Quantification of atmospheric emissions and energy metrics from simulated clamp kiln technology in the clay brick industry

The quantification of atmospheric emissions from clamp kilns in the clay brick industry has met with limited success globally. The complex configuration of clamp kilns using coal or other carbonaceous fuels and uncertainties regarding kiln combustion conditions, has proven to be a hurdle in measurement of emissions and standardization of process and energy metrics. To enable quantification of these metrics, a model kiln was designed to simulate operating conditions and configuration similar to transverse slice of a typical full-scale clamp kiln, but with lower capacity (20,000 to 35,000 bricks per cycle). Hourly measurements of flue gas at extraction duct were recorded for thirteen firing cycles obtained from various source factories, each lasting 8-14 days, for SO₂, NO₂, NO, PM, CO and CO₂ emissions in the extraction stack. A statistical mean efficiency for model kiln emissions capturing and channelling capacity was calculated from sulfur mass balance results of batches that lie within 95% confidence interval of assumed true mean (100%) to give 84.2%. Final emission factors (mean ± standard deviation) were quantified as 22.5 ± 18.8 g/brick for CO, 0.14 ± 0.1 g/brick for NO, 0.0 g/brick for NO₂, 0.14 ± 0.1 g/brick for NO_x, 1.07 ± 0.7 g/brick for SO₂, 378 ± 223 g/brick for CO₂; 0.96 ± 0.5 g/brick for PM₁₀; as well as 1.53 g/brick for hydrocarbons. Energy analysis indicate that a significant reduction of 0.9 MJ/kg (36%) in energy use could be achieved by clamp kiln operators, thereby reducing input costs, and significantly reducing atmospheric emissions.