Detailed Project Report (DPR) on bricks manufacturing from fly ash

BRICKS FROM FLY ASH
[CODE NO.3790]  


Bricks may be made from a  no. of  different  kinds  of material,  but  they  must usually possess  (can  be  capable  of developing)   a certain amount of plasticity.  fly ash is one  of them.   Fly-ash is an industrial waste of thermal power  stations using  pulverised coal.  it is finely divided residue,  resulting from  the combustion of pulverised coal in the boiler,  which  is transported by the flue gases and subsequently collected by means of electrical or mechanical precipitators.

There are about 40 major thermal power plants in India which produces about 15 million tones of fly ash every year. Such enormous quantities  need  huge  dumping  grounds,  and   create pollution problems.

Fly ash being a puzzolanie material forms cementations products in conjunction with time and thus find  use  in  civil Engineering  Works.  In advanced countries fly ash has been  used in  variety of product during the last 2-3 decades.   Whereas  in this  country  a  very limited use of fly ash has  been  made  in hydraulic structures.  However, very little has been done on  the diversified  use of lips fly ash viz. in road  construction  soil slabbing precast block etc.

Even though research and development and suprimental construction has shown that fly-ash can be used with considerable advantages in building construction, the  construction  industry has  still not taken to the use of fly ash to any  large  extent. The reasons asisigned for this may be.

1.    Unawareness of the usefulness of fly ash in conjuction with lime, cement or bricks in the various civil engineering works.

2.    Unavailability of ready mix lime fly ash mixture of standard quality.

There is considerable lack of awareness and appreciation about the possibility of use of fly ash in partial replacement of cement  to the extent of 15 to 20% without affecting in  any  way the  strength of the structure adversely or producing  any  other detrimental  affect.   This  report  is  intended  to  give   the essential technical information and data regarding the use of  in  building  construction and the process and feasibility of  making  lime fly ash mix which can be used in variety of works.  
Flyash lime bricks are chemically bonded bricks manufactured by utilising 80-82% of fly ash, which is a  major waste bye-product of pulverised coal fired in Thermal Power Stations, 9-10% of lime, 9-10% of sand and 0.2% of Chemical accelerator  (Covered by Central  Fuel  Research Institute,  Dhanbad's  patent).   The process know-how  has been developed by  Central  Fuel  Research Institute, Dhanbad  and  marketed  through  National   Research Development Corporation, 20-22,  Zamroodpur  Community  Centre, Kailash Colony Extension, New Delhi - 110 048.

For manufacturing flyash lime bricks no firing is needed. Curing in steam for predetermined period is employed to enable the bricks to gain desired strength.  Thus, flyash  lime  bricks satisfy  the  basic parameters of building  units,  moreover  the bricks  are  also suitable for the construction  of  building  in coastal areas where normal red clay burnt bricks are found to be affected.

COST ESTIMATION


Plant Capacity                    9000 Nos/Day               
Land & Building (15000 sq.ft.)  Rs. 1.25 Lac                    
Plant & Machinery               Rs. 15 Lac                  
Working Capital for 3 Month     Rs. 45 Lac  
Total Capital Investment        Rs. 65 Lac
Rate of Return                    33%                   
Break Even Point             66%            


