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Building a better future with cleaner bricks

Project completed
Workers packing the fired bricks
Workers packing the fired bricks from the VSBK at Langkloof Bricks. © Swisscontact Swisscontact

Clay brick production in South Africa produces large emissions of greenhouse gases due to the use of old, energy-inefficient clamp firing systems. To solve this problem SDC is supporting the South-South technology transfer of the Vertical Shaft Brick Kiln. This energy-efficient technology considerably reduces coal consumption and cuts CO2 emissions by half. The first pilot plant was inaugurated in September 2011 in Jeffrey’s Bay, Eastern Cape.

Country/region Topic Period Budget
South Africa
Climate change and environment
Employment & economic development
Biosphere protection
SME development
01.11.2013 - 31.10.2017
 CHF  4’150’000
Background

South Africa has a highly carbon intensive economy. With 90% of electricity generated from coal, the industrial sector contributes the most to CO2 emissions in the country. In order to curb emissions growth, the government has developed policies and regulations, among which the regulations and standards for air quality as well as the imminent carbon tax for industries. Faced with regulatory pressures, the industry has been in the forefront in seeking ways of introducing technologies and measures to reduce energy consumption and CO2 emissions in their production processes. In the previous phase, SDC and Swisscontact have supported the clay brick sector by introducing in South Africa an energy efficient firing technology, the Vertical Shaft Brick Kiln (VSBK). To date, six very energy efficient VSBK were constructed in one factory. Although the technology has been successfully transferred in South Africa, and the provision of services fully commercialized, the critical mass has not been reached yet. The project needs to improve or make the VSBK delivery package more attractive to a wider range of entrepreneurs and maximize what was invested. At policy level, by promoting only the VSBK technology, the 1st Phase failed to get government buy-in or endorsement which in turn hampered policy dialogue. This phase will continue with the investment made in supporting the adoption of the VSBK and will broaden its scope to include as well support to the clay brick sector in adopting other energy efficient measures and practices.
Objectives

Increased energy efficiency and lower CO2 emissions growth is achieved in the clay brick sector in South Africa.
Target groups

The direct beneficiaries of the project will be the clay brick producers and the workers of the factories newly converted to VSBK, who will benefit from improved working conditions.
Medium-term outcomes
  • Improved carbon footprint of clay brick production
  • Conducive policies and business environment for energy efficient clay brick sector
  • Adoption of low carbon clay bricks by the building sector in South Africa
Results

Results from previous phases:  

Since November 2009, the 1st phase of the VSBK Project has achieved the following results:

  • Successful transfer of the VSBK technology with fully commercialized services
  • Six pilot VSBK shafts in operation and performing beyond expectation with more than 50% energy savings. 18 more shafts currently under construction in the same site
  • Improved working conditions for labourers compared to traditional clamp kilns
  • Improved partnerships with Clay Brick Association and Department of Environmental Affairs
Directorate/federal office responsible SDC
Credit area Development cooperation
Project partners Contract partner
Swiss Non-profit Organisation
  • Swisscontact
  • SKAT


Other partners

SDC, Private sector, banks, CDM Africa, South African Department of Environmental Affairs, Clay Brick Association
Budget Current phase Swiss budget CHF    4’150’000 Swiss disbursement to date CHF    3’369’162
Project phases

Phase 2 01.11.2013 - 31.10.2017   (Completed)

  • Sector according to the OECD Developement Assistance Commitiee categorisation GENERAL ENVIRONMENT PROTECTION
    INDUSTRY
    Sub-Sector according to the OECD Developement Assistance Commitiee categorisation
    Biosphere protection
    Small and medium-sized enterprises (SME) development
    Type of support Official development assistance (ODA)
    Type of collaboration Bilateral cooperation
    Finance type Aid grant
    Aid Type Mandate with fiduciary funds
    Mandate without fiduciary fund
    Tied/untied aid Untied aid
    Project number

    7F07198

Clay brick manufacturing in South Africa is a modern state-of-the-art industry as far as clay mining and the production of “green” (unfired) bricks is concerned. However, bricks are still predominantly fired in inefficient clamp kilns, which date back to Roman times. Facing new environmental regulations, increasing coal costs and shrinking profits, South African brick entrepreneurs are actively looking for energy-efficient firing methods.

Working principles of the VSBK

The Vertical Shaft Brick Kiln (VSBK) is an energy-efficient brick oven, which origi-nated in China and was adapted and improved with support from SDC in India and Nepal. The kiln comprises a vertical shaft. The bricks are loaded at the top of the shaft and removed at the bottom in a continuous process.. The firing shaft is well insulated on all four sides to minimise heat loss. The hot exhaust gasses are used for the gradual preheating of the unfired bricks on top, thus reducing energy con-sumption and CO2 emissions by up to 50% compared to the more commonly used clamp kilns. The switch to VSBK technology signifies an important change in working conditions: instead of day shifts a 24-hour operation is introduced and workers’ skills are enhanced.

Finance for investment in VSBK

South Africa has been facing a severe financial crisis, which significantly affects the construction sector. Since the beginning of the crisis, clay brick production has been halved and the profit margins of the producers have practically disappeared. Impending environmental regulations will soon enforce the sourcing of cleaner, more energy-efficient brick firing methods. Confronted with these challenges, the VSBK project is facilitating access to “green funds” and the Clean Development Mechanism (CDM) market. The project supported the development and registration of a Programme of Activities that will generate Certified Emission Reductions to be sold on the CDM market.

Contribution to sustainable development

The VSBK project not only has a positive impact from an economical and environ-mental point of view, it also carries many significant social benefits:

  • Improved environmental, health and safety conditions
  • Skills development
  • Job creation
  • New opportunity for women

In contrast to traditional kilns, the VSBK emits virtually no gasses, thus benefitting workers’ health. The risks of falling from heights or of collapsing brick stacks are also greatly reduced with VSBK.  Proper use of the VSBK requires specific train-ing, allowing employees to improve their value on the job market.

This technology is not only expected to create a large number of jobs, these jobs will be physically less demanding. Thus women will be able to access other posi-tions within the brick factories.

100 shafts within four years

This project forms part of the Energy Efficiency Building Programme supported by SDC in South Africa. The project is implemented by a consortium of Swisscontact and Skat with active involvement of experts from India and Nepal.
It is estimated that over the next 5-10 years up to 50% of the brick enterprises will adopt this technology in South Africa. In the first four-year phase, the aim is to raise awareness among the brick entrepreneurs and the authorities. This should lead to the start of construction of 100 VSBK shafts with an annual production capacity of more than 180 million bricks. Emission of greenhouse gases will be reduced by 84’000 tons of CO2 per year.

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Last update 12.05.2020