The use of biomass in clay brick production at Algoa Brick
In 2017, Algoa Brick’s Plant 2 tunnel kiln was upgraded add sawdust biomass capabilities. The Bernini oil-fired furnaces were supplemented with 4 new Bernini solid fuel zones firing on a hybrid mix of coal and biomass (sawdust). The benefits were significant and the updated system was instantly successful. However the amount of biomass the hybrid system could handle was limited at about 1 metric tonne per day, and Algoa was keen to further improve it’s sustainable firing goals.
In mid-2020, Algoa Brick took delivery of a Bernini sawdust burning system capable of firing a complete zone of the Plant 2 tunnel kiln. The installation was successful and between November 2020 and August 2021, Algoa Brick was able to increase biomass use to 4t per day.
After 9 months of experience using 4t per day of biomass, Algoa Brick was also able to make improvements to its in-house biomass feeding system while having all the electrical controls integrated into a single Human Machine Interface (HMI).
“We are now set up for remote monitoring,” reports Nico.
Currently, Algoa Brick’s Plant 2 tunnel kiln is being fired exclusively on solid fuels – a combination of coal and biomass is used with the total amount of biomass dependent on availability (obtaining sawdust of the right consistency is more challenging than ordering coal!). Heavy furnace oil burning equipment remains installed underneath the sawdust unit in case of inclement weather – Algoa Brick currently only has capacity to store about 3 days’ worth of sawdust due to the high volume required (>60m3).
The Plant 2 tunnel kiln meets the new emissions requirement for ceramic processes. With their commitment to improving sustainability, this is a critical consideration for the Algoa Brick team.
“We are proud to remain at the forefront of the clay brick industry’s sustainability drive in South Africa and the world. Every fossil fuel Megajoule that can be substituted with a biomass Megajoule is a win – for us AND for the world. Although the carbon tax saving makes great business sense, the real savings will be enjoyed by our descendants,” concludes Nico.
