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Flyash based value added products, Coal Ash utilization, Fly Ash as Raw Material, Products from Waste

Fly ash is a type of pozzolan formed by the burning of pulverised coal. The fly ash is a fine amorphous powder, rich in alumina and silica generated through separation methods such as electrostatic, mechanical etc. The fly ash is a predominant material in the construction industry and used as an admixture.

Fly ash can be used as prime material in many cement-based products, such as poured concrete, concrete block, and brick. One of the most common uses of fly ash is in Portland cement concrete pavement or PCC pavement. Road construction projects using PCC can use a great deal of concrete, and substituting fly ash provides significant economic benefits. Fly ash has also been used as embankment and mine fill. Fly ash can be a cost-effective substitute for Portland cement in many markets. Fly ash is also recognized as an environmentally friendly material because it is a byproduct and has low embodied energy, the measure of how much energy is consumed in producing and shipping a building material.

The two major reasons for use of fly ash as an ingredient in building materials and concrete are because it improves the quality of finished products and breeds significant environmental benefits. This has led to major use of fly ash in the constructional activities. Hence, the factors responsible for growth of fly ash market are growing urbanization in emerging economies and increasing constructional activities globally.

Fly ash bricks as the name signifies, is made from fly ash generated from the thermal power stations along with lime and gypsum. Pulverized fuel ash is called fly ash and is mostly generated from thermal power stations where it is generated by burning of coal.

There has been rising problem of pollution worldwide, fly ash bricks reduces the problem of pollution by utilizing the fly ash produced from thermal power plants which might otherwise be a problem in disposal. Moreover, the conventional red bricks need to be burned in kilns and huge amount of coal is burned for the process, thus, adding to greenhouse effects caused by carbon dioxide emissions.

Additionally, other numerous benefits such as low water absorption, light weightedness and other properties have added to the significant popularity of fly ash bricks in the global market.

 

 

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Lime Bonded Fly Ash Brick - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Lime bonded fly ash bricks are the product of thermal power waste base products. There is no sophisticated machinery used in this production. There is good demand of this product. As a whole the project is cost effective tiny and small scale industry with supporting of government fund. Few entrepreneur may enter into this field.
Plant capacity: 20000 Nos. Bricks/DayPlant & machinery: Rs. 12 Lakhs
Working capital: Rs. 1 CroreT.C.I: -
Return: 25.78%Break even: 44.16%
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Bricks From Fly Ash - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Bricks may be made from a no. of different kinds of materials but they must usually posses a certain amount of plasticity. Fly ash is one of them. Fly ash is an industrial waste of thermal power station using pulverized coal. Fly ash generally contains about 5% to 6% unburnt carbon. Its addition in clay, therefore result in better burnt bricks together with economy in coal consumption during firing. In India the estimated production capacity of all the bricks industries is about 1200 million which is far below the market demand and the shortfall is likely to increase manifold in future. New entrepreneur may enter in this field.
Plant capacity: 250 Lacs Nos/AnnumPlant & machinery: Rs. 27.00 Lacs
Working capital: Rs. 62.0 LacsT.C.I: Rs. 158.0 Lacs
Return: 27.16%Break even: 65.69%
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Bricks From Fly Ash - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Bricks may be made from a number of different kinds of materials, but they must usually possess (can be capable of developing) a certain amount of plasticity. Fly ash is one of them. Fly ash is an industrial waste of thermal power stations using pulverized coal. It is finely divided residue, resulting from the combustion of pulverized coal in the boiler, which is transported by the flue gases and subsequently collected by means of electrical or mechanical precipitators. Fly ash being a puzzolanic material forms cementations products in conjunction with time and thus found use in civil Engineering works. In advanced countries fly ash during the last 2-3 decades. Whereas in this country a very limited use of fly ash has been made hydraulic structures. However very little has been done on the diversified use of lips fly ash viz. in road construction soil slabbing precast block etc. in India the estimated production capacity of all the bricks industries is about 900 million which is for below the market demand and the shortfall is likely to increase manifold in future years during which a large increase in the building activity is anticipated. It is well recognized that traditional method of hand moulding cannot cope with the heavy demand. There is very good scope for new investment. You can venture into this units.
Plant capacity: 83333 Nos./DayPlant & machinery: 30 Lakhs
Working capital: -T.C.I: 192 Lakhs
Return: 40.80%Break even: 53.00%
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Fly Ash Bricks by Triboelectric Beneficiation Process - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Production Schedule

