Energy efficient brick and pottery industry -
Transcript of Energy efficient brick and pottery industry -
30â TechâMoniTorâ â˘ânov-Decâ2011
IntroductionBrickâmakingâisâaâtraditionalâjobâinâruralâareasâ inâ manyâ developingâ countries.âBricksâareâanâindispensableâconstruc-tionâ materialâ withâ anâ ever-increasingâdemandâ asâ economiesâ inâ theâ regionâareâgrowing.â itâ isâestimatedâ thatâoverâ1,000âbillionâbricksâareâproducedâandâconsumedâinâAsiaâperâyear.âToâproduceâ1,000âbillionâbricks,âitâneedsâ110âmillionâtonsâofâcoalâperâannumâemittingâroughlyâ180âmillionâtonsâofâcarbonâdioxideâemis-sionsâ(heierliâandâMaithel,â2008).â
Biomassâsuchâasâwoodâandâriceâhuskâisâalsoâusedâforâkilnâfiring.âFromâgreen-houseâgasâstandpoint,âbiomassâfuelâ isâconsideredâasâcarbon-neutral,âbutâevenâbiomassâdirectâ fuelledâ traditionalâkilnsâwithâlowâenergyâefficiencyâhaveâproblemsâemittingâdark,âpollutingâsmokeâcausingâharmfulâ healthâ effectsâ toâ peopleâ andâdestroyingâproductivityâ ofâ neighboringâagriculturalâfieldsâasâsootâcoversâplantâleavesâobstructingâphotosynthesis.âTheâgrowingâinterestâonâblackâcarbonâ(com-monlyâknownâasâsoot)âasâoneâofâtheâsig-nificantâcontributorsâtoâglobalâwarming,âafterâcarbonâdioxide,âhasâbroughtâinterna-tionalâattentionâtoâidentifyâitsâsourcesâandâfindâwaysâtoâcurbâblackâcarbonâemissionsâ(UneP,â2011).âTheâUnePâstudyâidentifiedâtraditionalâkilnsâwithâdirectâfuelâsystem,âregardlessâofâfuelâusedâforâfiring,âasâoneâofâtheâmainâsourcesâofâblackâcarbon.
To mitigate climate change and improve local air quality, how can small brick factories using traditional kilns adopt cleaner technologies and improve
efficiency without causing rural unem-ployment?
TheâAsia-PacificâForumâforâenviron-mentâandâDevelopmentâ(APFeD)âshow-caseâProgrammeâinâ2008âselectedâtheâproposalâbyâtheâenergyâconservationâresearchâ andâ Developmentâ centerâ(enerTeAM)âtoââSetâupâaâdemonstra-tionâ modelâ forâ theâ applicationâ ofâ riceâhuskâgasificationâ inâbrickâandâpotteryâindustryâ inâVietânamââwithâdualâgoalsâofâintroducingâcleanerâtechnologyâââaâbiomassâgasâfuelledâkilnâââtoâreduceâairâ pollutionâ whileâ utilizingâ availableâriceâhusksâasâfuelâandâpresentâaâviableâbusinessâmodelâsuitableâtoâsmallâandâmediumâbrickâfactories.âTheâinstituteâforâGlobalâenvironmentalâStrategiesâ(iGeS)âsupervisedâandâmonitoredâtheâproject.ââ
Brick and pottery industry in Viet NaminâMekongâDeltaâââespeciallyâinâDongâThap,âVinhâLongâandâAnâGiangâprov-incesâââthereâareâapproximatelyâ4,500âtraditionalâriceâhuskâfuelledâkilnsâforâclayâburningâproducingâbricks,âtilesâandâpot-tery.âitâ isâaâmajorâsourceâofâ localâ jobsâwithâoneâkilnâownerâemployingâ10âtoâ100âemployees.â
Theâ brickâ andâ potteryâ industryâ inâVietânam,âevenâtheâsmallâscaleâenter-prisesâinâruralâareas,âareâwellâadvancedâcomparedâtoâoperationsâinâSouthâAsia.âTheâgovernmentâsupportedâtheâindus-tryâprovidingâincentivesâtoâimproveâbrickâmakingâtechnologiesâpavingâtheâwayâforâhollowâbricksâasâwellâasâexport-qualityâpotteryâproducts.âUnfortunately,âwhileâ
AbstractTheâ brickâ industryâ isâ consideredâtheâindustryâofâtheâpoorâemployingâmanyâ lowâskilledâworkersâ inâ ruralâareasâ inâ theâ Asia-Pacificâ region.âTraditionalâkilnsâemitâdarkâsmokeâwhichâ isâharmfulâ toâ theâhealthâofâtheâworkersâasâwellâasâotherâpeo-pleâ inâ theâ community.â Upgradingâtheâtraditionalâkilnâ technologyâwillâimproveâtheâqualityâofâ lifeâ inâbrickâproducingâ communities;â reduceâfuelâ consumptionâasâwellâ asâ car-bonâemissions.âAâcaseâstudyâonâaâ4-chamberâcontinuousâburningâkilnâintegratedâwithâriceâhuskâgasifica-tionâsystemâinâVietânamâimplement-edâbyâenerTeAMâandâsupervisedâbyâiGeSâisâdiscussedâtoâshareâhowâitâachievedâbetterâqualityâproducts,âreducedâ environmentalâ pollutionâandâ utilizedâ locallyâ availableâ bio-massâasâfuel.
