Detailed Project Report (DPR) on Fly Ash Bricks (Cap: 6000 Nos. Per Day)

FLY ASH BRICKS (CAP: 6000 NOS. PER DAY)

[EIRI/EDPR/4641] J.C.: 2858XL

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.

COST ESTIMATION

Plant Capacity            6000 Nos/Day  

Land & Building Owned    

Plant & Machinery                    Rs. 29.10 Lac 

Working Capital for 1 Month    Rs. 14.18 Lac 

Total Capital Investment          Rs. 45.28 Lac 

Rate of Return                          40%

Break Even Point                      73%

CONTENTS

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)