In zigzag kilns, bricks are arranged to allow hot air to travel in a zigzag path. The length of the zigzag air path is about three times that of a straight line, and this improves the heat transfer from the flue gases
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to the bricks, making the entire operation more efficient. In addition, better mixing of air and fuel allows complete combustion, reducing coal consumption to about 20 percent.
- The zigzag design also ensures uniform distribution of heat, increasing the share of Class I bricks to about 90 percent. It also reduces emissions considerably.
- The zigzag technology has two sub-types: natural and induced. The induced draft uses fans to regulate air While the natural draft has a chimney. The operational cost of the induced draft includes the cost of diesel and the maintenance of a generator to run the fan, which comes up to about Rs 250,000 a season. This cost is eliminated in the natural model, but it requires an initial investment in building a chimney
