Coal Briquette Pilot Plant Project, ZambiaPrepared by Energy and Environmental Concerns for Zambia, Lusaka, Zambia, for SPARKNET
Project summary
Location The Coal Pilot Plant Project is located in Chelston, east of Lusaka the capital city of Zambia. The project is about 15Km from the metropolis along the Great East road. The pilot project is the first Zambian coal briquette demonstration site. It is hoped that the Coal Briquette Pilot Project will demonstrate that coal briquettes can provide a viable energy alternative to use of charcoal or fuelwood in urban and peri-urban households.
Key statistics Location: Chelston, 15Km from Lusaka City Metropolis along Great East Road.
Scale: Small pilot project
Budget: US$ 306,684.60
Capacity: Current - 3 tonnes/ month; 36 tonnes/year, Projected- 83 tonnes/ month; 1000 tonnes / year
Capacity (Energy): Current - 19,500,000 Kcal / month; 234,000,000 Kcal/ year; Projected - 539,500,000 Kcal/ month; 6,474,000,000 Kcal / year
Contact details Coal Briquette Pilot Plant Project, National Institute for Scientific and Industrial Research, P.O BOX 310158, International Airport Road, Lusaka, 15302, Zambia
TEL: 260 01 281081/2/3
FAX: 260 01 283533/281084
E-MAIL: directorate@... / nisiris@...
Replication potential The replication potential of the project is good because the technology can be easily transferred, and the demand for an energy source for braziers or cook stoves in urban and peri-urban areas is high.
Funding Japanese International Cooperation Agency (JICA) and the Government of the Republic of Zambia (GRZ) through the Ministry of Science, Technology and Vocational Training and the Ministry of Power Transport and Communication provided funding for the project.
JICA provided most of the project funding and also provided the coal briquette and cook stove equipment meant for the pilot plant. GRZ provided counterpart funding through government grants to NISIR. The funds were mainly used in the civil work construction of the pilot plant.
Background In 1990 a FAO Survey of Zambia revealed that 39% of Zambia's total land area is covered with forests, out of which 1% or 3,300 Km squared has been disappearing every year. At this rate, Zambian forests will be depleted within 30 to 40 years, if measures are not taken to curb deforestation. This situation is mainly attributed to the dependence of 90% of Zambians on wood fuels as a household energy source. According to the Department of Energy (DoE) 1974-1996 Energy Statistics Bulletin, 76% of energy sources in Zambia are wood fuels and 83% of urban households use charcoal as an energy source as opposed to 24% in the rural communities. The forecast wood fuel consumption is one million tonnes per year by the year 2000; this is compounded by the relatively high population growth rate of 3% per annum and urbanisation rate of 4% per year. One convenient household energy source that can replace wood fuel is electricity. However, large investments would be required for the distribution infrastructure. In addition, most Zambians cannot afford the high connection costs and the high cots of electrical cooking appliances.
By 1989, Maamba Collieries was producing about a thousand tonnes of waste coal, with 40-55% carbon content, which was discarded in tailings ponds. Technical co-operation provided by the Japanese government led to the research and development (by NISIR) of coal briquettes, which utilise waste coal as the chief raw material in addition to bagasse, molasses (waste from sugar manufacturing) and slaked lime. The coal briquette is smokeless and odourless and emits low levels of sulphur dioxide gas. It is also more economical and hence more affordable than charcoal. NISIR also developed the clay stove, which was an energy management effort through improvement of combustibility of charcoal and briquettes. These research developments made the coal briquette a very good alternative to wood fuel as a source of household energy. The coal briquette also helps in the management of waste since all its raw materials are waste products of coal mining and sugar manufacture. According to forecasts it was projected that the demand for charcoal would amount to a thousand tonnes per annum, quarter of which would be the demand in Lusaka alone. In the light of this forecast, NISIR submitted a proposal to JICA for the development of a pilot coal briquette manufacturing plant, in order to satisfy part of the demand for wood fuel in Lusaka and also to show that manufacture of coal briquettes can be a viable business. JICA had already donated the briquette and cook stove manufacturing equipment during the research and development of the briquette. Thus the proposal was for the construction of a plant in which to fit the equipment already donated and to manufacture briquettes and stoves on a pilot scale. The pilot plant was commissioned on 15th December 1992 with the capacity to produce three tonnes of briquettes per month. It was projected that the plant would be able to produce 12 to 15 tonnes of briquettes per month by 1993.
