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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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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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Cenosphere - 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, Plant Economics

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. Cenospheres are formed from coal combustion ash when it is in a molten state. Flowing with the combustion gas stream, the temperature of the molten particles is rapidly quenched, thereby ‘freezing in’ a spherical shape. Cenospheres are unique free flowing powders composed of hard shelled, hollow, minute spheres. A small proportion of the pulverized fuel ash (PFA) produced from the combustion of coal in power stations is formed as Cenospheres. 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. Applications in Polyurethane: • Plywood Patching Compound • Synthetic Wood (Cast, Unfoamed) • Foam Carpet Backing • Electric Potting and Jointing Compounds • Tooling Blocks • Abrasive Wheels • De-Burring Chips • Pipe-Line Insulation 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. Thus, cenosphere is a good project for entrepreneurs to invest.
Plant capacity: 480 MT/annumPlant & machinery: Rs. 58 Lakhs
Working capital: -T.C.I: Cost of Project : Rs. 208 Lakhs
Return: 26.00%Break even: 49.00%
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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

Fly Ash is a burnt residue of pulverized coal (bituminous or sub-bituminous) and is siliceous in nature. In past few decades, R&D efforts were undertaken and it has been proved that this material can be utilized in number of ways in building construction products as well as in civil works with adequate durability. Major areas of fly ash utilization are Building materials such as Bricks, Blocks, Tiles, etc. Also used in Grouting, Engineered fills for low-lying land spaces for human settlement, use in Road Construction and Construction of ash dykes and embankments. Fly Ash brick is a product of basic cement clinker materials i.e. FLY ASH, STONE DUST/SAND, LIME, GYPSUM and BONDING AGENT. The mix is so ideally worked out to produce bricks of higher strength with consistency as well as uniformity. The manufacturing process is fully automatic with state of art technology. Though a new age product introduced in the market, Fly Ash bricks are very well accepted by the organized sectors in heavy industries, high rise buildings, large townships, colonies, etc. because of unique features and merits. Fly Ash Bricks provides a high level of moisture resistance. It's very economical, cost effective, nil wastage while transporting and handling. Fly Ash Bricks is available in various sizes. These qualitative bricks have high compressive strength and absorb low water. As a whole it is a good project for entrepreneurs to invest. Few Indian Major Players are as under • Chhattisgarh Electricity Co. Ltd. • Gujarat Narmada Flyash Co. Ltd. • Jindal Steel & Power Ltd. • Nalwa Steel & Power Ltd. • Periwal Bricks Ltd. • Prakash Ceramics Ltd. • Sand Plast (India) Ltd. • Tatanagar Bricks Ltd. • Tuticorin Salt & Marine Chemicals Ltd.
Plant capacity: Fly Ash Bricks 24000 Nos/DayPlant & machinery: Rs 40 Lakhs
Working capital: -T.C.I: Cost of Project : Rs 194 Lakhs
Return: 25.86%Break even: 59.27%
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Bricks from Fly Ash

Fly Ash brick is a product of basic cement clinker materials i.e. fly ash, stone dust/sand, lime, gypsum and bonding agent. The mix is so ideally worked out to produce bricks of higher strength with consistency as well as uniformity. The manufacturing process is fully automatic with state of art technology. Though a new age product introduced in the market, Fly Ash bricks are very well accepted by the organized sectors in heavy industries, high rise buildings, large townships, colonies, etc. because of unique features and merits.The Fly Ash Bricks are promoted as an alternative to burnt clay bricks within the construction sector in India. Fly Ash Bricks are durable, have Low water absorption, less consumption of mortar, Economical & eco-friendly, Low energy consumption and No emission of green house gases. These bricks are not affected by environmental conditions and remain static thus ensuring longer life of the building. Fly-ash bricks have a bright future in the country in the form of increasing number of takers and brick making plant providers who are offering machines equipped with technology and quality.Thus, due to demand it is a good project for entrepreneurs to invest. Few Indian Major Players are as under • Hind Infradevelopers India Pvt. Ltd. • Rana Infra Projects (P) Ltd. • Saisha Infra Projects Limited • Khanak Blocks & Bricks
Plant capacity: Fly Ash Bricks: 24,000,000 Pcs/annumPlant & machinery: Rs 152 lakhs
Working capital: -T.C.I: Cost of Project: Rs 336lakhs
Return: 28.00%Break even: 46.00%
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Cenosphere Processing Plant