Fly Ash required for the production of Fly Ash Bricks, the raw Fly Ash is subjected to Triboelectrostatic Beneficiation process making use of separation technologies. Separation technologies, LLC (ST) continues install fly ash beneficiation systems to supply high quality fly ash for the desired purpose. Fly Ash is a useful by-product from thermal power stations using pulverized coal as a fuel and has considerable pozzolanic activity. Fly ash-sand-lime bricks can be used as an alternative material for burnt clay bricks, which is one of the important building materials used for construction of housing and buildings. It can be used as facing bricks without any external plastering. It is estimated that the present production of building bricks is around 230 billion numbers annually, in India and the requirement is expected to be around 285 billion numbers, as per the estimates available. To fill the demand-supply gap, more units are required to be set up in different zones of the country.
Plant capacity: 12,000 Nos. / DayPlant & machinery: 260 Lakhs
Working capital: -T.C.I: Cost of Project : 655 Lakhs
Return: 42.00%Break even: 40.00%
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AAC BLOCKS (AUTOCLAVED AERATED CONCRETE BLOCKS) FLY ASH BASED - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

Autoclaved Aerated Concrete (AAC) is a non combustible, lime based, cementitious building material that is expanding into new worldwide markets. As a single component building material, AAC has achieved acceptance in new markets throughout the world. AAC products are equally suitable for residential construction, multistory buildings, commercial, and industrial construction. The products are made of natural materials: sand, lime, and water. These raw materials are processed to provide a building material with a large number of air pores; hence, aerated concrete. Fine pores (nearly 70% of the product) and the solid structure of calcium silicate hydrate gives AAC its exceptional material properties. The AAC has the features of light bulk density, good thermal insulation properties and sound-absorption, certain strength and process ability, and its raw materials is very rich, especially the reuse of fly ash enables the comprehensive utilization of industrial residue, curbs environmental pollution, no destroy on farmland, create good social and economic benefits. AAC is an ideal alternative of the traditional clay brick wall materials. For many years AAC has been strongly supported by national wall reform policy, tax policy and environmental policy. In a sentence, AAC has been an important factor in new building materials and has a broad market prospect. New entrepreneurs should venture into this field.
Plant capacity: 150000 M3/AnnumPlant & machinery: 1100 Lakhs
Working capital: -T.C.I: Cost of Project : 1790 Lakhs
Return: 44.00%Break even: 53.00%
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FLY ASH BRICKS FROM LIMESTONE - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Fly Ash bricks are alternative to burnt clay bricks in the construction sector in India. Fly ash bricks are an environment friendly cost saving building product. These fly ash bricks are three times stronger than conventional bricks with consistent strength. 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. India produces about 70 million tons of coal ash per year from burning about 200 million tons of coal per year for electric power generation. Coal ash management poses a serious environmental problem for India and requires a mission-mode approach. Currently, about one acre per MW of land is needed for ash disposal. The Ministry of Power, Govt. of India estimates 1800 million tons of coal use every year and 600 million tons of fly ash generated by 2031 to 2032. The country consumes about 180 billion tonnes bricks, exhausting approximately 340 billion tonnes of clay every year and about 5000 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. Ministry of Environment & Forest (MoEF) Had issued a Gazette Notification on 14th 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 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. Fly ash bricks are nowadays mostly used for construction and gaining its popularity over builders and engineers because of its high strength, uniformity and less consumption of mortar plastering. Above to this it is eco friendly bricks which saves environmental damage caused by burnt clay bricks and saves top agricultural soil which was the main raw material in the burnt clay bricks. Further ahead, by 2025-26 the number of middle class households in India is likely to more than double from the 2015 to 16 levels to 113.8 million households or 547 million individuals, indicative of increased household formation rate, and consequently increase demand for housing, thus providing a great market opportunity for new entrepreneurs according to NCAER. The demand is perceived to be higher for fly ash bricks & blocks than traditional bricks or blocks. The increased demand can be met by increased production levels of existing units or by setting up large scale manufacturing units. Fly ash utilization has great potential to lower green house gas emissions. Hence there is a bright market potential for fly ash bricks. New entrepreneurs should venture into this field.
Plant capacity: 12000000 Nos./AnnumPlant & machinery: 80 Lakhs
Working capital: -T.C.I: 409 Lakhs
Return: 43.00%Break even: 40.00%
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AAC BLOCKS AUTOCLAVED AERATED CONCRETE BLOCKS)Fly Ash Based - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Plant Layout