Project description In 1985, the government of the Republic of Zambia made a formal request to the Japanese government to fund and help conduct a feasibility study to ascertain the viability of producing coal briquettes and clay stoves for domestic applications. The feasibility study was conducted with significant input from NISIR. The study produced the following major results: - Two types of briquettes were developed i.e. igniter briquettes for ignition of the fire and ordinary briquette to maintain the fire. 1.3 Kg of briquettes can keep a fire burning for six hours. Each briquette weighs about 3.2 grams.
- The calorific value of briquettes was found to be 6,500 Kcal/Kg
- Briquettes are sturdy, quenchable and reusable
- Annual production of briquettes was pegged at 1000 tonnes per annum
- Lusaka was considered a suitable location for a coal briquette pilot plant
- With maintenance and insurance costs at zero, the project would be financially viable
JICA had provided the briquetting and cookstove equipment during the feasibility study phase. After the feasibility study, it was proposed by GRZ that a Pilot Coal Briquette Plant be constructed in Chelstone and the available briquette and cook stove equipment be fitted into it. The pilot plant was to be operational by 1992 with the capacity of producing three tonnes of briquettes per month and increasing to 12 to 15 tonnes of briquettes per month by 1993. The main resources required for the manufacture of the briquettes are waste coal or slurry from Maamba Collieries Limited, Bagasse and Molasses from Zambia Sugar Company. Table 1 shows the existing equipment at the pilot plant and their status as at 1999.
Table 1: Existing equipment at the pilot plant by 1999 | | CARBONIZER | BRIQUETTING MACHINE | CLAY STOVE MACHINE | | Year of purchase | September 1989 | March 1991 | March 1991 | | Country of Origin | Japan | Japan | Japan | | Manufacturer | Hashimoto Sangyo Company | Hashimoto Sangyo Company | Hashimoto Sangyo Company | | Quantity | 1 set | 1 set | 1 set | | Condition | Operational | Operational | Operational |
Cost of service The coal briquettes are cheaper than charcoal because resources used for their manufacture are waste from coal mining and sugar processing, and briquettes last longer than charcoal. A 25 Kg bag of coal briquettes costs about K10, 000 (Approximately US$2.00) were as the same quantity of charcoal costs about K 20,000 (Approximately $4.00). The cost of the coal briquettes is not very real because it does not take into consideration the cost of capital since the Japanese government donated the equipment. Including capital costs would therefore make the briquettes cost higher especially if the equipment was obtained using a loan.
Maintenance The money realised from the sale of briquettes is used for paying for the plant maintenance, cost of resources and labour. However, the money is not enough to overhaul the plant. The plant owners need to identify sources of funding, for overhauling the plant. This may be through internal funds such as increasing the costs of briquettes and identifying sources of efficiency gains.
Delivery structure The plant is the property of GRZ through NISIR, which is under the Ministry of Science Technology and Vocational Training. From the pilot phase, the project is to be upgraded into a commercial entity. NISIR is not necessarily interested in commercial ventures, its main interest being research and proving viability of projects after which commercial enterprises are to carry on with the projects. Until the plant is commercialised, it shall remain the property of NISIR. JICA is currently willing to provide the equipment required to upgrade the plant to a commercial level as long as Government of the Republic of Zambia supports the project through counterpart funds.
Implementation progress By 1992, the plant was operational and was to produce 12 to 15 tonnes of coal briquettes per month by 1993. However, the target to produce 12 to 15 tonnes per month by 1993 was not realised due to failure to upgrade the plant, as funds to do so were not forthcoming. The equipment was operational as of 1999 (Table 1).
By 1999 the project proved that manufacture of coal briquettes is viable. In light of this, GRZ through NISIR submitted a proposal to JICA for the upgrading and increasing of production capacity of the pilot plant, so that it moves from the pilot phase.
Project management
Implementation organisations The following are the contributions of the participating organisations:
JICA: Funding, consultancy, donation of cook stove and coal, Briquetting equipment and provision of technical labour.
NISIR: Construction of plant, provision of project personnel; provision of premises for pilot plant, provision of communication facilities and office space and provision of labour
Local project personnel The labour force at the pilot plant was as follows: Production Manager; two Technical Assistants to the Production manager, eight general workers; one Records Clerk; One Truck Driver and One Typist.