Cenosphere Processing Plant. Cenosphere Separation from Fly Ash. Production of Cenospheres from Coal Fly Ash. Cenospheres are inert, light weight and hollow spheres particularly made of alumina or silica and filled with inert gases or air. They are typically manufactured as a by-product of coal combustion in the thermal power plants. Cenospheres are hollow, low-density, spherical, and free-flowing aluminosilicate microspheres that are produced as a by-product of coal ignition at the coal-fired power plants. It is a rich-in-ceramic industrial waste formed at the time of coal combustion in the thermal power plants. Inside the each sphere there is a near vacuum that produces good properties of thermal and acoustic insulation making a product ideal for automotive acoustic insulation applications where the mass is a major factor to be considered. These spheres are used globally in several automotive application including tyres, brake linings, friction linings, dashboard, and clutch facings. The broad range of usage has increased the demand of cenosphere suppliers India in the industry. Cenospheres, the high strength, small sized, lightweight, non-porous, free flowing, hollow ceramic spheres produced in coal fired thermal power plants during the burning of lignite or coal at very elevated temperatures, find extensive usage across a number of industries owing to their physical properties. Cenospheres find usage as fillers in a number of applications, replacing resins and minerals and imparting diverse benefits such as reduced shrinkage, improved level of thermal insulation, weight reduction, improved level of fire resistance, and easier application. Uses of Cenosphere: Cenospheres in Paints and Coatings There are a great many uses for cenospheres in the paint and industrial coating industry, due to the additional qualities they provide. For example, cenospheres are often used in coatings to control infrared radiation, giving those coatings an advantage over ones that merely attempt to limit thermal conductivity. Cenospheres in Syntactic Foams Cenospheres are often used to make ‘syntactic foams’. These are specialized solids which use cenospheres as a filler to provide any number of advantages, from lower cost, to added strength, sound proofing, buoyancy and thermal protection. Cenospheres in Plastics and Polymers Cenospheres also have a use in the manufacture of plastics and polymers, as their re-formable shape or strength helps to avoid shrinkage in thermoplastics and thermosetting plastics. Cenospheres in Pharmaceuticals Cenospheres have been used in the pharmaceutical industry for many years, as the small balls can act as a near-perfect transport device when coated with drugs. Cenospheres in Advanced Industries Cenospheres are also being used in the development of metal matrix composites (MMC), a variety of materials that attempts to combine the high energy absorption, impact resistance, and low density of the spheres with the qualities of other substances. Market Outlook Cenospheres are providing emerging opportunities along with the future effects of major drivers and challenges that support the managers to make cost-effective decisions in favor of the business. The increasing demand from end-use industries including refractory, construction, paints and coatings, and oil and gas, which is expected to take the market to the next level in the near future. However, restricted sources of raw material and deficiency of quality control across developing countries are key factors that may restrain the growth of the industry. The global cenospheres market was valued at USD 346.8 Million in 2016 and is projected to reach USD 689.2 Million by 2022, at a CAGR of 12.16% from 2017 to 2022. The growing demand from end-use industries, such as paints & coatings, refractory, construction, and oil & gas is expected to drive the market in near future. However, limited sources of raw material and lack of quality control across emerging countries are major factors that may restrain the growth of the market. The Gray Cenospheres segment is estimated to experience the highest growth in the upcoming years because of its wide uses across the industrial segment. The demand will increase also because the gray cenosphere is produced more frequently as compared to the white cenosphere in fly ash. The demand for gray cenosphere suppliers India is rising because they deliver quality material which contains a low content of alumina and is high in silica and iron content that is used in a number of applications such as plastics, concretes, coatings, resins, bricks, and rubbers. The gray cenospheres segment is expected to witness the highest growth from 2017 to 2022, as they are widely used across industries. Gray cenospheres occur more frequently than white cenospheres in fly ash. These cenospheres have low content of alumina and high content of silica and iron. Gray cenospheres are used in various applications, such as concretes, plastics, resins, coatings, bricks, and