High Capacity Fly Ash Bricks & Blocks Unitindiablockmachine.com/admin/files/QT8 FlyAsh Bricks...

A Green Eco friendly Project

Prepared by www.indiablockmachine.com [email protected]

Name Of the Project

High Capacity Fly Ash Bricks & Blocks Unit

Preparation Date 10th, May, 2014

Project Report Version: 001:005

Project Name

Project Address

Name of the Director / Propriator / Partner

Prepared by

N.Gangadhar Reddy

Project Consultant, www.Indiablockmachine.com

(Please note- Replace this First page as per your details)



1. Project at a Glance 1 Product Details :

Type : NIC Product Code : BIS Code :

Bricks & Blocks Fly Ash-Lime-Gypsum (FAL-G) Based 320901009 IS: 12894 : 2002

2. Assumptions

The following assumptions have been made while preparing this Project Report.

a. Land required mentioned is approximate. 75% of land required is for storage of Finished Products.

b. The project can be started at a smaller land , if there is a good management practice of marketing as per the prevailing orders. This helps holding a slim stock.

c. Fly to be provided free of cost by power plants. Only transportation to be

arraigned by Project. All raw material prices assumed is landing price at project site.

d. The Unit aims for optimal fly ash utilization. e. Production is estimated at moderate capacity, 1 shifts a day. for ratios analysis

f. 300 working days is considered in a year during the first year. g. Boundary wall to be constructed from trail production bricks of Unit.

h. Sale price at site is estimated as per existing market Price.

i. Bricks of all sizes will be manufactured according to the market requirement,

though mainly 230mm x 110mm x 70mm are the major concentration area.



3. Introduction

FAL-G is not a brand name, but a product name like Ordinary Portland Cement (OPC). This name is given for easy identification of its ingredients. FAL-G stands for Fly-Ash-Lime-Gypsum. In recent days, Lime-Gypsum is being replaced by OPC cement as it is cheap and also quick setting. The process itself is concept development based on a cement theory called “Crystallo-Mineral Combination or setting behavior” in technical jargon. In a recent development it was found that use of OPC in many places is not only economical but also it provides quick setting, faster curing, improved strength, and overall better quality ( including strength) Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental threat across the globe. Power plants are facing an ever increasing challenge disposal of this polluting agent. This unit is proposed to manufacture FAL-G Bricks & Blocks by consuming the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving the invaluable top soil by not using them in brick making like conventional brick making. Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. This is the reason these bricks are also referred as Eco Bricks or popularly Green Bricks, (though the color is gray). Fly-Ash Bricks and Blocks are largely used in various constructions, such as load bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and wherever conventional bricks can be used. The general Fly ash bricks fall in the strength zone of 60-250 Kg/Cm2, thus is much stronger then conventional Bricks. These bricks gain strength over a period of time up to 2 years, where as the conventional bricks tend to lose strength over a period of time. Because of this strength, the same mix can be also be used to make the Paver Blocks in the same casting machine with interchanging the moulds. These green bricks can attain very regular and uniform shapes. As no burning is involved, so the shape also remains unchanged. As a result, the final Brick work with these green bricks consumes less mortar to build, less mortar to plaster. Further, the FAL-G being artificial cement itself, it forms a more uniform bond with cement, giving almost a homogeneous structure. Not only this, even exposed brickwork (without plastering) is a good durable structure. So people prefer to leave the Green Bricks Brickworks in garages, boundary walls etc. un-plastered.

4. Advantages of using Fly- Ash Bricks. The advantages are as follows

1. Environmental friendly : Consumes Fly ash 2. Environmental friendly : Saves invaluable top soil

3. Environmental friendly: needs no burning/backing.



4. Strength: Higher Strength Bricks.

5. Uniform Shape: Easier and faster Brick working.

6. Uniform Shape: Less Mortar in Brick work.

7. Uniform Shape: Less Mortar in Plaster.

8. Artificial Cement: Gains strength over time.

9. Artificial Cement: Walls can be left exposed/un plastered.

10. Better heat & sound insulation compared to red Bricks

11. Far Lesser brakeage during handling & transportation.

12. Better Vibration resistance compared to red Bricks

5. Market

Shelter is third skin, according to a German Concept, which implies it’s importance next to human Skin and Clothing. This also shows the attachment of human race to this fundamental requirement. Building Material accounts for major component of the construction cost. Depending on the location they can contribute to 60 - 70 % of the cost of construction. With the ever increasing population, the demand for housing increases. This directly creates demand for this prime commodity of building.

