| Abstract | This study discussed the economic factors of coal-fired brick production versus gas fired production. It suggests that gas firing would not only produce better quality bricks, but it would also save precious foreign
exchange now being used for coal purchase on the international market. At present, three factories are producing a total output of about 22 million
pieces of machine-made bricks per year in the Dacca area.
The price of the bricks from these factories is about 1 1/2 times greater than that of the
ordinary hand-made construction bricks. The high cost of the products of
automatic factories is mainly due to the high fuel cost and the high
capital equipment cost. In these industries, the cost of fuel accounts for 30 percent of the total cost whereas the fixed cost counts for 52 percent of the total cost. In a recent survey in Dacca, Tangail, Narayangonj, Ghorasal,
Bhairab and Brahmanbaria -- it was found by the author that 70 percent of the total requirement of bricks for Dacca city is supplied by the brick fields located on the western bank of Burigonga River. are These brick fields (1) completely seasonal, (2) temporary, (3) based on the availability of Government tender for supplying bricks, and (4) operated on leased land
for a maximum period of four to five.
The kilns used in these brick fields are known as trench kilns.
The present production cost of hand-made bricks from these fields amounts to Tk456/= per thousand bricks. Out of this sum the fuel cost amounts to
Tk218/= and the direct labour and material is valued at Tkl28/=. Besides fuel, the second factor is high capital enrollment at the beginning of each season.
The capital outlay for a coal-fed trench kiln having a production capacity 1.5 million bricks per year is Tk638,085/=, out of which the working capital amounts to Tk539,175/= and the main component of the
working capital is fuel valued Tk327,000/=. The utilization of natural gas in the field of brick manufacturing will reduce the necessity of importing coal on the one hand and will ensure the
supply of well burnt better quality bricks to the market on the other hand. Moreover, it is possible to bring down the price of brick by 2/3 of the present value by the use of gas instead of coal. The proposed semi-continuous shuttle kiln (981311 x 51 X 51 ) having a 321911 firing zone remains within the beget required to construct an average size coal fired trench
kiln of capacity 1. 5 million bricks per year. The kiln can produce 1.5 million bricks per year for one shift operation in a day and 3 million bricks per year for a two shift operation in a day.
The above kiln with a one
shift operation can save 0.6 million Taka from the cost of fuel in the first two years of its operation, and at the same time it will enjoy a special discount of Tk 54,000 over other industries using gas (based on the gas
consumption of 5MCF/1000 bricks. For a well designed kiln, the amount of natural gas required to burn 1000 bricks is about 4MCF) . From the third
year on, the gas bill would amount to Tk54,000/= per year, whereas for coal it would be Tk327,000/= per year for the same number of bricks.
The above idea has been developed while keeping in mind all the constraints, such as
technical know-how, foreign exchange, limitation of capital, etc. Locally available inspirator burners are used for its operation in the primary
stage. The only step required by the Government is to build one experimental kiln in conjunction with private investors to attract other brick field owners. |