Geo polymer concrete (Capacity: 200m3/day)

GEO POLYMER CONCRETE

[EIRI/EDPR/4576] J.C.: 2793XL

INTRODUCTION

 Geo polymer concrete is an innovative, eco-friendly construction material. 

 It is used as replacement of cement concrete. 

 In geo polymer concrete cement is not used as a binding material. 

 Fly ash, silica-fume, or GGBS, along with alkali solution are used as binders.

IS THERE A WAY TO USE OPC WITHOUT ENVIRONMENTAL IMPACT? 

 Replacing some limestone with fly ash and blast furnace slag called as blended cement 

 Using carbon dioxide emission captures and storage (CCS) 

 Accelerated carbonation where CO2 penetrate concrete reacting with Ca(OH)2 in presence of H2O forming CaCO3

COST ESTIMATION

Plant Capacity            200 m3/Day  

Land & Building (4000 sq.mt.)    Rs. 1.23 Cr    

Plant & Machinery                    Rs. 60 Lac 

Working Capital for 1 Month    Rs. 2.55 Cr 

Total Capital Investment          Rs. 4.50 Cr 

Rate of Return                          25%

Break Even Point                      54%

CONTENTS

INTRODUCTION

IS THERE A WAY TO USE OPC WITHOUT ENVIRONMENTAL IMPACT?

WHY GEOPOLYMER CONCRETE?

CONSTITUENTS OF GEO POLYMER CONSCRETE

SODIUM HYDROXIDE

POTASSIUM HYDROXIDE

SODIUM SILICATE (WATER GLASS) -AVAILABLE IN GEL FORM

FLY ASH

TABLE1: CHEMICAL COMPOSITION OF FLY ASH

GGBS

TABLE 2-CHEMICAL COMPOSITION OF GGBS

SILICA FUME

TYPES OF GEO POLYMER

SLAG BASED GEO POLYMER

ROCK BASED GEO POLYMER

FLY ASH BASED GEO POLYMER

FERRO-SILICATE BASED GEO POLYMER

ADVANTAGES OF GEO POLYMER CONCRETE

FIG: ADVANTAGES OF GEOPOLYMER CONCRETE

APPLICATIONS OF GEO POLYMER CONCRETE

FORMULATION OF GEOPOLYMER CONCRETE

MANUFACTURING FLY ASH BASED GEO POLYMER CONCRETE

PREPARATION ALKALINE SOLUTION1 FOR GEO POLYMER:

MIXING PROCEDURE FOR GEO POLYMER CONCRETE:

TEST OF FLY ASH BASED GEO POLYMER CONCRETE:

SLUMP TEST:

COMPRESSIVE STRENGTH TEST:

SPLITTING TENSILE STRENGTH TEST:

PROCESSING DETAILS OF GEO POLYMER CONCRETE

ALKALINE ACTIVATOR SOLUTION

MIX DESIGN

FIG: PRODUCTION OF GEOPOLYMER CONCRETE

GEO POLYMERISATION

FIG: CONCEPTUAL MODEL OF GEOPOLYMERISATION

TEST ON GEO POLYMER CONCRETE

CREEP TEST

DRYING SHRINKAGE TEST

MODULUS OF ELASTICITY AND POISSON’S RATIO

PROPERTIES

WORKABILITY

COMPRESSIVE STRENGTH

RESISTANCE AGAINST AGGRESSIVE ENVIRONMENT

BEHAVIOUR OF GEOPOLYMER AT ELEVATED TEMPERATURE

BOND STRENGTH

DIFFERENT PARAMETERS OF GEO POLYMERISATION

FINENESS OF FLY ASH

TEMPERATURE IMPOSED TO ACTIVATOR

MOLARITY

CURING

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

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)