Dr. Jane RomeroPolicyâresearcher/climateâchangeâSpecialistâinstituteâforâGlobalâenvironmentalâStrategiesâ(iGeS),â2108-11âKamiyamaguchi,âhayama,âKanagawa,â240-0115,âJapan
Tel:â+81-46-855-3847;âFax:â+81-46-855-3809e-mail:â[email protected];âWeb:âhttp://www.iges.or.jp
EnErgy EfficiEnt brick and pottEry industrythE casE of ricE husk gasification tEchnology in ViEt nam
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theâqualityâofâproductsâ improved,â theâproductionâprocessâmostlyâ relyingâonâtraditionalâkilnsâwithâdirectâfuellingâsys-temâusingâriceâhusksâremainedâpolluting.âAirâpollutionâfromâtheâkilnsâputâaâstrainâonâtheâqualityâofâlifeâinâtheâcommunities.
inâ2001,âtheâgovernment,âinâresponseâtoâclamoursâtoâimproveâairâquality,âissuedâaâregulationâtoâprohibitâtraditionalâbrickâmakingâkilnsâinâ2010â(Decisionâ115/2001/QD-TTgâofâtheâPrimeâMinister).âTheâten-yearâwindowâtoâcleanâupâ theâ industryâintroducedâsomeâcleanerâtechnologiesâsuchâasâhoffmanâkilnâandâ tunnelâkiln.âThoseâgovernmentâpromotedâalterna-tivesâuseâfossilâfuelsâeitherâfuelâoilâorâcoalâasâfuel,âanâadditionalâexpenseâcomparedâtoâtheâalmostâfreeâriceâhusks.âSomeâtun-nelâkilnsâbuiltâinâMekongâDeltaâconsumedâ20âtoâ30âtonsâofâfuelâoilâperâmonthâwhichâmadeâproductionâunprofitable.â
AsâillustratedâinâFigureâ1,âwhileâtheâuseâofâfossilâfuelsâcouldâreduceâlocalâairâpollution,âitâwouldâcontributeâtoâtheârisingâglobalâcarbonâemissions,âwhichâisâtheâmainâdriverâofâclimateâchange.â
Theâfossil-fuelledâkilnsâwereâdeemedâinadequateâtoâbothâmitigateâtheâpollutionâproblemâandâbeâanâeffectiveâbusinessâmodelâappropriateâtoâsmallâandâmediumâbrickâfactories.âTraditionalâkilnâownersâhadâlimitedâoptionsâââcloseâtheirâpollutingâfac-toryâandâcreateâunemploymentâorâswitchâtoâfossil-fuelledâkilnsâwithâhigherâproduc-tionâcostsâriskingâeventualâbankruptcy.âeventually,âtheâsocialârepercussionâisâsoâhighâthatâtheâgovernmentâwithheldâtheâfullâimplementationâofâtheâlawâcontinuingâtheâsearchâforâbetterâalternatives.â
How does the new system work?Theâ technologyâ isâ notâ newâ ââ con-tinuousâkilnsâandâbiomassâgasificationââsystemâareâprovenâtechnologiesâbutâtheâintegrationâofâbothâsystemsâappliedâtoâ
clayâburningâhasânotâbeenâtriedâbefore.âTheâdomeâshapedâtraditionalâkilnâcom-monlyâusedâ inâVietânamâhasâunevenâdispersionâofâheatâsoâ itâwasâreplacedâbyâaâ4-âchamberâcontinuousâburningâkilnâwithâbetterâenergyâefficiencyâ(Figureâ2).âitâwasâdevelopedâbyâSongklaâUniversityâinâThailandâforâwoodâandâsawâdustâfir-ing.âitâwasâmodifiedâforâriceâhuskâfiringâbyâenerTeAMâengineersâasâriceâhusksâareâabundantâinâtheâMekongâDelta,âesti-matedâatâoverâ3.6âmillionâtonsâperâyearâfromâpaddyâproduction.âTheâgasifierâwasâsuppliedâbyâAnKUr,âaâpioneeringâin-dianâgasificationâsystemsâmanufacturer,âwhileâ theâ burnersâ wereâ locallyâ fabri-catedâbyâenerTeAMâtoâreduceâcosts.âenerTeAMâ âcollaboratedâ withâ SMeâ