Autoclaved Aerated Concrete (AAC) is a non-combustible, lime based, cementitious building material that is expanding into new worldwide markets. As a single component building material, AAC has achieved acceptance in new markets throughout the world. AAC has a history of one hundred of years and has become the pillar industry in construction field. In our country aerated techniques have been developed for about 40 years, and its technique skills and equipments are becoming mature. The AAC has the features of light bulk density, good thermal insulation properties and sound-absorption, certain strength and process ability, and its raw materials is very rich, especially the reuse of fly ash enables the comprehensive utilization of industrial residue, curbs environmental pollution, no destroy on farmland, create good social and economic benefits. AAC is an ideal alternative of the traditional clay brick wall materials. For many years AAC has been strongly supported by national wall reform policy, tax policy and environmental policy. In a sentence, AAC has been an important factor in new building materials and has a broad market prospect. Uses and Applications AAC has been used in a variety of construction projects throughout the United States. It has been used for load-bearing walls and floor/roof systems in elementary and secondary school classrooms, multistory university dormitories, military base barracks, and various hotel chains. It has been chosen for its material properties and speed of construction. High rise buildings have utilized AAC for shaft and fire walls due to its tremendous fire ratings. Manufacturing and warehouse facilities have found that AAC non load bearing cladding panels provide both an aesthetically desirable and acoustically functional solution for their projects. AAC has been used in single and multifamily construction for its thermal, acoustical, and fire performance. AAC products are equally suitable for residential construction, multistory buildings, commercial, and industrial construction. The products are made of natural materials: sand, lime, and water. These raw materials are processed to provide a building material with a large number of air pores; hence, aerated concrete. Fine pores (nearly 70% of the product) and the solid structure of calcium silicate hydrate gives AAC its exceptional material properties. Market Survey The autoclaved aerated concrete sector of the construction industry is now in the phase of a tremendous growth cycle. The autoclaved aerated concrete industry must utilize competitive techniques as customers are looking for lowered costs. AAC is not a new building system but it is new to India. Autoclaved aerated concrete (AAC), though relatively unknown in India, is currently one of the many building products being touted as green or environmentally friendly. AAC is a lightweight manufactured building stone. Comprised of all natural raw materials, AAC is used in a wide range of commercial, industrial, and residential applications. AAC Reduces Additional Material Use and Minimizes Waste and Pollution. Today, concrete used in most places, including many urban areas, is in proportion of 1:2:4 (cement: sand: coarse aggregate). This ancient technology has vanished at many sites in various metros. Proper concrete mix design is being done. This helps achieve superior quality and economy to the constructor. Concrete will no longer be a civil engineers' product. It will be a formulation of several chemicals with cement playing a major role. The market size of cement and AAC is defined as the amount of cement and AAC products supplied to the total Indian marketplace, in a particular period. Therefore, market size is determined by supply rather than demand. The outlook (for autoclaved aerated concrete) is more optimistic. Overall demand improvement will lead to a reduction in the inventory of unsold residential and commercial premises. In addition to this, residential construction from high-end apartments to affordable housing is being announced and expected to come on stream. The Indian cement industry is on a capacity expansion spree and was expected in 2007-08 to add another 60 mn tonne, with an investment of around Rs 100 bn. Between 2005 and 2008 around 55 companies announced either greenfield or brownfield expansion plans. With these projects, Indias cement capacity was to touch a new high of approximately 200 mn tonne by 2008. Indian cement firms had also plans to increase their capacity by 74 mn tonne by 2010 with investment of Rs 300 bn. Companies like Zuari Cement, OCL, Dalmia Cement, Binani Cement, Birla Corp, India Cements, Saurashtra Cement, NCL Industries and JK Cement have proposed or are implementing capacity expansion projects. By 2008, about 21.5 mn tonne of additional capacity was expected to be realised through expansion only. ?
Plant capacity: 150000 cubic meter/ Annum Plant & machinery: 1100 Lakhs
Working capital: -T.C.I: Cost of Project : 1790 Lakhs
Return: 44.00%Break even: 53.00%
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CENOSPHERE PROCESSING - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

