Manufacturing of fly-ash brick

Manufacturing of fly-ash brick

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  INTRODUCTION TO FLYASHAND FLYASH BRICKSINTRODUCTION TO FLYASH AND FLYASH BRICKS Fly ash is a fine, glass-like powder recovered from gases created by coal-fired electric power generation. Flash material is solidified while suspended in the exhaust gases and is collected by electrostatic precipitators or filter bags. Since the particles solidify while suspended in the exhaust gases, fly ash particles are generally spherical in shape and range in size from 0.5 μm to 100 μm. They consist mostly of silicon dioxide (SiO2), aluminium oxide (Al2O3) and iron oxide (Fe2O3). Flyash Bricks is a building material, specifically masonry units, containing fly ash and water, compressed at 28 MPa (272 atm) and cured for 24 hours in a 66 °C steam bath, then toughened with an air entrainment agent.
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  1] To provideand promote business and services that strengthens the brick manufacturing sector for the ultimate benefit of its customers and society. 2] To be in the forefront of creating awareness about environment, & to be the largest player in the field of fly-ash brick production. 3] Nearly 73% of India’s total installed power generation capacity is thermal, of which coal-based generation is 90% – the remaining comprising diesel, wind, gas, and steam. The 85 utility thermal power stations, besides the several captive power plants, use bituminous and sub-bituminous coal and produce large quantities of fly ash. High ash content (30%–50%) contributes to these large volumes of fly ash
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  1] The countryconsumes about 180 billion tonnes bricks, exhausting approximately 340 billion tonnes of clay every year and about 5000 acres of top soil land is made unfertile for a long period. 2] The government is seriously concerned over soil erosion for production of massive quantities of bricks, in the background of enormous housing needs. 3] The excellent engineering property and durability of fly ash brick enlarges its scope for application in building construction and development of infrastructure, construction of pavements, dams, tanks, under water works, canal lining and irrigation work etc. 4] Enormous quantities of fly ash is available in and around thermal power stations in all the states. 5] The demand of bricks could be met by establishing small units near thermal Power stations and to meet the local demand with less transportation costs. MARKET DEMANDMARKET DEMAND
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  IMAGES OF BUILDINGS,MALLS, INFRASTRUCTURESIMAGES OF BUILDINGS, MALLS, INFRASTRUCTURES
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  GEOGRAPHICAL LOCATIONGEOGRAPHICAL LOCATION Forsetting up a fly ash brick industry these factors should be adhered:- Land requirement - at least 1.5 acre of land is required to set up a plant Factory location – fly ash generally is found near thermal power plant. Thus setting up an industry within 60 -70 km radius nearby a thermal power plant is an advantage. Availability of water – ample amount of water is required for running this industry Environmental issues – setting up a factory nearby a residential township or any other manufacturing industry is prohibited, as it generates huge dust and smoke and pollutes the air.
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  1] FLY ASH2] GYPSUM LIME 3] LIME 4] SAND
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  Procurement Of RawMaterial And Sand From Pits,Rivers,Seas etc.And Sand From Pits,Rivers,Seas etc.
