Case Study : Sustainability of Fly Ash

Bricks
INTRODUCTION:

Pulverized fuel ash commonly known as fly ash is a useful by-product from thermal
power stations using pulverized coal as fuel and has considerable pozzolonic activity.
This national resource has been gainfully utilized for manufacture of pulverized fuel
ash-lime bricks as a supplement to common burnt clay buildings bricks leading to
conservation of natural resources and improvement in environment quality.

These bricks are suitable for use in masonry construction just like common burnt clay
bricks. Production of pulverized fuel ash-lime bricks has already started in the country
and it is expected that this standard would encourage production and use on mass
scale. This stand lays down the essential requirements of pulverized fuel ash bricks so
as to achieve uniformity in the manufacture of such bricks.

MARKET DEMAND:

180 billion tones of common burnt clay bricks are consumed annually. Approximately
340 billion tones of clay- about 5000 acres of top layer of soil dug out for bricks
manufacture, soil erosion, emission from coal burning or fire woods which causes
deforestation are the serious problems posed by brick industry. The above problems can
be reduced some extent by using fly ash bricks in dwelling units.

Demand for dwelling units is likely to raise to 80 million units for lower middle and
low income groups, involving an estimated investment 0f $670 billion, according to the
associated chamber of commerce and industry. Demand for dwelling units will further
grow to 90 million by 2020, which would require a minimum investment of $890 billion.
The Indian housing sector at present faces a shortage of 20million dwelling units for its
lower middle and low income groups which will witness a spurt of about 22.5million
dwelling units by the end of Tenth plan period. There is ample scope for fly ash brick
and block units.
Good quality of bricks as well as required quantity is not available moreover during the
rainy seasons supply of clay bricks are very difficult. Therefore, in order to fulfill the
required demand there will be a great chance to sta-rt more units in the field of fly ash
bricks.

At present 20 nos units are engaged and 40 lakhs nos of bricks per month are
manufactured in our state. And there will be scope to start near about 100 units, which
will be produced more than 2 cores no of bricks per month in future. Thus marketing of
these product are well shinning.

The Following Is The Analysis Of An Average Fly Ash

Brick Producing Plant:

PRODUCTION CAPACITY PER ANNUM:

Quantity: 24 lakh bricks total value Rs. 78,00,000/

Motive Power required: 35 HP

POLLUTION CONTROL:

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. Since firing process is avoided. There are
no emissions and no effluent is discharged. Facial masks and dust control equipment may be
provided to the employees to avoid dust pollution more over all the raw materials are kept
under covered by polythene sheet to avoid air pollution.

ENERGY CONSERVATION:

General precautions for saving electricity are followed by the unit by providing energy meter.
These products are low energy consumption since no need of fire operation in the production
unlike conventional bricks. Thus considerable energy could be saved not only in manufacturing
activities but also during the construction.

Electrical HP Details:

Sl No Name of the Machine No: of m/s H.P Connected

1 Automatic Fly Ash Brick 1 12
 making machine
2 Pan Mixer 7.5 +7.5 2 15
3 Belt Conveyor 1 2
Other electrical fittings/
4 -- 6
lighting etc
Total H.P Connected 35

FINANCIAL ASPECTS

1. FIXED CAPITAL :

(a)Land & Building:

S.N DESCRIPTION AMOUNT Rs

1 Land Lease hold (45,000 Sq.f)
2 Building (60 x 40 = 2400 Sq. 3,00,000
feet.)
3 Overhead water tank 50,000
TOTAL 3,50,000

(b)Machinery and Equipment :

S.N DESCRIPTION QTY RATE AMOUNT

1 Automatic Fly 1 12,00,000 12,00,000
ash Brick
making machine
hydraulic
operated with
all accessories
and fitting with
18HP Motor
2 Pan Mixture 500 1 2,00,000 2,50,000
KG Capacity
with 7.5 HP
Motor
3 Belt Conveyor 1 50,000 50,000
with necessary
fittings and 2
HP Motor
TOTAL 15,00,000
VAT 4 % 60,000
GRAND TOTAL 15,60,000
Erecting and Electrification Charges 22,000
Office furniture 20,000
TOTAL 16,02,000

RECURRING EXPENDITURE (PER MONTH ):

(a)Raw Material Per Month: Rs.

S.N DESCRIPTION QTY RATE AMOUNT

1 Fly ash 420 Mt 250 1,22,500
2 Gypsum Lime 70 1,900 1,33,000
3 Lime 105 1,300 1,36,500
4 Sand 35 800 28,000
TOTAL 4,20,000

(c)Utilities Per Month : Rs.

S.N DESCRIPTION AMOUNT

1 Power 35 HP 3916 Units@ 19,583
Rs.5 per Unit
2 Water 1,000
TOTAL 20,583

Electicity Consumption:

Per shift the machine consumes 85-90 units.

Water Consumption:

10,000 lts of water per 1 lack bricks is consumed.

CONCLUSION:

From the above conversation and observation, we can conclude that the fly ash bricks
are the more economical and eco-friendly bricks. The plant consumed 85-90 units per
12000 fly-ash bricks.
One unit of electricity consumes 0.156 kg of coal. Therefore, 90 units of electricity will
consume 1.404 Kg of coal. This will release 3.67*1.104 = 5.15 Kg of Carbon Di-oxide into
the atmosphere per shift of making fly ash bricks.

Therefore, in manufacturing 1000 fly ash bricks, 7.5 units of electricity will be
consumed. This will consume 1.17 Kg of coal. So, ultimately per 1000 fly ash bricks,
4.29 Kg of carbon dioxide is released into atmosphere.

RESULTS:

Brick Type Coal Diesel Electricity Total carbon

consumed consumed consumed emission
per 1000 bricks
Without using fly ash 90 Kg 3 Lt. 10 units 339.9 Kg

With use of fly ash - - 7.5 units 4.29 Kg

(Electricity consumed in operating the brick making machine and pumping water for curing of bricks)

Brick: CO2 Advantages: Disadvantages: Scope:

emitted:

Fly ash bricks 4.29 Kg Due to perfect size Bonding is lower due to These days many
savings in cement smooth finish, this can new constructors
mortar for making be easily corrected by are using fly ash
the walls and using a lesser bricks for
plastering by 20- cement:sand ratio construction. Their
40% future

CONCLUSION:

The above table clearly shows that the fly ash bricks are the best from environment
point of view and at the same time facilitate with a wide range of good properties and
can bring a boom in construction industry in India and abroad. Hence we can conclude
that the amount of carbon emission in manufacturing of the fly ash bricks is minimum,
and the clay bricks pollute the environment the most!! So a good and aware engineer
must recommend the use of fly ash bricks for the construction.
REFERENCES:

1. Article published on “Estimating the amount of carbon emission that the construction
industry can influence”, in BIS’s IGT report.

2. National workshop on utilization of fly ash “use of coal fly ash in the Autoclaved
Aerated Concrete Block”, Journal by Rajdeep Chowdhury, June 2011.

3. Autoclaved Concrete, F.H. Wittmann, Ed., 364 pp., Publishing Co. Amsterdam (1992).

4. Wikipedia for seeking some basic information.

Submitted By:

Rahil Arshad

146208

B.Tech. Civil IV Yr.