Fly Ash Brick

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If you want to contribute something for a greener then please contact Sanjoy Banerjee at 09800893567

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Fly Ash Brick

  1. 1. DO YOU WANT A GREENER EARTH
  2. 2. McKinsey report India's demand is 315GW by 2017 Which is more than double the current installed capacity The Planning Commission of India wants to implement Rajiv Gandhi Grameen Vidyutikaran Yojna for the rural electrification with an investment of about Rs 34000 crore 11 th 5 YEAR Plan Wants to add 78 Gigawatts power generation Anil Razdan, Secretary, Ministry of Power statement “ India to emerge as a major power equipment manufacturing hub & vast opportunity exists, specially for small entrepreneurs”   “ It is a bonanza for the industry and an opportunity not to be missed.” THE FOREMOST REQUIREMENT OF INDIA
  3. 3. <ul><li>73% power generated in INDIA is from Thermal Power and 90% of it is coal based. </li></ul><ul><li>Ash content is 27% to 42% of the coal used. </li></ul><ul><li>Increase in FLYASH generation has risen from 4 crore to 11crore ton in the last decade and will rise to 1100 crore ton in coming decade. </li></ul><ul><li>The flyash generated in thermal power station causes many hazardous diseases like Asthma, Tuberculosis etc. </li></ul><ul><li>Till date only 14% of the Fly Ash generated is being utilized </li></ul>BUT
  4. 4. AND <ul><li>Approximately 10,000 hectares of top soil is being lost every year for brick manufacturing and road construction . </li></ul><ul><li>If we continue in this format, very soon, we will not have sufficient soil to produce our minimum required food . </li></ul>
  5. 5. Ministry of Environment & Forest ( MoEF ) <ul><ul><li>Had issued a Gazette Notification on 14 Sep 1999 </li></ul></ul><ul><ul><li>Stipulating that no person shall be permitted to manufacture clay bricks or tiles or blocks for use in construction activity without at least 25% of ash (fly ash, bottom ash, or pond ash on weight to weight basis), within a radius of 50 Km from coal or lignite based thermal power plants in INDIA. </li></ul></ul>
  6. 6. Ministry of Environment & Forest ( MoEF ) <ul><ul><li>Had amended the Gazette Notification on 27 Aug 2003 </li></ul></ul><ul><ul><li>making it compulsory to use fly ash for manufacturing building material </li></ul></ul><ul><ul><li>by increasing the radius from 50 Km to 100 Km </li></ul></ul><ul><ul><li>25% use of fly ash by 31 Aug 2004 </li></ul></ul><ul><ul><li>50% use of fly ash by 31 Aug 2005 </li></ul></ul><ul><ul><li>75% use of fly ash by 31 Aug 2006 </li></ul></ul><ul><ul><li>100% use of fly ash by 31 Aug 2007 </li></ul></ul>
  7. 7. Ministry of Environment & Forest ( MoEF ) <ul><ul><li>Had amended the Gazette Notification on 06 Nov 2008 </li></ul></ul><ul><ul><li>That Central Government will exercise its power on or after the expiry of a period of sixty days ( 05 Feb 2009 ) from the date of notification published and displayed in public, to implement the above notification. </li></ul></ul><ul><ul><li>It will be applicable to all construction agencies of Central or State or Local Government and private or public sector and it will the responsibility of all the agencies either undertaking construction or approving the design or both to ensure compliance </li></ul></ul><ul><ul><li>Submit annual returns to the concerned State Pollution Control Board or Pollution Control Committee. </li></ul></ul>
  8. 8. THE AMICABLE SOLUTION The has come out with an amicable solution by joining its hand with 1.Institute for Solid Waste Research & Ecological Balance ( INSWREB ) 2.Industrial Development Bank of India ( IDBI ) 3.Shanghai Electric Company ( SEC ) 4.The Community Development Carbon Fund ( CDCF ) of the World Bank ( WB ) And intends to jointly promote the Flyash Mission Do you want to participate in this Fly Ash Revolution
