Introduction:

Disposal of fly ash, a waste arising from coal fired thermal power stations currently poses a serious operational constraint and environment hazard. A 100 mw thermal unit generates about 0.15 million tones of fly ash per annum when using coals with an ash content of 40%.at this rate the present annual generation of fly ash would be of the order of 25.0 million tones approx. hence making the technology of fly ash bricks a significant important in coming years.

Fly ash is a very fine power material from thermal power plant, used as pozzolana which when mixed with water forms cementation product. Its particles are hollow, spherical in shape with fineness 250-400 sq.m/kg. Fly ash brick and blocks are made of fly ash, sand, cement or lime plus gypsum as binder. Automatic operation is feasible.

TYPICAL PHYSICAL CHARACTERISTICS OF LWA PRODUCT:

Aggregate Size              : 5~16 mm (The size is adjustable by process)
Bulk Density                   : 650-850 kg/m3         
Particle Density              : 1250~1450 kg/m3
Aggregate Strength       : >5.0 MPa (Variation as per size)
Water Absorption          : < 15 %

Production Process (FLY ASH BRICKS)
The process to make fly ash bricks, stipulates mixing of fly ash, lime, gypsum and sand in desired proportion. Suitable quantity of water is added to prepare a homogenized mix of raw materials. Fly ash being non-plastic raw material, raw material, raw mix is subjected to a pressure in a suitable hydraulic press with vibration technology to form a brick in molds designed to ISI standard. Then it is taken for heat humid curing for 12 hours and for natural drying in open the period of which varies 24-48 hours depending on the weather condition.
Machine Details
Production Line
Offered with either QT 6-15 E or qt9-15 Brick/Block machine along with Batching and mixing equipment to prepare the mix. Vibro compaction combined with compress of mix is carried out in moul supported over wooden. Bamboo pallet. Curing of released brick/block is done by moving to hot and humid chamber, maintained by low pressure steam in 1-2 days.
Machine Adventages

Energy efficient: No fuel burning involves, and requires much less overall energy

Stochastic signal and oscillations analyzing system CRASV5.0 is introduced to take overall inspection of whole machine oscillation frequency, range acceleration. Noise etc

State of art PLC system controls complete cycle operation of flow rate, pressure, synchronized table vibration, variable frequency, stop and start function

Vibration is powered by hydraulic oil system which is energy savingHot and Humid curing system envisaged for bricks and blocks ensures fast curing being economical and have relatively lower cost

Products

Durable with good compression strength 70-130 kg/cm2Low water absorption, low abrasion, low shrinkage, neglible efflorescence Uniform shape and size, sharper edges and corners, weight and strength accuracy less mortar consumption in masonry work and strength accuracy less mortar consumption in masonry work and saving in plastering cost strength increase with passage of time , better resistance to salinity and water

Features of Fly Ash Bricks compared to conventional (Red clay) Bricks

  • Compressive strength is more than conventional bricks.
  • More resistant to salinity and water than conventional bricks.
  • More lighter than conventional bricks.
  • Uniform in shape & size.
  • More durable as strength increases with passage of time.
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Plant & Technology Offered

The plant is a proven technology to manufacture fly ash bricks, with more than 1600 users worldwide. Our multi-purpose brick/block machine is design to meet mass production of various kinds of concrete masonry blocks like brick, blocks, pavers, slab, and curbs etc. we have achieved international quality assurance of ISO 9002, ISO 9001, British royal CCQS, and UKAS assurance.

Some of the salient features of the plants are:

  • The unique oscillation complex and material distribution system is optimized in order to ensure the final products superior quality with high density and strength.
  • The hot & humid curing system another revolution event in the involved craftwork for fast curing, which is economical and comparable low cost.
  • The system is optimized that the brick/ blocks weight accuracy is within the range of +/- 1-2%, and the strength accuracy is within the range of +/- 10%.
Suggested Raw Material
Fly ash60-70 %
Sand20-25 %
Cement8-10 %
Or Lime10-12 %
Gypsum3-4 %
Model No.HCQ6-15E
Machine Dimension (L*W*H*)6000x3500x2950 (mm) 
Useful Moulding Area (L*W)1250x550x40-200(mm)
Product Height40-200(mm)
Pallet size1380x580x3o (mm)
Cycle time15-20s
Power (Total)32.2 kW
Model No.QT9-15
Machine Dimension (L*W*H*)6050x3500x2950 (mm) 
Useful Moulding Area (L*W)1280x600x32-200(mm)
Product Height40-200(mm)
Pallet size1380x680x3o (mm)
Cycle time15-20s
Power (Total)42.7 kW
Plant Parameters
Plant capacity    75000 Bricks/day
NO. of working days 300300
No. of ShiftsNo. of Shifts 2 shifts/day(8 hours)
Total land          6000-8000 sq.mtr.
Covered Area 800-1200 sq.mtr.Covered Area  800-1200 sq.mtr.
Electricity Energy      63 KW
Man Power10 (plant)
Production Capacity
S.NOPARTICULARSMOLD(PCS)PRODUCTION/HOUR(PCS)
 HCQ6-15 EQT9-15HCQ6-15 EQT9-15
1BRICKS
 230X110X70MM(FROG)20253,6004,500
 230X110X70MM(W/O)30405,4007,200
 190X90X90(FROG)26364,6006,400
2HOLLOW BLOCKS
 400x200x200mm6912001800
 400x150x200mm81216002400
 400x100x280mm111520003000
3PERFORATED BLOCKS
 240X115X90202540005000
4RECTANGULAR PAVERS    
 200X100X60MM243048006000
     INTER LOCKING”S”PAVERS
 225X100X60~80 mm202540005000
6DUMBLE  PAVERS
 200X165X60~80 mm182136004200