Further, these bricks were factory-made by mixing the ingredients with water without consuming thermal energy Manufacturers of construction materials had also begun to note the importance and application of fly ash bricks. The government was encouraging manufacturing of fly ash bricks, and various concessions were given to such manufacturing. Of fly ash was available as waste material from thermal power plants. The quality and durability of fly ash bricks were considered very suitable for application in various construction projects. The use of fly ash in such circumstances was a priority. With construction progressing at very fast pace, the government was keen to develop a regular supply of bricks without causing damage to the soil. Production of clay bricks required clay that resulted in leeching the fertility of the land in the long run. A process outline for manufacturing fly ash bricks is given in exhibit 1: Fly Ash Lime Gypsum Sand Mixer Conveyor Brick Making Machine (press) Transportation Dry Curing Wet Curing Drying Inspection Sorting Dispatch Exhibit 1 Market potential: The annual demand for clay bricks for construction purpose was estimated to be 180 billion tones that required almost 340 billion tones of clay annually. The bricks were later dried in the open for one or two days and then cured using water. Water was added to the mix to form a paste after which the mixture was transferred to mould fitted in a hydraulic/mechanical process. The ratio of the input material was as follow: Fly ash: 60 to 80 percent *Sand 10 percent "Gypsum: 10 percent *Lime: 10 to 20 percent 2 The manufacturing process for those bricks, known as fly ash-lime-gypsum, required intimate mixing of fly ash, sand, added to make a fine blend. Manufacturing process: Government authorities had developed technology to replace burnt clay bricks with fly ash as a construction material for building walls. This would enable a waste product to be used in as a construction material and also conserve the environment and resources. The government was keen on promoting fly ash bricks in the construction sector. Second, it was estimated that there would be a substantial shortfall in the availability of different types of building materials, including bricks. Using fly ash for making bricks instead of clay would thus help preserve the fertility of the soil. Removing this top layer makes the land infertile for a long period. First, there were environmental concerns about the traditional way of making bricks from clay that comprise topsoil. Fly ash as a construction material was considered appropriate on two accounts. Market trends revealed that coal would be continue to be used as the prime fuel for many more years, resulting in a great amount of fly ash generation. The fly ash from the exits flue gas was collected at various stages of the flue gas path and at the dust collector fitted before the final chimney. When crushed coal is burned to generate heat, the residual product contained 80% fly ash. A huge quantity of coal is utilized to produce thermal power, the major power generation source. Background: Fly Ash was a residual obtained after combustion of coal. He wanted to ascertain the feasibility of the project using a cost-volume-profit (CVP) analysis. Though actual production would depend on market demand, the partners estimated that 2.4 million bricks could be sold per year at an average price of 7000 Dh per 1000 bricks. On the basis of preliminary analysis, he decided to set up a plant that would have the capacity to manufacturing four million bricks per year. Years of work in the construction industry had shown him the potential of using large volume of fly ash bricks in construction, especially in housing and in infrastructure projects. Radi, on the other hand, was sure of his plan. His long-time friend Ali Jabr was also interested but had a few doubts regarding the feasibility of the project. For quite some time, he had been doing some market research exploring the potential of his "dream project" - establishing a fly ash brick manufacturing unit in India - and had seen huge potential for profit in the project. Transcribed image text: Fly Ash Case In April 2013, Radi AlShamsi had a business plan.
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