  9. 9. THE PRODUCT <ul><ul><li>The Fly Ash mission aims to promote Fly Ash bricks as an alternative to burnt clay brick within the construction sector in India. Fly ash is mixed with two other ingredients available as industrial byproducts: </li></ul></ul><ul><ul><li>Lime from the acetylene industry, and </li></ul></ul><ul><ul><li>Gypsum from chemical plants. </li></ul></ul><ul><ul><li>This is proving to be a revolutionary invention that produces bricks without the sintering process and consequently no greenhouse gases are emitted. The ultimate product is none other than FaL – G Brick which is well qualified as emission-abating project to receive the benefits of carbon credits. </li></ul></ul>
  10. 10. COMPARISION Water absorption 6-12% Water absorption 20-25% Thermal conductivity 0.90-1.05 W/m2 ºC Thermal conductivity 1.25 – 1.35 W/m2 ºC Less porous More porous Compressive strength is around 100 Kg/cm 2 Compressive strength is around 35 Kg/cm 2 Lighter in weight Heavier in weight No plastering required Plastering required Dense composition Lightly bonded Uniform in shape and smooth in finish Uneven shape as hand made Uniform pleasing colour like cement Varying colour as per soil FLY ASH BRICK NORMAL CLAY BRICK
  11. 11. PROFITS WHICH CAN BE EARNED <ul><li>SETTING UP A CDM </li></ul><ul><li>EARN THROUGH CARBON CREDIT </li></ul><ul><li>PARTICIPATION IN GREENATHALON </li></ul>NTIL IDBI WB IN- DIRECT <ul><li>BY PROVIDING YOU THE TECHNOLOGY </li></ul><ul><li>BY SETTING UP THE PLANT ON LSTK </li></ul><ul><li>BY ENSURING THE INTIAL MARKETING </li></ul><ul><li>BY BUILDING UP MARKETING STRATEGY </li></ul><ul><li>BY CREATING A BRAND ESTABLISHMENT </li></ul>NTIL SEC DIRECT HOW WHO WILL HELP TYPE OF PROFIT
  12. 12. ROLE TO BE PLAYED BY NTIL <ul><li>Project management from site selection to commissioning </li></ul><ul><li>Lump Sum Turnkey Project </li></ul><ul><li>Educate and Train people to achieve a greener earth </li></ul><ul><li>Ensure implementation of the Community Development Mechanism (CDM) along with IDBI </li></ul><ul><li>Transfer the data and records as per the monitoring requirements of CDM for Carbon Credit payments from World Bank </li></ul><ul><li>Initial marketing of the product </li></ul>Project management, Liasoning, and annual maintenance of FaL-G plants. NORTH Techno Projects India (P) Ltd. (NTIL) Specific Responsibilities Areas Agency
  13. 13. ROLE TO BE PLAYED BY YOU <ul><li>Mobilize resources </li></ul><ul><li>Procure equipment and machinery </li></ul><ul><li>Market the products </li></ul><ul><li>Maintain the data and records as per the monitoring requirements </li></ul><ul><li>Implement environment management plans as agreed </li></ul><ul><li>Propagate Fly Ash Revolution and show the whole world the benefits </li></ul>Setting up and operating FaL-G plants Micro Enterprises/ High Capacity Automation Plants (HCAPs) Specific Responsibilities Areas Agency
  14. 14. ROLE DIAGRAM NTIL NGO WB IDBI U SEC MARKET FABMA INSWREB
  15. 15. PRICE PROFIT RATIO FaL - G Bricks ( Without Cement) 1.70 Total Cost Price 0.59 Total 0.11 VAT @ 4% 0.20 Marketing 0.10 Electricity 0.16 Manpower 0.02 2% Breakage Taken for SME / For HCAPS it will reduce by 30% overheads 75.71 % THEREFORE TOTAL PROFIT % 4.72 % Profit indirect 0.08 Indirect profit through Carbon Credit 70.99 % Profit direct 1.20 Profit 2.90 Selling Price 1.10   3.2 100 Total 0.19 1.20 0.16 5 Gysum 0.48 1.00 0.48 15 Lime 0.08 0.10 0.80 25 Sand 0.35 0.20 1.76 55 Fly Ash Amt / Brick Rate / Kg Wt / Brick % age Items 75x125x250 Size Wt 3.2 Kg For 1 Brick Raw Materials
  16. 16. PRICE PROFIT RATIO FaL - G Bricks ( With Cement) 2.33 Total Cost Price 0.60 Total 0.11 VAT @ 4% 0.20 Marketing 0.10 Electricity 0.16 Manpower 0.03 2% Breakage Taken for SME / For HCAPS it will reduce by 30% overheads 53.91 THEREFORE TOTAL PROFIT % 3.44 % Profit indirect 0.08 Indirect profit through Carbon Credit 50.47 % Profit direct 1.17 Profit 3.50 Selling Price 1.72   3.2 100 Total 1.23 4.80 0.26 8 Cement 0.10 0.10 0.96 30 Sand 0.40 0.20 1.98 62 Fly Ash Amt / Brick Rate / Kg Wt / Brick % age Items 250 x125x75 Size Wt 3.2 Kg For 1 Brick Raw Materials
  17. 17. THE AGREEMENT World Bank has issued a Letter of Intent for the purchase of 800,000 tons of carbon credits from the FaL-G brick and block industry @ US$ 17/ton of CO2 eq . A Letter of Intent was signed to this effect by Mr. Ken Newcombe, PCF Fund Manager & Sr. Manager: Carbon Finance Business , World Bank , And Mr. Kalidas, Director, INSWAREB at Washington on 3rd instant.
