054 of which about 50% has been assumed to be pucca houses. On the basis of the growth rate of 50% per annum, The projected number of pucca houses has been estimated and is shown in table - 1 Statistical YearBook of Bangladesh, 1998, Page - 45. TABLE - 1 Year 1999 2000 2001 2002 2003 2004 2005

No. of House 1017942 1053043 1088144 1123245 1158346 1193447 1228548

It appears from Table-1 that the additional number of pucca houses in Dhaka Divbision will raise from 35101 Nos. on an average per annum. Assuming that each pucca house requires about 40,000 bricks on as average, that total number of bricks to be required for the additional pucca houses has been worked out 140.40 crore. In additional to that demand for bricks in the private sector, huge demand for bricks come from that real estate developers for construction of multistoried apartment/commercial complexes. The apartment project was started in late 70's in Dhaka City. But in yearly 80's with the inception of Eastern Housing Ltd. the business started flourishing. Now this is a booming sector of the economy. A good number of real estate developers are now active in this business. During the last decade apartment project has got tremendous progress. World Bank estimated the demand for housing in urban areas of Dhaka,Chittagong, Rajshahi, Rangpur and Khulna for the period 1980 and 2000 as detailed in Table-11 Items aka ittagong ulna Total

1980 Population 35 14 07 56

2000 No.of Housing 08 02 01 08

Population 93 40 23 156

Demand of Housing No.of Housing 17 07 04 28

Bangladesh Urban Sector Memorandum, May, 1981, World Bank.

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12 05 03 20

The Study shows that annually the number of houses required to be built in Dhaka comes to 60,000 units which is likely to be 12 items higher than the number of actual unit constituted per year, Assuming 40,000 Nos of Bricks per house the total number of bricks to be required for apartment project comes to 800.00 crore PCS. In additional to the residential household, various Government departments and agencies are using bricks Empirical observation reveals that their requirement for bricks would not exceed 10% of the bricks required by household. Hence the total requirement for bricks in both public and private sector would be as shown in Table -111 TABLE -111 Total Requirement of Bricks Category

Demand in Million Nos.

Household 1404 Apartment 8000 Government 940 Total 10344 It appears from Table-111 that the annual requirement of bricks would be about 130,44 million Nos. 05. Existing Supply: At present the supply of bricks mostly comes from a bricks fields which produce bricks of inferior quality which are being sold at higher price. Due to non-existence of adequate number of automatic brick manufacturing plant in the area, the household users and the government and private institutional users are to use mostly this grade of brick to meet their demand. As such the brick fields will not be the competitor of automatic brick plant rather the automatic brick plant will have comparative advantage over fields in respect of quality and price. 06. Market Share: To what extent the proposed project will be able to win over the users by way of creating a market share for the product will depend on the efficiency of the sponsors to handle appropriate marketing strategies in the from of determination of product pricing, procurement of raw materials, maintenance of product quality, adoption of promotional measures etc. So long as the sponsors of the project will be able to adopt suitable and appropriate marketing strategies, it will create effective demand for the product. 07. Quality: Maintenance of quality of bricks is considered to be one of the determinants for the successful marketing of the product. To have better market, the quality of the product must be ensured; otherwise it may not be able to compete in the local market. The users/consumers for brick generally look forward to the following properties in bricks: proper size and thickness ; ● Bright Colour; ● Smoothness of surface ; ● Strength ● To maintain the above qualities, the project is required to be equipped with automatic machinery to be handled with.

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The proposed side located Goshairhat under Shariatpur district. Spot/Project has connected by road to upozilla road and the well river communication which road the year all necessary carrying can be done. Presently in shariatpur district near about 50 FCK Bricks fields are oprating and 25 Core Bricks (app) Produced all the production are consumed and big demand of adjacent districs can not full fil. If the Padma Bridge work starts then heavy demand of bricks will go up. beside presently all the production can be market by river with low cost carrying to Chadpur, Noakhali, Barishal, Khulna, Dhaka, Narrayanganj, Keranigonj, greates faridpur Dristrict.

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FINANCIAL ASPECT

A statement showing the forecast of earning which includes sales established cost of product and other cost is given the next page. The main assumptions are:a)

The project will work 300 days in a year on the basis of 8 hours 3 (three)-shift operation per day in kiln operation and 10 hours one shift for raw bricks production.

b) The price of raw materials and finished goods has been calculated on the current price basis. c)

Store and spares for the project has been calculated at 0.50%, 1.00% & 1.50% for the 1st, 2 nd & subsequent year on the machinery.

d) The cost of repair & maintenance for the project has been calculated at 0.50%, 1.00% & 1.50% for the 1st and 2nd & subsequent year on the machinery. e)

Rent, Tax, Insurance etc. for the project has been calculated 0.5% every year on the fixed cost.

f)

In wage & salaries increment will be at 5% per ye ar.

g) The capacity utilization has been assumed at 70%, 75% & 80% in the 1st, 2nd & subsequent year. h) Depreciation has been calculated at the following rates: -

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Building Machinery Furniture Transport Intangible assets Other items

5% 10% 20% 20% 19% 20%

Study on Auto Bricks Bangladesh Perspect

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