renewableâ âenergyâ Ltd.â â(cambodia)âwhichâhasâconsiderableâexperienceâonâriceâ huskâ gasificationâ forâ smallâ scaleâpowerâgenerationâonâhowâtoâintegrateâtheâgasificationâsystemâintoâtheâkiln.âââ
The 4-chamber continuous burning kilnBasically,âtheâmainâprincipleâtoâoperateâtheâ4-chamberâburningâkilnâisâtoârecoverâtheâheatâfromâtheâpreviousâprocessesâforâuseâinâtheâsubsequentâprocessesâasâillustratedâinâtheâfollowingâdiagramâandâdescribedâasâfollows:
â˘â FreshâoutdoorâairâflowâintoâtheâcoolingâchamberâDâtoâcoolâ theâfiredâbricksâwhileâtheâairâisâheatedâupâbeforeâgo-ingâintoâtheâfiringâchamber.
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With Non Fossil BAU (ton of CO2) Year
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Fig. 1. Trend of carbon emissions if traditional kilns shift to fossil-fuelled kilns
Fig. 2. The 4-chamber continuous burning kiln
Fresh air
Drying
Chimney/fan
Firing
Hot air control valves
Fresh air
A
PreheatingB
C
CoolingD
Rice husk
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â˘â Theâ exhaustâ gasâ fromâ theâ firingâchamberâ Aâ isâ channeledâ toâ pre-heatârawâproductsâinâtheâpreheatingââchamberâB.
â˘â Atâtheâpreheatingâchamber,âtheâgasâfromâfiringâchamberâreleaseâaâpartâofâ theâheatâtoâtheârawâproductsâasâwellâ asâcontinuouslyâbeingâventedâtoâtheâdryingâchamberâcâtoâdryâtheârawâproductsâbeforeâtheâgasâisâdis-chargedâ throughâ theâchimney.âTheâexhaustâ gasâ temperatureâ isâ aboutâ80°âcâtoâ100°âc.â
â˘â Theâ firingâ flameâ isâ thenâ shiftedâ toâtheânextâ chamberâafterâ finishingâaâbatch.âcontinuously,âtheâfiringâflameâisâsequentiallyâshiftedâtoâallâfourâkilnâchambersâ asâ theâ activityâ inâ otherâchambersâalsoâmoveâtoâtheânextâstepâofâtheâfiringâprocess.â
The rice husk gasification systeminâtheâgasifier,âriceâhuskâisâputâthroughâanâanaerobicâpyrolysisâtoâgenerateâcom-bustibleâgasâmixtureâfromâsolidâbiomassâ(Figureâ3).âTheâcombustibleâgasâmixtureâisâ thenâ conveyedâ throughâ oneâ ofâ theâ
manyâfilterâsystemsâtoâremoveâdust,âtarâandâotherâby-productsâtoâgetâaâcleanerâcombustibleâgas.âTheânumberâofâfiltersârequiredâisâbasedâonâtheâproductâquality,âcouldâbeâupâtoâsixâfiltersâforâglazedâpottery.
