Detailed Project Report on Comparison between Fly Ash and Cellular Lightweight Concrete (CLC) Bricks

COMPARISON BETWEEN FLY ASH AND CELLULAR LIGHTWEIGHT CONCRETE (CLC) BRICKS

[EIRI/EDPR/1449] J.C. 206,207

INTRODUCTION

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually refers to ash produced during combustion of coal. Fly ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the chimneys of coal-fired power plants, and together with bottom ash removed from the bottom of the furnace is in this case jointly known as coal ash. Depending upon the source and makeup of the coal being burned, the components of fly ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (SiO2) (both amorphous and crystalline) and calcium oxide (CaO), both being endemic ingredients in many coal-bearing rock strata.
 
Toxic constituents depend upon the specific coal bed makeup, but may include one or more of the following elements or substances in quantities from trace amounts to several percent: arsenic, beryllium, boron, cadmium, chromium, hexavalent chromium, cobalt, lead, manganese, mercury, molybdenum, selenium, strontium, thallium, and vanadium, along with dioxins and PAH compounds.

In the past, fly ash was generally released into the atmosphere, but pollution control equipment mandated in recent decades now require that it be captured prior to release. In the US, fly ash is generally stored at coal power plants or placed in landfills. About 43% is recycled, often used to supplement Portland cement in concrete production. Some have expressed health concerns about this.

In some cases, such as the burning of solid waste to create electricity ("resource recovery" facilities a.k.a. waste-to-energy facilities), the fly ash may contain higher levels of contaminants than the bottom ash and mixing the fly and bottom ash together brings the proportional levels of contaminants within the range to qualify as nonhazardous waste in a given state, whereas, unmixed, the fly ash would be within the range to qualify as hazardous waste.

COST ESTIMATION

Plant Capacity                                             60000 Nos./Day
Land & Building (Area 15000 sq.mt.)        Rs. 14.14 Cr
Plant & Machinery                                       Rs. 1.77 Cr         
W.C. for 2 Month                                         Rs. 1.17 Cr           
Total Capital Investment                             Rs.17.83 Cr.              
Rate of Return                                             21%   
Break Even Point                                        51%

CONTENTS

INTRODUCTION

CLASS F FLY ASH

CLASS C FLY ASH

BRICKS

FLY ASH FOR BRICK MAKING (CLAY-FLY ASH BRICKS)

AVAILABILTY OF FLY ASH & ITS CHARACTERISTICS FOR BRICK PRODUCTION

MARKET SURVEY

PRESENT MANUFACTURERS/SUPPLIERS OF BRICKS FROM FLYASH

VARIOUS FLY-ASH BRICK COMPOSITIONS

PROCESS OF MANUFACTURE

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF

FLY-ASH-SAND-LIME BRICK

(AS PER CBRI)

PLANT LAYOUT OF FLY ASH BRICKS PLANT

CELLULAR LIGHTWEIGHT CONCRETE (CLC) BRICKS

MATERIAL AND BLOCK DIMENSION OF CLC BLOCK

MANUFACTURING PROCESS OF CLC BRICKS

TECHNOLOGY AND PROCESS

CLC BRICK MANUFACTURERS IN JHARKHAND

B.I.S. SPECIFICATION

OTHER RELATED INFORMATIONS

APPARATUS FOR DIVIDING AERATED CONCRETE BLOCKS

LIGHTWEIGHT CONCRETE AND METHOD OF MAKING SAME

LOW SHRINKAGE, HIGH STRENGTH CELLULAR LIGHTWEIGHT CONCRETE

COMPLETE PLANT & MACHINERY SUPPLIERS

FOR CLC BRICKS AND BRICKS FROM FLY ASH

WHY CLC BRICKS IS BETTER THAN FLY ASH BRICKS

COMPARISION BETWEEN FLYASH AND CLC BRICKS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)