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Foundry Slag Waste to Building Material
This document discusses the promotion of using foundry slag waste from iron and steel production in foundries as an aggregate in paver block making. It begins by providing background on foundry slag waste and the Indian foundry sector, noting that approximately 5 lakh tonnes of slag waste is generated annually. It then describes the development of a technology to produce paver blocks by completely replacing coarse and fine aggregates with foundry slag. Test results found that paver blocks produced this way met strength standards. The document concludes by outlining the business potential and costs for setting up an enterprise to produce paver blocks using this waste-to-resource process.
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Foundry Slag Waste to Building Material
- 1. Promotion of Technologyfor Utilization of Slag Waste from Foundries in Paver Block Making Kolkata 20 January 2016 NSTEDB Department of Science & Technology Government of India 1
- 2. NSTEDB Department of Science& Technology Government of India 2
- 3. Secondary Raw Materials WASTEMATERIALS oIndustrial oAsh oMarble Sludge oFoundry Waste oEtc. POTENTIAL USE Material Process End Use Plain Concrete Crushed Aggregate Fresh Concrete Washed to remove cement & recover aggregate Aggregate Reinforced Concrete Crushed & Steel bars removed Steel recycled Crushed Concrete reused as aggregate NSTEDB Department of Science & Technology Government of India 3
- 4. What is foundryslag waste? NSTEDB Department of Science & Technology Government of India o The slag is a non-metallic inert by-product primarily consists of silicates, alumina silicates and calcium alumina-silicates produced during production of iron and steel in foundry units Batala Jalandhar Ludhiana Delhi Agra Indore HowrahRajkot Ajmer Mumbai Kolhapur Chennai Jaipur Ahmedabad Bhopal Bhavnagar Belgaum Coimbatore There are approx 5,500 units in the Country located in the areas marked in the map engaged in various types of metal castings 4
- 5. Indian foundry sector…at a glance NSTEDB Department of Science & Technology Government of India Casting production - Fourth largest casting producer in world - Annual production – 10 million tonnes (approx.) Decentralized unorganized production - Decentralized production > 5,500 units - Annual turnover – Rs. 400 billion - Employment to 0.5 million workers (direct) and 1.5 million workers (indirect) Resource intensive process - 90% small to medium using cupola technology - Low productivity and high energy consumption - No pollution control measure 5
- 6. Indian foundry sector…at a glance NSTEDB Department of Science & Technology Government of India Slag generated is approximately 10% of the total production #source-The Institute of Indian Foundrymen 6
- 7. Challenge identified NSTEDB Department ofScience & Technology Government of India Waste generation - Slag waste generation – 5 lakh tonnes/ annum (approx.) Use - Slag dumped in open field, barren land 7
- 8. NSTEDB Department of Science& Technology Government of India 8
- 9. NSTEDB Department of Science& Technology Government of India 9
- 10. Howrah foundry sector…at a glance NSTEDB Department of Science & Technology Government of India Technology used - DB Cupola furnace Production - No. of units > 200 units Raw materials - High ash coke, metal and limestone Slag generated* - 60,000 metric tonnes/ year 10
- 11. Current Building Material Technology Scarcityof natural sand/ aggregate Soil and land pollution High cost of building material Introduction of New Technology Project Intervention Reduced Pollution Reduced Cost of Building Material Dissemination Co-Benefits for Environment, Business & People Dissemination 11
- 12. NSTEDB Department of Science& Technology Government of India Innovative Solutions 12
- 13. Technology developed NSTEDB Department ofScience & Technology Government of India • Methodology developed for replacement of coarse and fine aggregates, used in conventional production of Paver Blocks • Paving blocks produced by completely replacing 6-8 mm aggregate with Foundry Slag • A lab scale plant set up at Datia, Madhya Pradesh 13
- 14. NSTEDB Department of Science& Technology Government of India Foundry Slag Grinding 14
- 15. NSTEDB Department of Science& Technology Government of India 8 – 10 mm foundry slag aggregate 15