rubbers. North America is projected to be the fastest-growing cenospheres market during the forecast period, due to the growing oil & gas and automotive industries in the region. The market in Middle East & Africa, Asia-Pacific, and South America is also expected to witness significant growth, due to growing demand for cenospheres from the oil & gas and construction industries in these regions. Industries such as oil and gas, building, plastics, aerospace, automotive, and surface coating continue to be some of the leading consumers of cenospheres and new application areas are being devised at an encouraging pace. Owing to their natural properties, cenospheres can be used in forms such as dry, wet, or slurry. Owing to their inert nature, cenospheres are not affected by acids, alkalis, water, or solvents. Hence, cenospheres have an impressive reusability quotient. Cenospheres are nearly 30% lighter than conventionally used resins and nearly 75% lighter than most minerals used as fillers or extenders. The main application of cenospheres as bulk fillers in all the end-user industries is expected to act as catalysts for the growth of the overall cenospheres market over the forecast period. Moreover, as cenospheres are small in size and have great compressive strength they are used as a structural lightweight filler, thus the cenospheres market is expected to see rapid growth in all developed and developing countries in the future. The cenospheres market can be segmented as: • Automotive • Construction • Oil & Gas • Paints & Coating • Others (Refractory, Bulk Fillers, Etc.) Cenospheres find a wide range of applications in the construction, oil & gas and infrastructure industry and are used in commercial, industrial, residential and infrastructure construction projects. The growing construction industry output is expected to be one of the most significant factors for increased demand of cenospheres in the global market. Rapid urbanisation is leading to new construction activities, which is further expected to boost the demand of cenospheres in building and construction tasks. Moreover, growing urbanisation is expected to contribute to the growth of the global cenospheres market at a CAGR close to or below the global GDP growth over the forecast period. The market is becoming healthier for competitions, which is a positive factor influencing the cenospheres manufacturers. The growth of technology and automation in the manufacturing and supply of all automobiles has further increased its attractiveness among the consumers and all end-use industries. Prominent market players are trying to develop strong, long-lasting and lightweight cenospheres for all the vehicles in the automotive industry, which can be used efficiently and sustain load depending on the vehicle type. The advancement in the material science technologies in the manufacturing industries have enabled them to use new invented materials, such as alloys of steel and aluminium, which make the cenospheres of the vehicles stronger and durable under extreme load conditions. Tags Cenosphere Processing, Cenosphere Processing Plant, Cenospheres from Fly Ash, Cenosphere Processing Project, Fly Ash to Cenospheres Process, Cenosphere Manufacturing Process, Cenosphere Separation from Fly Ash, Cenosphere Manufacture, Production of Cenospheres, Cost Of Manufacturing Plant for Cenosphere, Production of Cenospheres from Fly Ash, Separation of Cenosphere from Fly Ash, Cenosphere Manufacturing, Lightweight Cenosphere Processing, Cenosphere Production, Cenosphere Manufacturing Plant, Cenosphere Manufacturing Company, Cenospheres Industry, Cenosphere Processing project ideas, Projects on Small Scale Industries, Small scale industries projects ideas, Cenosphere Processing Based Small Scale Industries Projects, Project profile on small scale industries, How to Start Cenosphere Processing Industry in India, Cenosphere Processing Projects, New project profile on Cenosphere Processing industries, Project Report on Cenosphere Processing Industry, Detailed Project Report on Cenosphere Processing, Project Report on Cenosphere Processing, Pre-Investment Feasibility Study on Cenosphere Processing, Techno-Economic feasibility study on Cenosphere Processing, Feasibility report on Cenosphere Processing, Free Project Profile on Cenosphere Processing, Project profile on Cenosphere Processing, Download free project profile on Cenosphere Processing, Industrial Project Report
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
  • One Crore is equivalent to ten million (10,000,000)
  • T.C.I is Total Capital Investment
  • We can modify the project capacity and project cost as per your requirement.
  • We can also prepare project report on any subject as per your requirement.
  • Caution: The project's cost, capacity and return are subject to change without any notice. Future projects may have different values of project cost, capacity or return.

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