THE FOREMOST REQUIREMENT OF INDIA

McKinsey report
India's demand is 315GW by 2017
Which is more than double the current installed capacity

The Planning Commission of India wants to implement

Rajiv Gandhi Grameen Vidyutikaran Yojna
for the rural electrification with an investment of about Rs 34000 crore

11th 5 YEAR Plan

Wants to add 78 Gigawatts power generation

Anil Razdan, Secretary, Ministry of Power statement

“India to emerge as a major power equipment manufacturing
hub & vast opportunity exists, specially for small entrepreneurs”

“It is a bonanza for the industry and an

opportunity not to be missed.”
BUT
 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 AMICABLE SOLUTION
The has come out with an amicable
solution by joining its hand with
1.Institute for Solid Waste Research & Ecological
Balance (INSWREB)
2.Industrial Development Bank of India (IDBI)
3.Shanghai Electric Company (SEC)
4.The Community Development Carbon Fund
(CDCF) of the World Bank (WB)
And intends to jointly promote the Flyash Mission
Do you want to participate in this
Fly Ash Revolution
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.
COMPARISION

NORMAL CLAY BRICK FLY ASH BRICK

Varying colour as per soil Uniform pleasing colour like cement

Uneven shape as hand made Uniform in shape and smooth in finish

Lightly bonded Dense composition

Plastering required No plastering required

Heavier in weight Lighter in weight

Compressive strength is around 35 Kg/cm2 Compressive strength is around 100 Kg/cm2

More porous Less porous

Thermal conductivity 1.25 – 1.35 W/m2 ºC Thermal conductivity 0.90-1.05 W/m2 ºC

Water absorption 20-25% Water absorption 6-12%

PROFITS WHICH CAN BE EARNED
TYPE OF WHO HOW
PROFIT WILL
HELP
DIRECT NTIL  BY PROVIDING YOU THE TECHNOLOGY
 BY SETTING UP THE PLANT ON LSTK
SEC  BY ENSURING THE INTIAL MARKETING
 BY BUILDING UP MARKETING STRATEGY
 BY CREATING A BRAND ESTABLISHMENT

IN- NTIL  SETTING UP A CDM

 EARN THROUGH CARBON CREDIT
DIRECT IDBI
 PARTICIPATION IN GREENATHALON
WB
ROLE TO BE PLAYED BY NTIL
Agency Areas Specific Responsibilities

NORTH Project Project management from site

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

Micro Setting up  Mobilize resources

 Procure equipment and machinery
Enterprises and  Market the products
/ High operating  Maintain the data and records as
Capacity FaL-G plants per the monitoring requirements
 Implement environment
Automation
management plans as agreed
Plants  Propagate Fly Ash Revolution and
(HCAPs) show the whole world the benefits
ROLE DIAGRAM

NGO FABMA MARKET

SEC NTIL U

WB IDBI INSWREB
PRICE PROFIT RATIO FaL-G Bricks (Without Cement)

Raw Materials For 1 Brick Wt 3.2 Kg Size 75x125x250

Items age % Wt/Brick Rate/Kg Amt/Brick
Fly Ash 55 1.76 0.20 0.35
Sand 25 0.80 0.10 0.08
Lime 15 0.48 1.00 0.48
Gysum 5 0.16 1.20 0.19
Total 100 3.2 1.10
Taken for SME/For HCAPS it will reduce
Selling Price 2.90
by 30% overheads
2%Breakage 0.02 Profit 1.20
Manpower 0.16
Profit direct % 70.99
Electricity 0.10
Marketing 0.20 Indirect profit through Carbon Credit 0.08
VAT @ 4% 0.11 Profit indirect % 4.72
Total 0.59
Total Cost Price 1.70 % THEREFORE TOTAL PROFIT 75.71%
PRICE PROFIT RATIO FaL-G Bricks (With Cement)

Raw Materials For 1 Brick Wt 3.2 Kg Size 250x125x75

Items age % Wt/Brick Rate/Kg Amt/Brick
Fly Ash 62 1.98 0.20 0.40
Sand 30 0.96 0.10 0.10
Cement 8 0.26 4.80 1.23
Total 100 3.2 1.72

Taken for SME/For HCAPS it will reduce

Selling Price 3.50
by 30% overheads
2%Breakage 0.03 Profit 1.17
Manpower 0.16
Profit direct % 50.47
Electricity 0.10
Indirect profit through Carbon
Marketing 0.20 Credit 0.08
VAT @ 4% 0.11
Profit indirect % 3.44
Total 0.60
Total Cost Price 2.33 % THEREFORE TOTAL PROFIT 53.91
THE AGREEMENT
World Bank
has issued a Letter of Intent for the purchase of

800,000 tons of carbon credits from the FaL-G brick and block industry
@ US$ 17/ton of CO2 eq.
A
Letter of Intent
was signed to this effect by