The word Cenosphere is derived from two Greek words Kens (hollow) and Sphaira (sphere). Cenospheres are light weight, inert hollow sphere comprising largely of silica & alumina and filled with air or inert gas. Cenospheres are a naturally occurring by product of the burning process of pulverized coal fired boilers. They are formed during the molten state of ash and attain spherical shape to have minimum surface tension. Any gas bubbles (generally inert gases e.g. N2, Co2, unburnt coal particles etc.) flowing along the combustion gas stream, are also trapped inside the spheres. These bubbles cause the production of Cenosphere; bubbles may occur in multiple forms within the frozen particles, or as a single, concentric form, that are nearly as great as the diameter of the particle. They are found floating on the surface of fly ash lagoon. Cenospheres are unique free flowing powders composed of hard shelled, hollow, minute spheres. A small proportion of the pulverised fuel ash (PFA) produced from the combustion of coal in power stations is formed as Cenospheres. Cenospheres are made up of silica, iron and alumina. Cenospheres have a size range from 1 to 500 microns with an average compressive strength of 3000+ psi. Colors range from white to dark gray. They are also referred to as microspheres, hollow spheres, hollow ceramic microspheres, micro balloons, or glass beads. Cenosphere are chemically inert & are reclaimable and labeled as Environmentally sound. Advantages The Advantages of Cenospheres are: Spherical Shape, Lightweight, Inert, Free Flowing, Insulating, High Melting Point, Hard, Electrical Properties, Low Oil Absorption & Good Packing Factor Applications Cenospheres is versatile filler with applications in a wide variety of products, both commercial and industrial. These are as diverse as oil well cementing and PVC cushion vinyl flooring. However, in each case, Fillite is used for its unique properties, such as strength, low density and chemical resistance. Below are the main applications areas in which Fillite is commonly used. Applications in Polyurethane, Cement, Latex Emulsions, PVC, Epoxy Resins & Unsaturated Polyester Resins. Market Survey Cenosphere are a by-product from coal ash. These hollow light weight spheres are produced around the world. Most all of the Cenosphere produced today are recovered from ash ponds or lagoons typically onsite at the coal fired power plant. Fly ash, or the residue from coal after combustion, has been a long-standing challenge for the Indian power sector, which is dominated by coal. Currently, 53 per cent of the total installed power capacity in the country is based on coal. Given that Indian coal has a very high ash content, in the range of 35 to 45 percent, the country currently generates approximately 160 million tones of fly ash, of which only 80 million tones is being utilized. Cenosphere Processing is a 100% export oriented Unit. Improvements in the durability and strength of manufacturers’ end products and a reduction in product weight enhance marketing strategies. SSI (Sphere Services Inc) was one of the first companies to introduce Cenosphere to the world on the internet. Since that time the Cenosphere have become more widely used and demand has increased for the product. Since the demand has increased supply has been coming from overseas from other Countries. Sometimes new suppliers will have trouble developing quality control measures for the material. Having a quality product chemically and physically on a consistent basis is critical for the end use customer.
Plant capacity: 480 MT/AnnumPlant & machinery: 57 Lakhs
Working capital: -T.C.I: Cost of Project : 132 Lakhs
Return: 27.00%Break even: 59.00%
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AAC Blocks (Autoclaved Aerated Concrete Blocks) Fly Ash Based - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