Add to the above fact the area under discussion and its surrounding area is undergoing a major infrastructure revolution. As Residential, Commercial, IT companies, and Industrial establishments are coming in, we can conclude that the Bricks unit will prosper and flourish in this environment. There is a central government gadget notification mandating government departments and CPWD to use 100% Fly Ash Bricks in their all constructions- directly of through contractors. This factor will help the marketability of this product immensely. Fly Ash policy of the Government also mandates that 20% of Fly ash Generated by a power plant must be given free of cost to SME sector on a priority basis.



6. Carbon Credits Estimates

FAL-G Bricks have already qualified as a CDM projects in India for earning

Carbon Credits since January 2004. But as the conventional FAL-G Bricks Units are very small in size, having a daily production of 3000 to 6000 Bricks per day, thus CDM Project for this industry has been designed as a bundled approach. Already two bundles of FAL-G: CDM projects have been registered and the third bundle is under process of registration. The first bundles have already received their first trench of payment in August-2007.

This Unit, unlike the above said units is a high capacity Bricks Production Plant.

Its production capacity is around 20 times higher than conventional units discussed as above. Thus this plant can be individually treated as a Single CDM project as well.

Generally, the existing FAL-G:CDM project estimates a saving of 350 Tons of

Carbon Credits for every Million of Bricks. Thus the Present Project of 24,000,000 will have an annual Carbon Credits Generation of Approximately 8400 CERs. In present day market it stands around EURO 17 per CER. ( data as on 2012-June )

POST SCRIPT ON CDM STATUS AS ON DATE

The CDM projects which are aimed to get carbon credits or CERS

have been on hold post Dec-2012 scenario, as all the participating nations

need to decide on a newer framework. All the environmentalists are very

much hopeful that the newer version of the CDM framework will be more

beneficial to the Green ventures like this project.

For latest updates on CDM and its resumption and its onward

registration, please check www.unfccc.org.



7. Raw Materials, Sources and Availability.

Fly-Ash:

A lot has been said about this raw material in this Project Profile itself. But this Raw material is freely available in Thermal Power plants. There are no taxes on this item whatsoever. Transportation charges are only to be attended by the entrepreneur.

However, the proposed Unit will get Fly Ash from locally available Thrmal Powerplants, which is having best quality fly ash not only in the country, but also in the whole world Lime/OPC:

Lime used in this process is known as Hydrated Lime, which can be obtained by Calcining Brunt Lime. One KG of Brunt Lime gives 2.2 Kgs of Hydrated Lime after Calcining. Brunt Lime can be obtained from Kuddur, Andhra Predesh where Lime Kilns and High Quality Brunt Lime are pettily available. Alternativily Hydrated lime is available as an industrial by-product of Paper Mills This Project however aims to utilize OPC cement as a substitute for Lime. It will give faster strength to the bricks, besides giving improved consistent quality. It also ensures a better cost effectiveness for the same. Using OPC will be a standardized practice compared to Lime, as, unlike OPC, Lime quality changes widely across suppliers and across seasons. The other prime advantages of using OPC (compared to Lime) is it’s easy availability locally through nationwide Retail Network of Cement Companies. Gypsm:

This too is an industrial waste. This is available at Fertilizer Plant as in industrial wastes

Sand / Crusher Dust.

Sand is used as an economizer and to increase the strength of bricks to some extant. Sand is procured locally. Crusher dust can also be successfully used in place of sand.



8. Process

The Process of manufacture is simple and suitable to start. A mix of Fly Ash, Cement, Gypsum and Sand/Crusher Dust are automatically weigh batched in a batching plant.

1. Loading of Raw materials- Mini Loader Loads materials into Batching plant

2. Automatic Batching – The Raw materials are automatically weighed as per the preset weights by means of Load cells and its control circuit. Cement, if it is available in Bulk, then silo and screw controller is used to auto weight. Otherwise, the batching is programmed as per 1 bag of cement.

3. Mixing - From the batching plant the mixture hopper pulls the materials and then the

mix is blended homogenously and intimately in a semi wet form in a Twin shaft mixture. The Water is automatically added as per time set. The TWIN SHAFT mixture ensures that a perfect mix is done in shortest possible time.

4. Carrying to Brick machine - The mix is carried to the casting machine by means of

conveyer belt.

5. Automatic Brick Making- there are a series of operations which is achived by automatic PLC system. Pallet is pulled into the Machine. The mix is then collected fed into the machine moulds. There is a T boggy which uniformly spreads the materials in the moulds. Automatic PLC controlled Vibration and hydraulic pressure is given for a while and bricks are cast on the pallets. The dual application of Pressure and vibration ( in a patent pending micro-sequence application ) ensures perfect compaction with best quality of bricks

6. Automatic Stacking - The pallets along with the freshly cast bricks are rolled on a

roller platform to the pallet stacker. The Pallet stacker stacks the pallets along with the bricks automatically and the

7. Fork lift shifting– The Final stack of 5 to 10 pallets and bricks are lifted with a Fork

Lifter and carried to the drying bay/room for 24 Hours for initial setting.