Mr. Ken Newcombe, PCF Fund Manager & Sr. Manager:

Carbon Finance Business, World Bank,

And

Mr. Kalidas, Director, INSWAREB

at Washington on 3rd instant.
SOLUTION MATERIALIZATION

The flyash generated in thermal power station causes many hazardous diseases
like Asthma, Tuberculosis etc. These six criteria pollutants are sulphur di-oxide
(SO2),
Carbon Mono-oxide (CO), Nitrogen oxide (NO2), Ozone (O3), suspended
particulates and non-methane hydrocarbons (NMHC) now referred to as volatile
organic compounds (VOC). Land degradation
The thermal power stations are generally located on the non-forest land and do
not involve much Resettlement and Rehabilitation problems. However it's
effects due to stack emission etc, on flora and fauna, wild life sanctuaries and
human life etc. have to be studied for any adverse effects. One of the serious
effects of thermal power stations is land requirement for ash disposal and
hazardous elements percolation to ground water through ash disposal in ash
ponds. Due to enormous quantity of ash content in India coal, approximately 1
16
Acre per MW of installed thermal capacity is required for ash disposal.
According to the studies carried out by International consultants if this trend
continues, by the year 2014 -2015, 1000 sq. km of land should be required for
ash disposal only.Besser
is the US based Company, leaders in the production of plant and
machinery
for the last 100 years
ROLE
Agency Areas Specific Responsibilities

INSWAREB Technology Provide technological know how

Provide logistical support for
(Institute for provider procuring equipment, machinery and
Solid Waste raw materials
Research & Provide guarantee to enterprises
Ecological against technical failure
Balance )
Market Conduct programs to encourage
entrepreneurs
Facilitator Conduct awareness programs and
workshops for brick users
ROLE
Agency Areas Specific Responsibilities

ECPL Carbon Enroll micro enterprises under the

Carbon Credit project
(Eco Transaction Find a potential buyer and negotiate
Carbon Coordinator price
Private Coordinate carbon transaction activities
Limited) with the buyer and the CDM Executive
Board
Obtain host country endorsement
Undertake monitoring as per the
requirements of CDM and the World
Bank
Pass on the carbon benefits to the
micro enterprises as per the terms
mutually agreed
ROLE
Agency Areas Specific Responsibilities

CDCF Purchasing Coordinate with the CDM executive

Board
(Community Emission Register the project with CDM
Development Reductions Executive Board
Make payments to ECPL as per the
Fund of The (ER)s terms mutually agreed
World Bank) Monitor the implementation of
specific communication programs by
ECPL
SCHEMATIC FAL-G PLANT PROCESS (STEP 1)
Procurement of Raw Material

Procurement
Of
RAW MATERIAL

FLY ASH LIME/GYPSUM STONE DUST

FROM FROM FROM
THERMAL PLANTS CHEMICAL PLANTS STONE CRUSHER
SCHEMATIC FAL-G PROCESS (STEP 2)
Storage of Raw Material

Storage
of
Raw Materials

GYPSUM
FLY ASH STONE DUST In bags
LIME SLUDGE .stored in godowns ,
In open yard In open yard
Dumped in open yard
duly wetted duly wetted
or
and and
stored in packets
covered by Plastic sheet covered by Plastic sheet
SCHEMATIC FAL-G PROCESS (STEP 3)
Batch Mixing of Raw Material

Mechanized
transportation
of required quantity
FLY ASH Raw Materials to SAND
Roller Mixture

LIME GYPSUM
SCHEMATIC FAL-G PROCESS (STEP 3)
Wet mixing in Roller Mixer
Raw materials are kneaded under rollers for achieving
homogenous mortar

FLY ASH

SAND LIME/GYPSUM
SCHEMATIC FAL-G PROCESS (STEP 4)
Mechanized Transfer from Pan Mixer to Automatic Brick Making Machine

r ho
ta
or ROLLER mo
m MIXTURE ge
iz ed n ize
e n dm
o g or
om tar
h

HYDRAULIC
VIBRO PRESS
COMPRESSION
SCHEMATIC FAL-G PROCESS (STEP 5)
Drying & Curing

The green bricks

are dried up under sun
The dried up bricks
from 24 to 48 hours
are stacked
and subjected for water spray curing
once or twice a day
for 7-21 days
depending on ambience

DESPATCH TO THE MARKET

THE GREATEST CHALLENGE FOR CONSTRUCTION

Is to provide higher quality Housing & Roadways

By using construction materials that can be produced in a
 Socially
 Environmentally and
 Economically sustainable way.

Another major problem Is

 Labour availability is the biggest challenge that the construction
industry faces today.
 Scarcity and high costs of labour pushed the industry to optimum
mechanization.