FLY ASH BRICKS MANUFACTURING

BANKABLE PROJECT REPORT ON FLY ASH BRICKS MANUFACTURING.

INTRODUCTION

Fly Ash Bricks Manufacturing, Fly Ash Bricks are manufactured from fly ash,  lime, gypsum, and sand in the required proportion and are mixed in a pan mixer.  Fly ash bricks are made from fly ash suspension coming from thermal power and foundry industries. Here coal is the main fuel for these big industries.

Here coal is burned for heat generation, during the burning of coal mineral particles like clay, quartz, shale, and feldspar are fused in suspension. It is a burned fine particle floated out from the combustion chamber with the exhaust gases.

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After coming out, it comes together and solidifies by cooling into spherical glass particles. These spherical glassy particles are called Fly Ash. In this post, you learn about FLY ASH BRICKS MANUFACTURING.

In the modern age of technology fly, ash is collected by electrostatics participators. This fly ash is the main by-product of coal combustion. This fly ash may create a disposal problem. Some good quality fly ash is used for other purposes.

FLY ASH BRICKS MANUFACTURING

Thermal power stations and all the big foundry industries required fuel in the form of coal. Here coal is burned for heat generation, during the burning of coal mineral particles like clay, quartz, shale, and feldspar are fused in suspension.

It is a burned fine particle floated out from the combustion chamber with the exhaust gases. After coming out it comes together and solidifies by cooling into spherical classy particles.

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These spherical glassy particles are called Fly Ash. In the modern age of technology fly, ash is collected by electrostatics participators. This fly ash is the main by-product of coal combustion. This fly ash may create a disposal problem. Some of the good quality fly ash is used for other purposes.

The properties of fly ash are as follows:

Physical Properties.

1. Specific Gravity – 2.54 to 2.65 gm/cc
2. Bulk Density – 1.12 gm/cc
3. Fineness – 350 to 450 M2/Kg

Chemical Properties.

1. Silica – 35-59 %
2. Alumina – 23-33%
3. Calcium Oxide – 10-16%
4. Loss on ignition – 1-2%
5. Sulfur – 0.5- 1.5%
6. Iron – 0.5- 2.0 %

On the national level, fly ash is used to manufacture pulverized fuel ash-lime Bricks to improve the environment quality. This is a supplement of common burnt clay Bricks. Bricks named fly ash Bricks are manufactured by blending pulverized ash in large quantities, lime, and accelerators as different materials, molding into bricks, and curing at different temperatures and pressures.

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Sometimes crushed bottom fuel ash and sand are also added to the raw material compositions of fly ash bricks to make them coarser to control water absorption to the final products.

Production of fly ash bricks has been started all over the country. It is estimated that in the coming time fly ash bricks will become very popular as it is chemically inert materials.

BASIS & PRESUMPTION-FLY ASH BRICKS MANUFACTURING

1. The cost concerning plant & machinery, raw materials, and finished products has been taken at the time of preparation of this project report and may vary depending upon various factors.
2. This report is detailed only in Techno-Economic –Feasibility aspects.
3. Tax, Freight, Installation, and electrification cost is taken at 15% of the cost of machinery and equipment.
4. Non-refundable deposits, project report cost, trial production, and security deposits with the Electricity Board are taken under pre-operative expenses.
5. Depreciation has been considered:
6. (a) On Building @ 5%
7. (b) On plant and machinery @ 10%
8. (c) On office furniture and fixtures @ 10%
9. (d) On other fixed assets @ 10%.
10. Interest in capital investment has been taken at 12.50% per annum.
11. Promoter contribution has been taken at a minimum of 05% or 10% of total investment.
12. All calculations have been based on a single shift running.
13. The unit will install a D/G set to meet the problem of insufficient power supply.
14. Capacity utilization has been taken as 1st. Yr.-70%, 2nd. Yr.-75%, and 3rd. Yr.-80%.
15. This project may be set up where the raw materials are easily available.
16. It has been presumed that the unit will run at least 300 days in a year.

LOCATION OF THE UNIT-FLY ASH BRICKS MANUFACTURING

The location of the unit is an important factor given the basic consideration. It should justify to suitable the following benefits:-

1. Availability of raw materials & consumables.
2. Availability of Power, Fuel, Water.
3. Banking facility.
4. Marketing prospectus.
5. Good communications.
6. Labor facility.

 RAW MATERIALS AND CONSUMABLES

The main raw materials and consumables are as below:-

1. Fly Ash.
2. Gypsum.
3. Lime.
4. Sand.

ITEMS TO BE PRODUCED -FLY ASH BRICKS MANUFACTURING

1. 1. Fly Ash Bricks.

INSTALLED CAPACITY.

Fly Ash Bricks -24 lakhs per annum.

WORKING HOURS-FLY ASH BRICKS MANUFACTURING

The unit will work one shift per day.

-i.e. 8 hours per day.

-i.e. 25 days per month.

-i.e. 300 days per annum.

INSPECTION AND QUALITY CONTROL

The Bureau of Indian Standards has published the following specifications:-

1. BIS- IS:12894: 2002.
2. Compressive strength achievable: 60-250 Kg/Cm.
3. Water absorption: 5 – 12%.
4. Density: 1.5 gm/cc.

POLLUTION CONTROL -ASH BRICKS MANUFACTURING

The technology adopted for making fly ash bricks is eco-friendly. It does not require steaming or auto-calving as the bricks are cured by water only. Facial masks should be provided to the employee.

Dust control equipment may be installed to avoid dust pollution. The raw materials should be kept covered by a polythene sheet.

MARKET PROSPECTS-FLY ASH BRICKS MANUFACTURING

Common bricks have greater markets in India due to industrialization, expanding housing sector projects, and increasing the living standard of the common men. However, a survey conducted by the Govt. agency indicates that about 180 billion tones of clay burnt red bricks are consumed per annum.

This means that the upper layer of about 5000 acres of land is dug out every year. Red bricks are finally fed to burning coals; this is a separate problem creation. Erosion of soil and burning of wood and coal causes deforestation; it is the creation of serious problems for the brick industries. These problems can be reduced by using fly ash bricks.

Units for fly ash bricks are coming rapidly and hoped that it will reach up to 90 million units by the year 2020. People are taking more interest in fly ash bricks. It will be spread all over the country very soon. There is ample scope for fly ash bricks.

At present about one crore of fly ash brick is required per month for construction activities. Fly ash bricks are manufactured whole the year whereas, in the rainy season, red bricks cannot be produced. On the whole, it is estimated that in the coming time, its demand will be on the upper level.

FLY ASH BRICKS MANUFACTURING PROCESS.

The manufacturing process of fly ash is not too hard. It has neither complex technology nor skilled work. For manufacturing fly ash, lime, gypsum, and sand in the required proportion are mixed in a pan mixer. It may be fed manually or automatically. Water is added to the required quantity.

The ratio of materials may vary depending on the quality of raw materials. The mixer is fed automatically to the brick manufacturing machine through the conveyor belt.

Here bricks are pressed automatically and placed on wooden planks made for the purpose. Here it is kept for two days and then transferred for water curing for 10 to 15 days. Bricks are sorted and tested before supply.

The ratio for material mixing:-

1. Fly ash 70%
2. Line 10%.
3. Gypsum 5%.
4. Sand 15%.