03-10-2016, 04:17 PM
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Introduction 2
Fly Ash bricks may be produced by two types of recipe; 1) fly ash, lime, gypsum and sand 2) fly ash, sand & cement.
These bricks can be extensively used in all building constructional activities similar to that of common burnt clay bricks. The fly ash bricks are comparatively lighter in weight and stronger than common clay bricks.
In view of superior quality and eco-friendly nature, and government support the demand for Fly Ash Bricks will be picked up.
Since fly ash is being accumulated as waste material in large quantity near thermal power plants and creating serious environmental pollution problems, its utilization as main raw material in the manufacture of bricks will not only create ample opportunities for its proper and useful disposal but also help in environmental pollution control to a greater extent in the surrounding areas of power plants.
Market Potential
The country consumes billion tones bricks, exhausting billion tones of clay every year and acres of top soil land is made unfertile for a long period. The Government is seriously concerned over soil erosion for production of massive quantities of bricks, in the background of enormous housing needs.
The excellent engineering property and durability of fly ash brick enlarges its scope for application in building construction and development of infrastructure, construction of pavements, dams, tanks, under water works, canal lining and irrigation work etc. Enormous quantities of fly ash is available in and around thermal power stations. The demand of bricks could be met by establishing manufacturing units near thermal power stations and to meet the local demand with less transportation costs.
Process of Manufacture
Raw materials like Fly ash, lime sand and gypsum OR Fly Ash, Cement & Sand are manually fed into a pan mixer where water is added in the required proportion for intimate mixing. The proportion of the raw material is generally in the ratio 60-80% of fly ash, 20-25% sand and 8-10% Cement OR 60-80% of fly ash 10-20% lime, 10% Gypsum and 10% sand, depending upon the quality of raw materials.
After mixing, the mixture is shifted to the hydraulic/mechanical presses. The bricks are carried on wooden pellets to the open area where they are dried and water cured for 21 days. The bricks are tested and sorted before dispatch.
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 the firing process is avoided, there are no emissions and no effluent is discharged. On the other hand, it solves the problem of fly ash disposal.
Energy Conservation
General precautions for saving electricity are required to be followed by the unit by adopting energy conservation techniques not only to conserve the power but also to save considerable expenditure in their own and also in the interest of the nation as a whole.
Machinery
The machinery required to produce Fly Ash Bricks is available in various types, models & design depending on manufacturers experience & standards. The mainly procedure to produce Fly Ash Bricks is Hydraulically Pressing the mixed materials. The main components of Fly Ash Bricks Plant are as per followings….
Batching System mainly includes Storage Bin, Storage Silo, Weighing System & Conveyors. Batching System is provided to store, weigh & transfer the Raw Materials to the Pan Mixer.