Afterâtheâpyrolysisâprocess,âtheâashâandâ non-flammableâ remainingâ riceâhusksâareâremovedâbyâwater.âTheâwaterâusedâforâashâremovalâisârecycledâsoânoâwastewaterâisâdischarged.âTheâashâisâcol-lectedâandâsoldâtoâsugarâcaneââfarmersâorâgardenersâtoâbeâusedâasâfertilizer.âTheâcombustibleâ gasâ isâ ventedâ toâ theâ dif-fuserâtoâremoveâdustâandâbeâcooled.âTheâwastewaterâisâalsoâcollectedâforâreuse.â
The pilot project WhileâAPFeD,âiGeSâandâenerTeAMâprovidedâtechnicalâassistance,âaâwillingâtraditionalâkilnâownerâhasâtoâbearâtheâcostâofâsettingâupâtheânewâsystem.âTAnâMAiâceramicsâco.âLtd.âinâSaâDec,âDongâThap,âVietânamâagreedâtoâbeâbuildâtheâdem-onstrationâproject.âitâisâaâmediumâsizedâenterpriseâwithâ59âemployeesâengagedâinâmanufacturingâandâtradingâofâbricks,âpotteryâandâotherâceramicâproducts.â
Toâacquireâ theâgasificationâsystem,âTAnâMAiâhadâtoâsecureâaâbankâloanâwhichâwasâguaranteedâbyâtheâProjectâonâPro-motingâenergyâconservationâinâSmallâandâMediumâenterprisesââ(PecSMes)âhostedâbyâtheâMinistryâofâScienceâandâTechnol-ogyâco-financedâbyâUnitedânationsâforâDevelopmentâProgramâ(UnDP)âandâtheâGovernmentâofâVietânamâmanagedâbyâVietinBank.âTheâprocessâtookâlongerâthanâinitiallyâplannedâasâpartiesâwereânotâawareâofâtheânecessaryâprocedures.âitâwasâtheâfirstâ gasificationâ technologyâ projectâ inâVietânamâwithânoâdefinedâstandardsâyet.âAâdialogueâamongâpartiesâwasâconvenedâtoâfacilitateâtheâtransaction.âTheâresultsâofâtheâdialogueâbecameâtheâbenchmarkâforâpartiesâtoâaidâfutureâprojects.ââ
Theâ22.6âm3âxâ4âchambersâwasâcon-structedâbehindâ theâ traditionalâkilnâasâshownâinâtheâphoto.âitâwasâconstructedâbyâTAnâMAiâusingâlocalâmaterials.âTheâimportedâ gasifierâ wasâ assembledâ byâenerTeAMâ inâcollaborationâwithâ theâcambodianâpartnersâwhoâalsoâassistedâinâcalibratingâvariousâparametersâappro-priateâforâclayâburning.â
During construction of new kiln Commissioning of gasifier Layout of integrated system
Cold water in from scrubber pump
Drain tubwith spout
PVC duct hose
PVC flexible hose pipe Flare valve
Combustion air inlet
Separation tank
Venture scrubber(Cools & removes particulates from gas)
Biomass in
GL
Reactor
Gasifier(Converts biomass
to hot gas)
SS sieve(For char â water
separation)
Coarse filter(Removes tar, particulates
and moisture)
Gas blower(Delivers gas
to burner)
Flare(For testing gas quality)
Hopper
Water in from char removal pump
Air Hot
gas line
Drain box Gas
control valvedrain tub
Shut-offvalve
Producergas burner
Air Air
Fig. 3. Illustration of the biomass gasification system
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Theâchamberâcanâholdâupâtoâ12,000âbricksâ(1âkgâââ1.2âkgâeach)âandâtheâfir-ingâperiodâisâ36âhours.âTheâkilnâcanâalsoâproduceâotherâproductsâlikeâterracottaâwithâvariationâ inâ theâdurationâofâfiringâtime.âTheâqualityâofâtheâfinishedâproductâisâbetterâthanâthatâofâtheâtraditionalâkilnâwithâonlyâlessâthanâthreeâperâcentârejectsâsoâmostâcustomersâpreferredâproductsâfiredâbyâtheânewâgasifier-kilnâcomplex.â
Theâ averageâ annualâ productionâcapacityâisâestimatedâtoâbeâaboutâ200,000âequivalentâstandardâterracottaâproductsâandâ450,000âflooringâtilesâperâyear.âLike-wise,âitâwasâestimatedâthatâtheâpaybackâperiodâcouldâbeâlessâthanâfourâyearsâtoâtheâUS$176,000âtotalâinvestmentâcost.âTheâequipmentâlifetimeâisâ20âyears.