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  PROPORTIONING OF RAWMATERIAL Fly ash: 55-60% Sand: 20-25% Sludge Lime: 15-20% Gypsum: 5% 1] NORMAL METHOD Fly ash: 60-65% Sand: 18-27% Sludge Lime: 8-12% Gypsum: 5% 2] PROFITABLE METHOD
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   Manufacturing Process
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  PRODUCT SPECIFICATIONS:- 230 x100 x 75 mm 230 x 150 x 80 mm 1] Flyash brick size details:- [ 4 inches ] [ 6 inches ] 230 x 100 x 100 mm 230 x 150 x 100 mm 2] Compressive strength:- 75-150 kg/cm2 3] Water Absorption:- 8-12% 4] Efflorescence:- Nil 5] Density:- 1700 kg/m3 230 x 100 x 75 mm [ weight about 4.75 – 5 kg approx ] 6] Weight:- 230 x 150 x 75 mm [ weight about 2.75 – 3 kg approx ] 7] Load bearing capacity:- More than 25% as compare to clay bricks. 8] Composition:- Cement, Thermal station flyash, Crushed sand / stone dust and chemicals 9] Drying shrinkage:- Maximum average drying test shrinkage 0.035 – 0.04% 10] Brick colour:- Gray / Dark gray
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  COST COMPARISION OFHOLLOW BLOCK MASONARY WITH CLAY BRICK MASONARY DESCRIPTION NORMAL CONCRETE BRICK METHOD FLYASH BRICK METHOD SAVINGS / EXCESS 1 2 3 4 CEMENT MORTAR LABOUR PLASTER COST OF THE PRODUCT 10.35 21.45 27.00 55.96 6.56 14.84 20.66 56.90 3.79 6.61 6.34 0.94 TOTAL SAVING PER SQ.FT. ₹15.80 ALL UNITS PER SQUARE FEET₹ COST COMPARISION OF HOLLOW BLOCK MASONARY WITH CLAY BRICK MASONARY
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  (A)LAND & BUILDING DESCRIPTION AMOUNTRs 1 Land Lease hold 30,000 2 Building (60 x 40 = 2400 Sq. feet.) 2,00,000 3 Overhead water tank 40,000 TOTAL 2,70,000 FIXED CAPITAL
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  (b)Machinery and EquipmentDESCRIPTION QTY RATE AMOUNT 1 Automatic Fly ash Brick making machine hydraulic operated with all accessories and fitting with 18HP Motor 1 12,00,00 0 12,00,00 0 2 Pan Mixture 500 KG Capacity with 7.5 HP Motor 1 2,50,000 2,50,000 3   Belt Conveyor with necessary fittings and 2 HP Motor 1 50,000 50,000 TOTAL 15,00,000 VAT 4 % 60,000 GRANT TOTAL 15,60,000 Erecting and Electrification Charges 22,000 TOTAL 1,58,2000
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  (a)Raw Material Per Month: Rs. S.N DESCRIPTIONQTY RATE AMOUNT 1 Fly ash 400 Mt 200 80,000 2 Gypsum Lime 80 2,00 0 1,60,000 3 Lime 100 1,20 0 120,000 4 Sand 35 800 28,000 TOTAL 3,88,000 RECURRING EXPENDITURE (PER MONTH):
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  (b) Salaries &Wages Per Month : Rs. S.No DESIGNATIO N NO SALARY Amount 1 Production Manager 1 -- Self 2 Un skilled workers 15 3500 52500 3 Office assistant 1 4,000 4,000 4 Watch man 1 3,500 3,500 Total 18 60,000
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  (c)Utilities Per Month :Rs. S.N DESCRIPTION AMOUNT 1 Power 35 HP 3916 Units@ Rs.5 per Unit 19,583 2 Water 1,000 TOTAL 20,583 (d)Other Expenses Per Month : Rs. S.N DESCRIPTION AMOUNT 2 Postage and stationery 1,000 3 Repairs and maintenance 2,000 4 Travelling and transportation 3,000 5 Insurance 1,000 6 Telephone 2,000 TOTAL 9,000
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  WORKING CAPITAL ASSESSMENT DESCRIPTION AMOUNT 1Raw Material (Required for one week) 90,534 2 Work in progress (Required for one month) 1,09,583 3 Finished Good (Required for 5 days) 1,05,917 4 Bill receivable (Required for two weeks) 2,06,900 TOTAL 512,934
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  TOTAL PROJECT COST   a. Land Lease hold:-  30,000₹ b. Building:-   2,00,000₹ c. Plant & Machinery:-  15,82,000₹ d. Raw materials:-  3,88,000₹ e. Salaries and Wages:-  60,000₹ f.  Utilities:-  20,583₹ g. Other:-  9,000₹ h. Working Capital:-  5,12,934₹
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  DOCUMENTS REQURIED FORSMALL SCALE INDUSTRY 1] Clearance from the municipal corporation 2] State pollution control board clearance 3] Sanction from the electricity board 4] Ownership/tenancy rights of the premises where unit is located 5] Copy of partnership deed/Memorandum of articles of association in case     of a private limited company 6] Sale bill of product manufactured 7] Sale bill of each end product 8] Purchase bill of each raw material 9] Purchase bill of machinery installed 10] BIS/QC certificate if applicable 11] An affidavit giving status of the unit, machinery installed,                      power requirement, etc.
