Laxmi En Fab Pvt. Ltd.
AUTOCLAVED AREATED CONCRETE (AAC)
Laxmi En Fab Pvt. Ltd. AUTOCLAVED AREATED CONCRETE REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097
Website : www.aacplant.co.in,www.aacautoclave.com Email:
[email protected] [email protected] , ,
[email protected] [email protected]
Laxmi En-Fab Pvt. Ltd Ahmedabad Ahmedabad – Gujarat –India, –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Page 1
Autoclaved aerated concrete (AAC), also known as autoclaved cellular concrete (ACC) or autoclaved lightweight concrete (ALC), was invented in the mid-1920s by the Swedish architect and inventor Johan Axel Eriksson It is a lightweight, precast building material that simultaneously provides structure, insulation, and fire and mold resistance. AAC products include blocks, wall panels, floor and roof panels, and lintels It has been refined into a highly thermally insulating concrete-based material used for both internal and external construction. Besides AAC's insulating capability, one of its advantages in construction is its quick and easy installation, for the material can be routed, sanded, and cut to size on site using standard carbon steel band saws, hand saws, and drills. Even though regular cement mortar can be used, 98% of the buildings erected with AAC materials use thin bed mortar, which comes to deployment in a thickness of inch. This varies according to national building codes and creates solid and compact building members. AAC material can be coated with a stucco compound or plaster against the elements. Siding materials such as brick or vinyl siding can also be used to cov er the outside of AAC materials
AAC has been produced for more than 70 years, and it offers advantages over other cementations construction materials, one of the most important being its lower environmental impact. AAC’s improved thermal efficiency reduces the heating and cooling load in buildings AAC’s workability allows accurate cutting, which minimizes the generation of solid waste during use AAC’s resource efficiency gives it lower environmental impact in all phases of its life cycle, from processing of raw materials to the disposal of AAC waste. AAC’s light weight also saves cost & energy in transportation. AAC’s light weight saves labors.
Laxmi En-Fab Pvt. Ltd Ahmedabad Ahmedabad – Gujarat –India, –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Main ingredients include fly ash, water, quicklime, cement, aluminum powder and gypsum. The block hardness is being achieved by cement strength, and instant curing mechanism by autoclaving. Gypsum acts as a long term strength gainer. The chemical reaction due to the aluminum paste provides AAC its distinct porous structure, lightness, and insulation properties, completely different compared to other lightweight concrete materials. The finished product is a 2.5 times lighter Block compared to conventional Bricks, while providing the similar strengths. The specific gravity stays around 0.6 to 0.65. This is one single most U SP of the AAC blocks, because by using these blocks in structural buildings, the builder saves around 30 to 35 % of structural steel, and concrete, as these blocks reduce the dead load on the building significantly.
ASSUMPTIONS: The major raw material Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental threat across the globe. Power plants are facing an ever increasing challenge disposal of this polluting agent. This unit is proposed to manufacture AAC Bricks & Blocks by consuming the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving the invaluable top soil by not using them in brick making like conventional brick making. Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. The steam curing requires far less fuel, compared to the backing for each cubic meter of Bricks. This is the reason these bricks are also referred as Eco Bricks or popularly Green Bricks, Carbon Credit is estimates are for reference purpose. The Project owner must handle his part of CDM project to get Carbon credits, through independent consultants. Carbon credit can be transacted on registration. The PCN preparation & presentation, the PDD preparation & presentation, host country approval and the UNFCCC Registration might take somewhat 6 months to 2 years year. So it may be wise to start early.