Environmental impacts and energy performance Toâensureâthatâtheânewâkilnâcompliesâwithâtheâgovernmentâpollutionâstandards,âtheâexhaustâemissionâwasâmeasuredâbyâaâthirdâpartyâauthorizedâbyâtheâMinistryâofâenvironmentâandânaturalâresourcesâinâDongâThapâprovinceâ(Tableâ1).âââ
Dust,âash,âtarâandâotherâ impuritiesâareâfilteredâduringâtheâgasificationâproc-essâsoâthereâisânoâblackâsmokeâemittingâfromâtheâexhaustâvent.â
Theâ energyâ performanceâ ofâ theâ4-chamberâ continuousâ burningâ kilnâwithâriceâhuskâgasifierâcomparedâtoâtra-ditionalâkilnâwithâdirectâfuellingâsystemâisâpresentedâinâTablesâ2âandâ3.
Summary and way forward Theâpilotâprojectâshowedâtheâsuperior-ityâofâtheânewâkilnâintegratedâwithâriceâ
huskâ gasifierâ inâ termsâ ofâ producingâqualityâproducts,âbetterâenergyâperform-ance,âandâinâeliminatingâtheâblackâsmokeââidentifiedâwithâtraditionalâkilnsâandâotherâpollutantsâasâshownâinâtheâcomparisonâinâTableâ4.âWithâlittleâingenuity,âtheâprojectâshowedâtheâpossibilityâtoâcomeâupâwithâaâlow-carbonâalternativeâfromâexistingâtechnologies.â
Seminarsâ coupledâ withâ visitsâ toâtheâ actualâ pilotâ projectâ locationâ wereâconductedâtoâpromoteâ itsâreplication1.Throughâ theâ pilotâ project,â otherâ kilnâ
ownersâ couldâ learnâ andâ seekâ assist-anceâonâhowâtoâshiftâtoâenergyâefficientâandâenvironment-friendlyâtechnologyâtoâsustainâtheirâoperations.âTheâprojectâalsoâdemonstratedâtheâpossibilityâ forâsmallâandâ mediumâ enterprisesâ toâ accessâfundingâsupportâfromâorganizationsâpro-motingâmeasuresâtoâimproveâtheâenvi-ronmentâandâmitigateâclimateâchange.âitâisââfeasibleâtoâreplicateâandâdiffuseâthisâtechnologyâinâotherâcountriesâthoughâitâmayâneedâmodificationsâifâotherâtypesâofâbiomassâareâusedâasâfuel.â
Finished products after firingFlame from burner Raw bricks before firing
Indicator Unit National standard Testing results
Dust Âľg/m3 300 200
NOxÂľg/m3 200 2.79
SO2Âľg/m3 350 155.2
Noise dB 75 66.4
CO Âľg/m3 30,000 3,400
HF Âľg/m3 20 11.6
Table 1. Exhaust gas emission testing results
Type of kilnThermal energy
consumption standard (MJ/kg)
Note
Traditional kiln 3.54Fuelledâdirectlyâbyâ
riceâhusk
4-chamber continuous burning kiln with rice husk gasifier
2.48Usingâriceâhuskâtoâprovideâfuelâgas
Table 2. Comparison of specific thermal energy consumption
Type of kilnFuel quantity (in kg of
rice husk per 1,000 equivalent product)
Traditional kiln 2,654
4-chamber continuous burning kiln with rice husk gasifier
1,858
Table 3. Rice husk consumption for 1,000 products
1ââForâmoreâinformation,âcontactâMr.âLeâhoangâViet,âDirectorâââenerTeAMâatâ[email protected]âandâTAiâMAiâatâ[email protected].