INTRODUCTION    
VARIOUS SPECIAL FEATURES OF FLYASH LIME BRICKS ARE AS FOLLOWS    
FLY ASH LIME BRICKS - SPECIFICATION    
USES AND APPLICATIONS    
ADVANTAGES OF FLYASH SAND LIME BRICKS:    
PROPERTIES & CHARACTERISTICS    
CHARACTERISTICS OF FLYASH-SAND-LIME BRICKS:    
ADVANTAGES OF FLYASH-SAND LIME BRICKS OVER CLAY-BRICKS:    
PROPERTIES OF BURNT CLAY FLASH BRICKS:    
CLAY-FLYASH BURNT BRICKS:    
ADVANTAGES OF CLAY FLY ASH BRICKS:    
B.I.S. SPECIFICATION    
RAW MATERIAL    
1. FLY ASH    
2. LIME    
3. WATER    
4. STAIN CHEMICALS    
PROPERTIES & CHARACTERISTICS OF RAW MATERIALS USED    
PROPERTIES OF FLY ASH:    
PHYSICAL PROPERTIES OF FLY ASHES:
CHEMICAL PROPERTIES OF FLY ASH FROM DIFFERENT THERMAL
   POWER STATIONS IN INDIA    
COMPARISION PROPERTIES WITH ISI:    
CHEMICAL REQUIREMENTS    
PHYSICAL REQUIREMENTS    
B.I.S. SPECIFICATION FOR LIME:    
CLASS A:-    
CLASS B:-    
CLASS C:-    
CLASS D:-    
CLASS E:-    
CHEMICAL REQUIREMENT:    
FLY ASH LIME BRICKS - SPECIFICATIONS:    
GENERAL REQUIREMENTS:    
DIMENSIONS AND TOLERANCES:    
MATERIALS:    
FLY ASH:    
BOTTOM ASH:    
SAND:    
LIME:    
ADDITIVES:    
PHYSICAL CHARACTERISTICS:    
COMPRESSIVE STRENGTH:    
DRYING SHRINKAGE:    
EFFLORESCENCE TEST:    
WATER ABSORPTION:
SAMPLING AND CRITERIA FOR CONFORMITY:    
TABLE : CLASSES OF BURNT CLAY-FLY ASH BRICKS    
GENERAL QUALITY    
IMENSIONS AND TOLERANCES:    
TOLERANCES:    
PHYSICAL REQUIREMENTS:    
COMPRESSIVE STRENGTH:    
WATER ABSORPTION:    
EFFLORESCENCE:    
MARKET OVERVIEW OF FLY ASH BRICKS    
CURRENT FLY ASH DISPOSAL PRACTICES AND EFFECTS    
FLY ASH - A RESOURCE    
GOVERNMENT INITIATIVES    
PRESENT MANUFACTURERS/SUPPLIERS OF BRICKS FROM FLYASH    
VARIOUS FLY-ASH BRICK COMPOSITIONS    
FLYASH SAND-LIME BRICKS: (AS PER CBRI)    
BURNT CLAY-FLY ASH BRICKS: (AS PER CBRI)    
FLY ASH SAND-LIME BRICKS: (AS PER CENTRAL FUEL RESEARCH
   INSTITUTE, DHANBAD)    
FLY ASH BRICK COMPOSITION : (AS PER ISWAR B. VISAKHAPATNAM)    
ANOTHER FLY ASH LIME BRICKS COMPOSITION:    
OTHER FLY ASH SAND LIME BRICK COMPOSITION:    
SAND-LIME BRICKS COMPOSITION: (AS PER CBRI)    
PROCESS OF MANUFACTURE    
1.   GRINDING & MIXING :
2.   PRESSING :    
3.   REMOVAL & STACKING FOR CURING/AUTOCLAVING :    
AUTOCLAVING :    
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF FLY-ASH-
   SAND-LIME BRICK (AS PER CBRI)    
CERTAIN FEATURES    
BRICK COMPOSITION:    
MAJOR COMPONENTS:    
ALIENT TECHNICAL FEATURES:    
ENVIRONMENTAL ASPECTS:    
MAJOR PLANT EQUIPMENT & MACHINERY:    
AS PER TRADITIONAL BRICK PRODUCTION -    
TECHNOLOGY PACKAGE:    
RED SOILS:-    
ADMIXTURE:-    
MARINE SOILS:-    
MANUFACTURE OF PROCESS OF FLY ASH BRICK    
PROCESS OF MANUFACTURE OF SAND-LIME BRICKS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF FLY ASH    
SUPPLIERS OF LIME    
SUPPLIERS OF GYPSUM    
SUPPLIERS OF MACHINERY FOR BRICK MAKING FROM FLY ASH    





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)