Clay bricks are moulded in front of the first pilot plant of the VSB kiln in Mthyoka, Malawi.
The first pilot plant of the VSB kiln in Mthyoka, Malawi, serves as a template for our own plant which is currently under construction.
Briquettes made from rice husks have already been tested as external fuel in the test furnace.
The first VSBK which was co-financed by atmosfair, is currently being built in Blantyre. Production will start here at the beginning of 2025.
The traditional way of firing bricks in Malawi. Here, blanks are stacked and firing chambers are left open, into which firewood is then inserted.
Summary
| Total savings : | Approx. 1,000 tonnes of CO₂ per brick kiln per year |
| Technology transfer : | Energy-efficient brick firing in a Vertical Shaft Brick Kiln (VSBK) using biomass waste as a sustainable fuel. |
| Local environment : | Prevention of deforestation and land degradation by using biomass waste as fuel. |
| Further advantages : | Job creation in the construction, maintenance, and operation of VSB kilns. Development of a more sustainable construction sector in Malawi through increased efficiency in building material production, the use of renewable fuels, purchase of previously unused biomass waste, and reduction of health risks for brick producers by minimizing exhaust gases. |
| Project partners : | GIZ Malawi, Construction Materials Africa (local organisation), Malawian brick companies |
Ecological and health problems of traditional brick production
Bricks are a vital and popular building material in Malawi, a country with a growing population and significant demand for new housing and other infrastructure. Currently, brick production is largely informal. Bricks are stacked outdoors to form “clamp kilns” and fired using firewood and charcoal in the cavities below. This method is energy-inefficient, requiring large amounts of wood and contributing to deforestation. Additionally, this production method is labor-intensive, presents health and accident risks, and produces inconsistently fired bricks due to the difficulty of controlling the temperature.
In 2018, the Malawian government enacted a law requiring the use of energy-efficient and environmentally friendly materials and technologies in the construction of public and commercial buildings. However, there is currently no significant brick production in Malawi that meets these standards. atmosfair is addressing these challenges by introducing Vertical Shaft Brick Kilns (VSBK), which produce high-quality bricks efficiently and are fueled exclusively with renewable biomass.
Efficient brick firing with the VSBK
The VSBK is a kiln with one or two vertical shafts. Green bricks are placed at the top, move downward during firing, and are removed at the bottom as finished bricks. Approximately 70% of the required fuel is incorporated into the brick mass, allowing the bricks to burn efficiently from the inside. Producers use biomass waste such as sawdust or rice cultivation residues from Malawi. The remaining 30% of the fuel is supplied externally, using renewable materials like briquettes or pellets made from rice harvest waste, helping to preserve Malawi’s forests.
Protection of the Malawian forest
Firing bricks in insulated VSBK shafts requires only about 0.8 MJ/kg of brick, representing an energy savings of over 50% compared to traditional brick production. Beyond these efficiency gains, the use of biomass waste in place of firewood helps protect local forests, which is critical for Malawi. Current models show that 45% of deforested areas in the region are not regrowing. For brick producers, the VSBK increases production capacity and offers a more stable income.
Our partners
MIERA (More Income and Employment in the Rural Areas of Malawi) is a GIZ Malawi project focused on promoting sustainable building materials. It supports small businesses by organizing training and fostering networking opportunities. A key element of the project is the development of energy-efficient brick kilns.
The local organization, Construction Materials Africa, is responsible for selecting suitable small businesses, training them, and assisting in the purchase of renewable fuels. atmosfair provides low-interest loans to these small businesses for the construction and operation of energy-efficient kilns.
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