34â TechâMoniTorâ â˘ânov-Decâ2011
Energy efficient brick and pottery industry
Theâprojectâwasâ recognizedâ inâ theâ2010â enerGYâ GLoBeâ Awardsâ asânationalâWinnerâforâVietânam.âTheâaward-ingâwasâheldâinârwandaâduringâUnâsâcel-ebrationâofâWorldâenvironmentâDayâ2010.ââ
ReferencesenerTeAMâ(2009).ââFeasibilityâstudyâofâsettingâupâaâdemonstrationâofâtechnicalâ
andâfinancialâmodelâforâtheâapplicationâofâriceâhuskâgasificationâinâVietânam,ââunpublishedâ(submittedâtoâiGeS).
enerTeAMâ(2010).ââFinalâreportâonâset-tingâupâaâdemonstrationâmodelâforâtheâap-plicationâofâriceâhuskâgasificationâinâVietânam,ââunpublishedâ(submittedâtoâiGeS).
heierli,âUrsâandâSameerâMaithelâ(2008).âBrick by brick: the Herculean task of
cleaning the Asian brick industry (Berne,âSwitzerland,âSwissâAgencyâforâDevelop-mentâandâcooperationâSDc).
UnePâ andâ WMoâ (2011).â integratedââAssessmentâ ofâ Blackâ carbonâ andââTroposphericâ ozone:â Summaryâ forââDecisionâ Makers.â Accessedâ atâ http://www.unep.org/dewa/Portals/67/pdf/Black_carbon.pdf.â
Evaluation parameters Traditional kiln 4-chamber kiln with rice husk gasification Coal fuelled kiln
Product variety Variousâproductsâ(bricks,âterracottaâceramics,âtiles,âetc.)
Variousâproductsâ(bricks,âterracottaâceramics,âtiles,âetc.)
Bricksâonly
Burning process completelyâinterrupted intermittentâwithâtheâpilotâflame
continuousâwithâfixedâfireâarea
Batch duration Longâ(severalâweeks) Shortâ(daily) Shortâ(daily)
Investment required Multipleâinvestmentâlevels Multipleâchoicesâwithâflexibleâkilnâsizeâandâconfiguration
highâinvestment
Fuel type Biomass Biomass Fossilâfuelâ(coal)
Fuel sources Availableâlocally Availableâlocally notâavailableâlocally
Technology features noâheatârecovery heatârecoveredâbyârecoveryâchambers
heatârecoveredâbyârecoveryâzones
GHG emission carbon-neutral carbon-neutral high
Overall local pollution risks
high Veryâlow Low
Air pollution affecting cash crops
high none none
Air pollution affecting human health and safety
high Veryâlow Low
Table 4. Analysis of alternatives
UNEP Climate Finance Innovation FacilityTheâclimateâFinanceâinnovationâFacilityâ(cFiF)âsupportsâfinance-industryâengagementâinâtheânewâclimateâsectorsârenewableâenergyâ(re)âandâenergyâefficiencyâ(ee).âTheâFacilityâprovidesâdevelopingâcountryâfinancialâinstitutionsâwithâtechnicalâassistanceâandâfundingâforâtheâdevelopmentâofâclimateâfocusedâfinancialâproductsâandâservices.âTheâsupportâcoversâupâtoâ50%âofâtrueâcosts,âdispersedâinâmilestoneâbasedâtranches,âwithâtheâremainingâoutâofâpocketsâexpensesâcoveredâbyâtheârequestingâfinancialâinstitution.Aâbroadârangeâofâactivitiesâareâeligibleâforâsupport,ârangingâfromâfeasibilityâstudies,âtoâmarketâassessmentsâandâlegalâreviews.âTheâoverallâaimâofâcFiFâisâtoâhelpâmobiliseâaâscalingâupâofâfinancialâflowsâintoâclimateâchangeâsolutions.âMoreâbroadly,âbyâencouragingâearlyâactionâwithinâtheâfinanceâcommunity,âtheâfacilityâhelpsâcultivateâon-the-groundâleadershipâamongstâfinancialâactorsâthatâcanâhaveâreplicationâeffectsâacrossâmarketsâandâgeographies.initiatorsâofâtheâfacilityâareâtheâUnitedânationsâenvironmentâProgrammeâandâtheâFrankfurtâSchoolâofâFinanceâ&âManage-ment.âinvestmentâcommitteeâmembersâcomeâfromâADB,âBMU,âKfWâandâUneP.
Forâmoreâinformation,âcontact:
Frankfurt School â The UNEP Collaborating Centre for Climate & Sustainable Energy Finance SonnemannstraĂe 9-11
60314 Frankfurt am Main, Germany Tel: +49-0-69-154008-0; E-mail: [email protected]
Web: http://www.climate-finance.org