Sale price at site is estimated a conservative Rs 3200/- per cubic meter. AAC B locks of all sizes will be manufactured according to the market requirement, though mainly stipulated sizes as per the BIS standards. Production is estimated at 80% capacity, 300 working days is considered in a year during the first year
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Why AAC Bricks? Energy saving
Easy to install
Less Weight
Endurance
Precision
Energy Efficient
Non Toxic
Thermal Insulation
Fire Resistance
Acoustic Performance
Moisture Resistance
Workability
Non Toxic
Thermal Insulation
Fire Resistance
Acoustic Performance
Moisture Resistance
Workability
Earthquake Resistant
cost saving
Fire Resistant
Pest Resistant
Water Barrier
High Strength
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 5
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 6
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 7
Large size, however light weight Light weight = saves foundation cost, helps the mason High load-bearing strength High durability = long life, impervious to rot or pest Dimensional accuracy High economy Effortless handling, rapid construction Best thermal insulation, 6 - 10 times better than regular dense concrete Unsurpassed fire-resistance = life, property and insurance cost saver Excellent sound absorption, ideal for the hospitality industry Good workability, better than wood (can be sawn, drilled, nailed, milled at site) Hurricane and earthquake resistance Not rotting (contrary to timber)
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Page 8
MARKET PLACE:
Fly ash is available incessantly and of satisfactory quality. Users are of the opinion that strength, sturdiness, finish, availability, price are the important qualities in blocks. Very high attention is observed among traditional manufacturers regarding use of fly ash in their products. Technical assistance & increased product awareness among the public and considered important for promoting the shift in the manufacturing practices. High preference for fly ash products is observed among those customers contacting manufacturers. Increased media coverage & favorable policies are considered key to increasing utilization of fly ash bricks & blocks. The current prices of fly ash blocks are in the same range of cement blocks & traditional bricks. But comparatively fly ash blocks are having more strength, fire resistance, earthquake resistance, light weight, lesser brakeage and saves structural cost by 40%. Average 60% of electricity comes from coal based power station, the country has a huge stock of fly ash amounting to 60 million tons annually. Despite the entire efforts present scenario is not too encouraging as only 5% country’s total ash has been consumed in different sector. With the rise in population and increase in constructional activities considering the Improvement in the standard of living the demand for building bricks is increasing day by day. Market share of different walling materials Type of walling material Burnt Clay Brick Fly Ash Bricks Cement Concrete Blocks
Market Size (Rs. Crores) 32825 1135 485
% of
95.3 3.3 1.4
Total
34445
100
Total market
The project activity product output AAC Blocks awareness levels were very low and are yet to penetrate in the markets. As stated above the prime reason why clay brick accounts for 95% of the share is that they are cheap and have traditionally been believed to be the most suitable walling material for building construction
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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RAW MATERIALS, SOURC S AND VAILA LITY:
FLY A H : Fly ash raw aterial is freely av ilable in hermal P wer plants. A lot has been s id about this ra material in this p oject pro ile itself. There are no taxes on this it m wh tsoever. ransport tion charges are o ly to be ttended y the ent epreneur.
Lime: Active powered lime is a req produc In pha In pha poweri a lime
irement or giving the real aeration to the
. e 1 we can aim to uy the active lime irectly. e-2 we c n think o having back word integration and ma ing a lim g unit at site to have a more competitive advantage, we an also t ink of urning kiln inside he factor premise
The pr ject financials however have not considered the costs of owering nit, and the lime kiln in thi project. Differe t qualities of lime re availa le, and d pending on the ra materials. The mix design c n be chosen to get the optimal quality of production
OPC This Project aim to utilize opc cem nt as main binder aterial. It will give faster strength to the bricks, besides givin improved consist nt qualit . It also e nsures a better cost effectiveness for the s me. Usin OPC will be a standardized practic . The other prime dvantage of using pc (com ared to o her bind rs) is it’s easy availability locall through nationwide retail N twork of Cement Compa ies.
Gypsu 4%
Main row m terial OPC 10%
Aluminu m 1%
Lime 15%
ly Ash 70%
Lax Ah edabad – Gujarat –India,
i En- ab Pvt. Ltd
We : www.aa cplant.co.i , www.aa autoclave. com,
Gyps m: This to is an industrial w ste. This is available as an industrial byproduct Fer ilizer Pla t. Gypsu is responsible to ive long erm strength to th Blocks.
f
Alum num Powder: Fin ly groun Aluminu powder is used i very limited quantity (less t an 0.5%), so tha it reacts with acti e lime, a d silica in base ma erial to make the a ration, a d sw ll the pro uct, making it ver light weight product.
