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)