Autoclaved Aerated Concrete (AAC) is a non-combustible, lime-based cementitious building material that is expanding into new worldwide markets. As a singlecomponent building material AAC has achieved acceptance in new markets throughout the world. The AAC has the features of light bulk density good thermal insulation properties and sound absorption, certain strength and process ability, and its raw materials is very rich, especially the reuse of fly ash enables the comprehensive utilization of industrial residue curbs environmental pollution no destroy on farmland create good social and economic benefits. AAC is an ideal alternative of the traditional clay brick wall materials. AAC Blocks have Good heat insulation and humid retention. They are non-flammable. Autoclaved Aerated Concrete (AAC) products are 4 times lighter in weight than ordinary concrete. Its characteristic structure comprising millions of tiny pores, it offers optimum solidity at low weight. Uses and Applications AAC products are equally suitable for residential construction, multistory buildings commercial and industrial construction. The products are made of natural materials: sand lime and water. These raw materials are processed to provide a building material with a large number of air pores; hence, aerated concrete. Fine pores (nearly 70% of the product) and the solid structure of calcium silicate hydrate gives AAC its exceptional material properties. They are fire proof and provide insulation. Its low density permits use in larger building units which serves as a distinct advantage in pre fabrication. Appreciable savings are effected in foundation loads in multi storeyed construction. It is therefore being used increasingly as walling units in some developed countries. Market Survey The autoclaved aerated concrete sector of the construction industry is now in the phase of a tremendous growth cycle. The autoclaved aerated concrete industry must utilize competitive techniques as customers are looking for lowered costs. AAC is not a new building system but it is new to India. Autoclaved aerated concrete (AAC) though relatively unknown in India is currently one of the many building products being touted as green or environmentally friendly. There will be phenomenal growth in autoclaved aerated industry in the near future. Autoclaved aerated concrete blocks having different architectural finishes and color will also play a prominent role in near future. With a high growing good infrastructure and urbanization, the autoclaved aerated concrete Industry is poised for growth in the near future.
Plant capacity: 500 CUM/Day Plant & machinery: Rs.1117 Lakhs
Working capital: -T.C.I: Cost Of Project : Rs. 1886 Lakhs
Return: 36.00%Break even: 39.00%
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Fly Ash Beneficiation - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually refers to ash produced during combustion of coal. Fly ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the chimneys of coal-fired power plants, and together with bottom ash removed from the bottom of the furnace is in this case jointly known as coal ash. Depending upon the source and makeup of the coal being burned, the components of fly ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (SiO2) (both amorphous and crystalline) and calcium oxide (CaO) but may include toxic constituents in quantities from trace amounts to several percent such as: arsenic, beryllium, boron, cadmium, chromium, hexavalent chromium, cobalt, lead, manganese, mercury, molybdenum, selenium, strontium, thallium, and vanadium, along with dioxins and PAH compounds. In the past, fly ash was generally released into the atmosphere, but pollution control equipment mandated in recent decades now requires that it be captured prior to release. In the US, fly ash is generally stored at coal power plants or placed in landfills. About 43% is recycled, often used to supplement Portland cement in concrete production. Market Survey It is estimated that the total mineral wealth of flyash is approx. of the order of Rs.30,000 crore/year which is expected to grow 2.5 times by the end of the century. Significance of this area could well be understood from the fact that, just 1 million ton of flyash if put to use for different high value added applications has the potential of yielding a total turnover of Rs.500 crore per year. By contrast, if the same amount of flyash is to be used for say manufacturing of bricks, the total output may be to the tune of just Rs.25 crore. Current market investigation on the utilization of various flyash & application in the country is virtually absent for commercial applications. It can be concluded that currently there is a negligible market for these products though the potential may be substantial. The market prospects for high value added product is not easy to determine as the product is not in commercial use and the technology is in its early stages of commercialization. However, the market potential has been indicated for the products, that it may substitute in future. The total market potential that exists for high value added products by 2000 AD is estimated to be Rs.5000 crore. The actual market size has been estimated for metal extraction under two different scenarios assuming setting up of a 1 lakh ton and 1 million ton flyash processing plant.
Plant capacity: 150000 Lakh Nos. /annumPlant & machinery: 435 Lakhs
Working capital: -T.C.I: Cost of Project: 1217 Lakhs
Return: 29.00%Break even: 49.00%
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  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
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