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  Step 1: ProvisionalSSI Registration To obtain SSI registration the business must first apply for Provisional SSI Registration Certificate (PRC). Provisional Registration Certificate is given when the unit is in a pre – operative period and helps the SSI unit obtain term loans and working capital from financial institutions/banks under priority sector lending. Step 2: Start the Business Start the business with the provisional SSI registration certificate. Commence activity or production. Step 3: Permanent SSI Registration Once the business commences production or activity, the business can apply for and obtain permanent SSI registration. Obtaining permanent SSI registration will help the business obtain the following benefits.
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   Comparison Between NormalClay Bricks And Fly Ash Bricks     NORMAL CLAY BRICK     FLYASH BRICK Varying colour as per soil Uniform pleasing colour like cement Uneven shape as hand made Uniform in shape and smooth in finish Lightly bonded Dense composition Plastering required No plastering required Heavier in weight Lighter in weight Compressive strength is around 35 Kg/cm2 Compressive strength is around 100 Kg/cm2 More porous Less porous Thermal conductivity 1.25 – 1.35 W/m2 ºC Thermal conductivity 0.90-1.05 W/m2 ºC
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   Characteristics ofFly Ash Bricks  The standard size of the brick is 230mmx110mmx70mm.    The bricks are manufactured and tested as per IS 12894-2002.  Fly ash bricks are sound, compact and uniform in shape, size and colour. Smooth rectangular faces of the bricks are accompanied with sharp and square corners.    They are free from visible cracks, warpage, flaws and organic matter.    Economical & environment friendly.  28% lighter than ordinary clay bricks.    Compressive strength: 7.5N/mm2 on an average.  
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   Technical Advantages Energy Efficient  Fire resistant  Sound Resistant  Structurally sound  Strong • Durable • Versatile  Safe • Secure • Robust  Economical  Less wastage and breakages  It can reduce 10% of water consumption.  Reduce dead load on total Building Structure  Compression strength improves by more than 15 %.  Less mortar consumption in masonry & saving in plastering cost.  Uniformly in shape and size.
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  A] STRENGTHS:- 1) CostAdvantage 2) Unlike metals or organic materials flyash can withstand the onslaught of natural forces. 3) Flyash brick industry is an labour intensive industry. It has the potential to generate employment. B] WEAKNESSES:- 1) Flyash industry is an highly messy job with an immerse dusty working environment. 2) Due to lack of modern technologies and machineries to check pollution, flyash Industry does not posses that eagerness in common man eyes. C] OPPURTUNITIES:- 1) Flyash industry has now replaced brick in infrastructure development 2) Flyash is an good raw material for bricks. Thus it can substitute brick during construction. D] THREATS:- 1) Number of workers willing to work in flyash industry is decreasing day by day due to health concerns 2) Availability of flyash is scarce.
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  CONCLUSION 1]Fly ash utilizationin the country has remained less than 30% during the past 5 years and it might take several years to reach the final goal of cent percent utilization. 2]It is estimated at present nearly 160 million ton fly ash is produced every year, out of which hardly 40-50 % is used in all possible applications. 3]To utilize such a huge quantity of ash, we have to take necessary actions from government side and from nongovernment side for utilisation point of view. Manufacturing of flyash bricks is a safe method for disposing flyash.