- 16. NSTEDB Department of Science& Technology Government of India Foundry Slag Based Paver Block Production Unit 16
- 17. 17 Foundry Slag WasteUtilization Enterprise details • Micro enterprise ~ Rs. 25 lakhs investment • Product - Paving block (can be expanded to other building materials with low CAPEX) • Working days - 300 in a year • Production capacity - 1500 blocks per day Foundry slag waste requirement • Paving block - Approximate 5 kg weight (hexagonal) • Composition - 1:4:4 (M30 grade) • Raw materials - Cement, sand, foundry slag waste aggregate • Annual consumption - 1,000 Tons per enterprise Impacts • Jobs created - 6-8 persons • Waste utilized - 1,000 Tons per year • Business generated - Rs. 72 lakhs/ year (Rs. 16 per block)
- 18. Product certification NSTEDB Department ofScience & Technology Government of India The paving blocks produced by using the foundry slag were tested by the NIT Bhopal and Shriram Institute for Industrial Research, New Delhi The results up till M30 grade blocks were found to be very positive and duly complying to IS 15658:2006 The Compressive Strength test results of M30/ M40 grade blocks were found to be higher than those manufactured by using aggregate 18
- 19. Product certification NSTEDB Department ofScience & Technology Government of India 19
- 20. NSTEDB Department of Science& Technology Government of India 20 The Technology Package o Processing of foundry slag waste through medium duty jaw crushers o Use of OPC grade cement o Mixing of concrete through ordinary concrete mixers o Production through vibration in table vibrators o PVC moulds for shaping o Open atmosphere curing for 7 days
- 21. Market opportunity NSTEDB Department ofScience & Technology Government of India • Howrah district • Rural road – 948.68 kms** • Pavers required – 960 lakhs numbers* • Metro rail • Private housing • Shopping mall • Petrol pump • Tourism park Sources: * http://dcmsme.gov.in/dips/HOWRAH_wb.pdf 21
- 22. The business NSTEDB Department ofScience & Technology Government of India 22 CAPEX (CAPITAL COSTS) Vibrating table - Rs. 3 lakhs Moulds (2000 nos.) - Rs. 6 lakhs Jaw crusher - Rs. 3 lakhs Concrete mixer - Rs. 1 lakhs Miscellaneous - Rs. 1 lakhs Infrastructure (shed, office, electricity etc.) - Rs. 6 lakhs Total investment - Rs. 20 lakhs OPEX (WORKING CAPITAL) For a period of 1 month including raw material, labour, electricity etc. - Rs. 10 lakhs Total investment ~ Rs. 30 lakhs (approx.) (excluding land)
- 23. The business NSTEDB Department ofScience & Technology Government of India ASSUMPTIONS Selling price of a hexagonal paving block - Rs. 15 per block Production period - 300 days No. of units per day - 1500 nos. Total production per year – 4,50,000 units 23 Existing production technology Raw material Cement 3.60 Stone aggregate 4.35 Sand 2.15 Manpower 1.50 Energy 0.95 Overheads 1.30 TOTAL 13.85 Slag based technology Raw material Cement 3.60 Foundry slag 2.60 Sand 2.15 Manpower 1.50 Energy 0.95 Overheads 1.30 TOTAL 12.10
- 24. The business NSTEDB Department ofScience & Technology Government of India 24 ASSUMPTIONS Selling price of a hexagonal paving block - Rs. 16 per block Production period - 300 days No. of units per day - 1500 nos. Total production per year – 4,50,000 units PROFITABILITY IN EXISTING PAVING BLOCK PRODUCTION (FROM SINGLE MACHINE) Production cost - Rs. 13.85 per block (including expenses and bank loan returns) Profitability - Rs. 9.5 lakhs per year PROFITABILITY IN FOUNDRY SLAG WASTE BASED PAVING BLOCK PRODUCTION (FROM SINGLE MACHINE) Production cost - Rs. 12 per block (including expenses and bank loan returns) Profitability - Rs. 18 lakhs per year
- 25. The enterprise establishmentcost NSTEDB Department of Science & Technology Government of India The establishment of an enterprise can be financed through the PMEGP scheme of the Ministry of MSME Total project cost – Rs. 25 lakhs • Entrepreneur’s contribution – 2.5 lakhs • Term loan (from Banks) – 15.75 lakhs • Govt. of India subsidy – 6.75 lakhs PMEGP (Prime Minister’s Employment Generation Programme) scheme (KVIC) • General Category • Urban – 15% • Rural – 25% • Entrepreneur’s contribution – 10% • Special Category • Urban – 25% • Rural – 35% • Entrepreneur’s contribution – 5% 25
- 26. NSTEDB Department of Science& Technology Government of India Thanks 26