PR JECT T A GL NCE: Product Details:
AAC light weight
Type:
Fly Ash
locks
ased or and Base
Technology Area: Infr structure & Green- Tech Capacity Utilization:
80%
CONSUMPTION O RAW
ATERI LS AN ENERGY NEEDED FOR
PR DUCTION OF UILDING MAT RIALS: 160 140 120 100
con umtion of r w mat rial in Kg/ 3
80 60
Consumtion of nergy in Kw /M3
40 20
Clay Bricks p=1. kg/m3
Porous Clay Masonr y p=0.8kg/ 3
Lax Ah edabad – Gujarat –India,
Calcium silicat m sonry unit p 1.4kg/m3
Aac mas nary unit p=0.4kg/m3
i En- ab Pvt. Ltd
We : www.aa cplant.co.i , www.aa autoclave. com,
BRIEF PRODUCTION PROCESS: 1.
COAL FLY ASH: The fly ash of coal will be sent to the slurry preparing pond by wheel loader to be prepared required concentration coal fly ash slurry by add rated water, which will be pumped into slurry tank to be stored and ready to be used
2. QUICK LIME: The powder will sent into the lime powder silo for storage and read to be used by bucket elevator, after coming into the factory. 3. GYPSUM: The gypsum in the storage shed will be added into slurry pond according to the required proportion, while preparing slurry 4. CEMENT: The cement will be transported into factory by tank truck and directly is pu mped into cement silo to be used 5. ALUMINUM POWDER PAST: The purchased aluminum powder past in the bucket or bag will be stored in its store house, When being used, it will be lifted to second floor of the batching building, then measured and added in to aluminum mixer to prepare 5% suspending liquid to be used. 6. SCRAPE AND WASTE SLURRY: The cleaning waste water under the casting machine will be pumped to ball mill to be used as grinding water. The scrape from the cutting machine will be prepared to slurry and pumped into waste slurry tank to be used. 7. BATCHING, MIXING, CASTING:
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Coal fly ash will be sent to electronic scale in the batching building by pump at the bottom slurry tank to be measured. When the slurry concentration arrives at batching requirement, the control system will turn of the pump to stop pump slurry. The measured the slurry will be directly discharged into casting mixer. Lime and cement will be sent to electronic scale in the batching buildin g by single screw conveyer at the bottom of their silos. When measuring ar rives at the required quantity, they will be sent to casting mixer by screw conveyer. Aluminum Powder will be measured by manual and added in to aluminum mixer to be prepared suspending liquid one by one for each mould. The finished suspending liquid can be directly added into the casting mixer. The slurry temperature should be arrived at required process temperature before coasting. And mold will be moved to the bottom of the casting mixer by ferry car. 8. CUTTING AND GROUPING: After precuring, the green block arrive at the required strength, the crane will take it to the cutting machine section. After remove the mould, the green block will be cut according to the required size. The green block after cutting will be move to the curing trolley with the bottom plate by crane in front of autoclave for grouping. The seven trolley for each autoclave with 14 pieces of green block. 9. AUTOCLAVED AND FINISHED PRODUCT: The green block after grouping, will be move into autoclave by windlass for curing. The whole curing period is approx 12 hours, pressure approx 1.2mpa, temperature approx 1850. After curing, the product will be pulling out of auto clave and be sent to the store yard. 10. THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING: After unloading, the side plate on the trolley will be lifted to returning rail by crane, and be returned to the side of the cutting machine, which will be combined with the mould and sent to mold returning line for cleaning and oiling to be reused.