8. Curing - Soon after the initial setting, the Blocks/ Bricks are stacked for curing in layers. The layers are stacked in a way to enable water and air to go all around, to ensure proper curing and drying. The curing process is continued for 7 days. The blocks are allowed to normally dry for a day. Now they are ready for dispatch.

Alternatively, the blocks/bricks can be steam cured for 8 hours or mist cured for 24 hours immediately after production, and made ready for dispatch immediately.

9. Dispatch - the cured bricks can be dispatched to market.

A Compressive strength of 80 to 250 Kg/Cm2 is generally obtained from the mix design, as suggested in the “Elaborated Details Page” of this Project Profile. The resulting bricks will have around 5 %water absorption and around 1.5 to 1.7 Gms/CC Density. Please refer the “Process Flowchart Drawing” given in following page



9. Process Flow Chart.

Dry for 24 Hours and Eco-Bricks Ready for Sale

Fly Ash

Crusher

Dust/

Sand

OPC/lime

Gypsm Main

Raw Materials

From 20%

to 70%

60to 5 %

OPC 6% Gypsum 1% Or Lime 10%

Quantity

Water Twin Shaft Mixture

to mix ingredients

Bricks Casting on Machine

Water Curing For 7 Days

Stacking and drying Under Shade/ under plastic



10. Quality Control. For Production of good Quality Fly Ash Bricks, The following precautions must be taken.

1. Moisture Content in Fly Ash should not be more than 5% 2. The color of Fly Ash should be either Light Steel or Smoke Gray.

3. It should never contain un-burnt Carbon by not more than 5%

4. Phospho Gypsum should better be made acid free by washing, if it is acidic

5. Special emphasis should be given to curing.

6. Proper stacking and layering can greatly enhance the quality of Bricks & Blocks.

7. Fresh Laid bricks to be protected from rain showers by Polythene Sheets.

8. Fresh Laid bricks to be protected direct heavy sun drying by Polythene Sheets.

9. Controlled drying under PVC covers of Fresh Laid bricks is advisable.

10. Stacks should not be allowed to fully dry at any time (within first 6 days).

11. Pollution Control Needs

• There are no solid or liquid effluents out of this plant.

• The unit is a Green unit as it consumes Fly-ash, saves fertile top soil and earns CER

• Workman working in the Bricks production Unit to be provided with protective equipments like dust masks, safety goggles, Gum Boots, Gloves etc.

12. Energy Conservation needs

The management has to be vigilant in ensuring higher productivity by the optimal utilization of man and machine hours. Periodic checks on working stages, functioning of machinery, their preventive maintenance and timely repairs will help in energy conservation.



13. Statutory clearances needed The following is a list of regulatory or statutory clearances needed for this project. The State to State requirement may vary. Please check your state industrial law. DIC (District Industry Center) is the Best place to check for the following requirements. Many DICs provide a single window system to facilitate the clearance of all documents in one go

A. The following clearances must be required before setting up of this plant a. MSME-1 certificate from District Industries center

b. NOC or Consent to Establish ( For Air and Water ) from Pollution control Board

c. Sales tax/VAT, entry tax, CST registration from state sales tax department

d. IEC (Import Export code) from Director General of Foreign Trade of the state.

e. Land conversion ( to non-agriculture ) from revenue department

B. The following clearances will be required after setting up of this plant a. MSME-2 certificate from District Industries center

b. NOC or Consent to Operate ( For Air and Water ) from Pollution control Board

C. The following clearances/registrations may be needed for the operation of the plant.

Please check your state laws a. NOC from local authorities/Sarpanch/local government body

b. ESI for Employees’ insurance.

c. PF with provident fund department

d. Inspector of factories for factory approval.

14. Project Time Line

The Project gestation period is approximately 3 months as per the following schedule. Day-0 : Booking of Order and advance payment to China Day-25: Machine ready by China companies Day-30: balance payment and machine loading at china factory Day-35: Ship bound to India port. Day 40: Sending of plant staff/operator for training to Bhubaneswar Day 55: Ship reaches India port Day 65: Custom clearances and Machines reaching Client site Day 65: work shed electrical connection and panel, water connection ready at site Day 70: Installation engineers reach site Day 80: Trail production start

Day 90: Commercial production Start.

High Capacity Fly Ash Bricks & Blocks Unitindiablockmachine.com/admin/files/QT8 FlyAsh Bricks...

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