Project management team Dr. J Kaoma- Project Supervisor (NISIR); Mr. S Mwonu- Senior Project Technical Officer (NISIR); Mr. J Bwalya- Project Technical Officer; Mr. M Bweembya- Project Technical Officer (NISIR); Mr. R Khondowe- Assistant Project Technical Officer (NISIR); Mr. A Mukumbwa- Assistant Project Technical Officer (NISIR); Mr. Nayagama- Project Expatriate (JICA)
Lessons learnt Social The project has demonstrated that briquettes have better combustion properties than charcoal, which means that there is relatively less carbon monoxide poisoning in households using coal briquettes. Currently, the pilot plant is unable to meet the demand for coal briquettes in Lusaka, hence there is need to upgrade the plant to a commercial level. The high demand for the briquettes shows that people have appreciated the briquette technology and are willing to use it.
Economic The project has demonstrated that coal briquettes are an easily available household fuel with lower prices and better combustion properties than charcoal. The project has shown the possibility of commercialising production of coal briquettes and also the possibility of business opportunities in supply of raw materials required for the manufacture of coal briquettes. The project has also demonstrated that there is relatively high demand for the coal briquettes as the current production at the plant is unable to meet the demand in Lusaka alone. A 25 Kg bag of coal briquettes costs about K10, 000 (Approximately US$2.00) were as the same quantity of charcoal costs about K 20,000 (Approximately US$4.00), which is twice the price of the Briquettes.
Technical The feasibility studies of the project showed that 1.3 Kg of coal briquettes can burn for six hours, whilst the same weight of charcoal would burn for one and a half hours. On the other hand studies also showed that the calorific value of each briquette is about 25.2MJ/Kg while that of charcoal is 30.4MJ/Kg. Thus, though Briquettes have a lower calorific value than charcoal, they last longer than charcoal. Briquettes are also quenchable and reusable unlike charcoal, which is difficult to reuse once it has been quenched.
Ecological / environmental The charcoal consumption per household in Zambia is about 2.5Kg per day which comes to about 693,500 tonnes per year; where as the projected potential demand for coal briquettes is about 520,125 tonnes per year. The projected demand for briquettes translates to about 3,835,000 square meters per tonne of wood, which is approximately equal to 511Km Squared of forest. Saving 511 Km squared of forest translates into 102,200 tonnes of carbon dioxide being absorbed from the atmosphere, hence contributing to the reduction in green house gas emissions which have been linked to global warming. Apart from reducing the rate of deforestation by substituting charcoal as a household energy source, the processing of coal briquettes does not contribute significantly to pollution. Carbonisation of the coal slurry during briquette processing produces volatile gases and sulphur compounds which are burnt before emission into the atmosphere. However, the amount of sulphur dioxide in the emissions is within tolerable limits. About 7,628,500 tonnes of carbon dioxide are emitted per year due to charcoal production in Zambia, which is more than that projected for the production of the same amount of coal briquettes, which would result in the emission of 188,467 tonnes of carbon dioxide per year. The combustion of charcoal per year in Zambia emits about 1,779,983 tonnes of carbon dioxide per year where as the combustion of the same amount of briquettes would produce 1,067,990 tonnes of carbon dioxide. Furthermore, the briquettes have good combustion properties and hence release little or no carbon monoxide, therefore reducing indoor air pollution.
Implementation lessons After the pilot plant was commissioned on 15th December 1992 with a coal briquette production capacity of three tonnes per month, it was projected that the production capacity would be increased to 12 to 15 tonnes per month by 1993. This projection has not been implemented to date (the year 2003) and the plant continues production at the capacity of three tonnes per month. There is need to ensure that pilot projects have a sustainability plan drawn at the time they are initiated. Such a plan should show how the project shall run economically or how it will be commercialised, such that when the project period is over business enterprises can take it up on a commercial basis.
References and Documentation NISIR, Ministry of Science Technology and Vocational Training (1999) The Application for Japanese Grant Aid for Coal Briquette Development Centre Project (Upgrading)
Maamba Collieries Limited- Preinvestment and Technical Report on Proposed Coal Briquetting Plant (in Maamba)
NISIR, Ministry of Science Technology and Vocational Training (1989) Coal Briquette Development Project- Pilot Plant Study.
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