  18. 18. SOLUTION MATERIALIZATION The flyash generated in thermal power station causes many hazardous diseases like Asthma, Tuberculosis etc. These six criteria pollutants are sulphur di-oxide (SO2), Carbon Mono-oxide (CO), Nitrogen oxide (NO2), Ozone (O3), suspended particulates and non-methane hydrocarbons (NMHC) now referred to as volatile organic compounds (VOC). Land degradation The thermal power stations are generally located on the non-forest land and do not involve much Resettlement and Rehabilitation problems. However it's effects due to stack emission etc, on flora and fauna, wild life sanctuaries and human life etc. have to be studied for any adverse effects. One of the serious effects of thermal power stations is land requirement for ash disposal and hazardous elements percolation to ground water through ash disposal in ash ponds. Due to enormous quantity of ash content in India coal, approximately 1 16 Acre per MW of installed thermal capacity is required for ash disposal. According to the studies carried out by International consultants if this trend continues, by the year 2014 -2015, 1000 sq. km of land should be required for ash disposal only. Besser is the US based Company, leaders in the production of plant and machinery for the last 100 years & Besser GmbH USA and Eco Carbon Pvt. Ltd. (ECPL) India has came together to elevate the construction industry ECPL Registers these High Capacity Automation Plants (HCAPs) as CDM projects in The Community Development Carbon Fund ( CDCF ) of the World Bank in order to get about Rs. 50 lakh to Rs 70 lakh Carbon Credit every year per plant of 2 lakhs bricks/day capacity apart from the normal profit earned . State Bank of India has set up an exclusive department in order to enlarge their portfolio in CDM (Clean development Mechanism) projects is considering to extend funding to all these HCAPs at National level. Such funding covers FCNR loan, Term loan and working capital loan .
  19. 19. ROLE <ul><li>Conduct programs to encourage entrepreneurs </li></ul><ul><li>Conduct awareness programs and workshops for brick users </li></ul>Market Facilitator <ul><li>Provide technological know how </li></ul><ul><li>Provide logistical support for procuring equipment, machinery and raw materials </li></ul><ul><li>Provide guarantee to enterprises against technical failure </li></ul>Technology provider INSWAREB (Institute for Solid Waste Research & Ecological Balance ) Specific Responsibilities Areas Agency
  20. 20. ROLE <ul><li>Enroll micro enterprises under the Carbon Credit project </li></ul><ul><li>Find a potential buyer and negotiate price </li></ul><ul><li>Coordinate carbon transaction activities with the buyer and the CDM Executive Board </li></ul><ul><li>Obtain host country endorsement </li></ul><ul><li>Undertake monitoring as per the requirements of CDM and the World Bank </li></ul><ul><li>Pass on the carbon benefits to the micro enterprises as per the terms mutually agreed </li></ul>Carbon Transaction Coordinator ECPL (Eco Carbon Private Limited) Specific Responsibilities Areas Agency
  21. 21. ROLE <ul><li>Coordinate with the CDM executive Board </li></ul><ul><li>Register the project with CDM Executive Board </li></ul><ul><li>Make payments to ECPL as per the terms mutually agreed </li></ul><ul><li>Monitor the implementation of specific communication programs by ECPL </li></ul>Purchasing Emission Reductions (ER)s CDCF (Community Development Fund of The World Bank) Specific Responsibilities Areas Agency
  22. 22. SCHEMATIC FAL-G PLANT PROCESS (STEP 1) Procurement of Raw Material Procurement Of RAW MATERIAL FLY ASH FROM THERMAL PLANTS LIME/GYPSUM FROM CHEMICAL PLANTS STONE DUST FROM STONE CRUSHER
  23. 23. SCHEMATIC FAL-G PROCESS (STEP 2) Storage of Raw Material Storage of Raw Materials FLY ASH In open yard duly wetted and covered by Plastic sheet LIME SLUDGE Dumped in open yard or stored in packets STONE DUST In open yard duly wetted and covered by Plastic sheet GYPSUM In bags , stored in godowns .
  24. 24. SCHEMATIC FAL-G PROCESS (STEP 3) Batch Mixing of Raw Material Mechanized transportation of required quantity Raw Materials to Roller Mixture FLY ASH LIME SAND GYPSUM
  25. 25. SCHEMATIC FAL-G PROCESS (STEP 3) Raw materials are kneaded under rollers for achieving homogenous mortar Wet mixing in Roller Mixer FLY ASH LIME/GYPSUM SAND
  26. 26. SCHEMATIC FAL-G PROCESS (STEP 4) ROLLER MIXTURE VIBRO PRESS HYDRAULIC COMPRESSION homogenized mortar homogenized mortar Mechanized Transfer from Pan Mixer to Automatic Brick Making Machine
  27. 27. SCHEMATIC FAL-G PROCESS (STEP 5) Drying & Curing The green bricks are dried up under sun from 24 to 48 hours The dried up bricks are stacked and subjected for water spray curing once or twice a day for 7-21 days depending on ambience DESPATCH TO THE MARKET
  28. 28. THE GREATEST CHALLENGE FOR CONSTRUCTION <ul><li>Is to provide higher quality Housing & Roadways </li></ul><ul><li>By using construction materials that can be produced in a </li></ul><ul><ul><li>Socially </li></ul></ul><ul><ul><li>Environmentally and </li></ul></ul><ul><ul><li>Economically sustainable way. </li></ul></ul><ul><ul><li>Another major problem Is </li></ul></ul><ul><ul><li>Labour availability is the biggest challenge that the construction industry faces today. </li></ul></ul><ul><ul><li>Scarcity and high costs of labour pushed the industry to optimum mechanization. </li></ul></ul>

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