DR. PRADEEP KUMAR HBTU KANPUR Fly ash Bricks DR. PRADEEP KUMAR HBTU KANPUR

73% power generated in INDIA is from Thermal Power and 90% of it is coal based. Ash content is 27% to 42% of the coal used. Increase in FLYASH generation has risen from 4 crore to 11crore ton in the last decade and will rise to 1100 crore ton in coming decade. The flyash generated in thermal power station causes many hazardous diseases like Asthma, Tuberculosis etc. Till date only 14% of the Fly Ash generated is being utilized

AND Approximately 10,000 hectares of top soil is being lost every year for brick manufacturing and road construction. If we continue in this format, very soon, we will not have sufficient soil to produce our minimum required food.

Ministry of Environment & Forest (MoEF) Had issued a Gazette Notification on 14 Sep 1999 Stipulating that no person shall be permitted to manufacture clay bricks or tiles or blocks for use in construction activity without at least 25% of ash (fly ash, bottom ash, or pond ash on weight to weight basis), within a radius of 50 Km from coal or lignite based thermal power plants in INDIA.

Ministry of Environment & Forest (MoEF) Had amended the Gazette Notification on 27 Aug 2003 making it compulsory to use fly ash for manufacturing building material by increasing the radius from 50 Km to 100 Km 25% use of fly ash by 31 Aug 2004 50% use of fly ash by 31 Aug 2005 75% use of fly ash by 31 Aug 2006 100% use of fly ash by 31 Aug 2007

Ministry of Environment & Forest (MoEF) Had amended the Gazette Notification on 06 Nov 2008 That Central Government will exercise its power on or after the expiry of a period of sixty days (05 Feb 2009) from the date of notification published and displayed in public, to implement the above notification. It will be applicable to all construction agencies of Central or State or Local Government and private or public sector and it will the responsibility of all the agencies either undertaking construction or approving the design or both to ensure compliance Submit annual returns to the concerned State Pollution Control Board or Pollution Control Committee.

THE PRODUCT The Fly Ash mission aims to promote Fly Ash bricks as an alternative to burnt clay brick within the construction sector in India. Fly ash is mixed with two other ingredients available as industrial byproducts: Lime from the acetylene industry, and Gypsum from chemical plants. This is proving to be a revolutionary invention that produces bricks without the sintering process and consequently no greenhouse gases are emitted. The ultimate product is none other than FaL – G Brick which is well qualified as emission-abating project to receive the benefits of carbon credits.

FLY ASH BRICK NORMAL CLAY BRICK COMPARISION FLY ASH BRICK NORMAL CLAY BRICK Uniform pleasing colour like cement Varying colour as per soil Uniform in shape and smooth in finish Uneven shape as hand made Dense composition Lightly bonded No plastering required Plastering required Lighter in weight Heavier in weight Compressive strength is around 100 Kg/cm2 Compressive strength is around 35 Kg/cm2 Less porous More porous Thermal conductivity 0.90-1.05 W/m2 ºC Thermal conductivity 1.25 – 1.35 W/m2 ºC Water absorption 6-12% Water absorption 20-25%

PROFITS WHICH CAN BE EARNED HOW WHO WILL HELP TYPE OF PROFIT BY PROVIDING YOU THE TECHNOLOGY BY SETTING UP THE PLANT ON LSTK BY ENSURING THE INTIAL MARKETING BY BUILDING UP MARKETING STRATEGY BY CREATING A BRAND ESTABLISHMENT NTIL SEC DIRECT SETTING UP A CDM EARN THROUGH CARBON CREDIT PARTICIPATION IN GREENATHALON IDBI WB IN- DIRECT

ROLE TO BE PLAYED BY NTIL Specific Responsibilities Areas Agency Project management from site selection to commissioning Lump Sum Turnkey Project Educate and Train people to achieve a greener earth Ensure implementation of the Community Development Mechanism (CDM) along with IDBI Transfer the data and records as per the monitoring requirements of CDM for Carbon Credit payments from World Bank Initial marketing of the product Project management, Liasoning, and annual maintenance of FaL-G plants. NORTH Techno Projects India (P) Ltd. (NTIL)

ROLE TO BE PLAYED BY YOU Setting up and operating FaL-G plants Micro Specific Responsibilities Areas Agency Mobilize resources Procure equipment and machinery Market the products Maintain the data and records as per the monitoring requirements Implement environment management plans as agreed Propagate Fly Ash Revolution and show the whole world the benefits Setting up and operating FaL-G plants Micro Enterprises/ High Capacity Automation Plants (HCAPs)

PRICE PROFIT RATIO FaL-G Bricks (Without Cement) 75x125x250 Size Wt 3.2 Kg For 1 Brick Raw Materials Amt/Brick Rate/Kg Wt/Brick % age Items 0.35 0.20 1.76 55 Fly Ash 0.08 0.10 0.80 25 Sand 0.48 1.00 15 Lime 0.19 1.20 0.16 5 Gysum 1.10   3.2 100 Total Taken for SME/For HCAPS it will reduce by 30% overheads 0.02 2% Breakage 0.16 Manpower 0.10 Electricity 0.20 Marketing 0.11 VAT @ 4% 0.59 Total 1.70 Total Cost Price 2.90 Selling Price 1.20 Profit 70.99 % Profit direct 0.08 Indirect profit through Carbon Credit 4.72 % Profit indirect 75.71% THEREFORE TOTAL PROFIT %

PRICE PROFIT RATIO FaL-G Bricks (With Cement) 250x125x75 Size Wt 3.2 Kg For 1 Brick Raw Materials Amt/Brick Rate/Kg Wt/Brick % age Items 0.40 0.20 1.98 62 Fly Ash 0.10 0.96 30 Sand 1.23 4.80 0.26 8 Cement 1.72   3.2 100 Total Taken for SME/For HCAPS it will reduce by 30% overheads 0.03 2% Breakage 0.16 Manpower 0.10 Electricity 0.20 Marketing 0.11 VAT @ 4% 0.60 Total 2.33 Total Cost Price 3.50 Selling Price 1.17 Profit 50.47 % Profit direct 0.08 Indirect profit through Carbon Credit 3.44 % Profit indirect 53.91 THEREFORE TOTAL PROFIT %

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