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Equipments Equipment is depend of selection of process , base material , selection of automization etc. below is given general base equipment
Raw material processing equipment •
Jaw crsher
•
Hoist conveyor
•
Block lime silo
•
Electronic vibrating feeder
•
Ball mill –lime
•
Sand silo
•
Electronic vibrating feeder
•
Belt conveyor
•
Ball mill -wet -sand
•
Bucket elevator
•
Cement silo
•
Gypsum silo
Pouring processing equipment
•
Weighted / batch slurry mixer
•
Main Mixer desert mortar after Cutting Balance desert mortar for per mould
•
Lime –OPC – gypsum mixer
•
Screw conveyor for lime
•
Aluminum mixer
•
Main pouring mixer
•
Lime &gypsum measure
•
Spiral gate valve
•
Pneumatic controlling valve
•
Slurry measurer
•
PLC electric measuring controlling system
•
Air compressor
•
Mould
•
Mould bottom plate
•
Steam curing car
•
Electronic platform balance
•
Main Slurry mixer –fly ash
•
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Cutting processing equipment
•
Hoist for mould move
•
•
Tractor
•
•
Vertical cutting machine with arrangement
•
Hoist for semi finish product Horizontal cutting machine with Arrangement
Cutting processing equipment
•
Hoist for mould move
•
•
Tractor
•
•
Vertical cutting machine with arrangement
•
Hoist for semi finish product Horizontal cutting machine with Arrangement
Hardening or curing process equipment
•
Autoclave
•
Steam boiler
•
Coal crushing and handling equipment
•
Chimany
•
Dust collector
•
Steam controlling valve
•
Steam controlling penal
•
Steam line
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Photograph of plant equipment
Storage silo
Fly ash mixing tank
Mould mover
final mixer
cutting machine
Steam curing car
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Boiler-dust collector-chimney
Mixing section
Autoclave
autoclave
mould goes to autoclave
Mould
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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ready AAC block
fitting of AAC block
AAC block construction
AAC block wall
Housing make by AAC block
Housing make by AAC block
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
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Page 18
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 19
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 20
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 21
LAYOUT This is basic layout actual layout depend on plant size, design, degree of automization,land size, scope of raw material coming as well outgoing position, many factor affect on plant design
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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RAW MATERIAL SUITABILITY:
Approximately 95% of the waste materials can be made suitable for AAC line through proper mixdesign. Also we can have many different mix designs for the same density…same strength of Blocks. We will help you to get the Best quality blocks at optimal cost by means of designing proper Mix as per your inp ut raw materials. The following are basic guidelines (certainly not the final call) on the suitability of basic raw materials for AAC.
1. Fly Ash (6570%) Grade (%)
Index Item Degree of fineness
Gr I
Gr II
(0.045 square hole sieve left amount)
30
45
(0.080 square hole sieve left amount)
15
25
Ignition loss
5
10
SiO2
4555
40
SO3
1
2
Reference: The fineness can be 0.045 or 0.080 square sieve left amount. 2. Lime (825%) Grade Item
Super Gr
1st Gr.
2nd Gr.
A(CaO +MgO) Quailty Fraction%
90
75
65
MgO Quality Fraction %
2
5
8
SiO2 Quality Fraction %
2
5
8
CO2 Quality Fraction %
2
5
7
Digestion speed ,min
Digestion temperature ,
Undigested residue quality fraction ,%
5
10
15
Fineness (0.080 square hole sieve left amount) %
10
15
20
6090
3. Cement (615%) SiO2
Ai203
FE20
Cao
Mgo
C3S
C2S
C3A
C4AF
2123
57
35
6448
45
4459
1830
512
1018
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Page 23
4. Gypsum/Plaster (35%) CaSO4
>
70%
Mgo
<
2%
Chloride
<
0.05%
Preferably ground residue
<
1015%
5. Aluminum Power (about 0.08%) Type and recommendation for supply depend on raw materials and mix formula Metal Content
Approx.
>=65%
Powder
NOTE: Use of Cement is depend on moisture, if moisture is high cement requirement becomes high. Soluble Oil usage per process is 1 liter.
TECHNICAL COMPARISON : Parameter
AAC Block
Size
(600x200x100-300) mm
Variation in dimensions Compressive strength Dry Density
+/-1mm 30-50 kg/cm2 550-700 kg/m3 4-6 Hour depending on thickness
Fire Resistance Sound Reduction Index (dB) Thermal Conductivity W/(Km)
Concrete Block
Brick
(400x200x100-200) mm +/-3mm 40-50 kg/cm2 1800 kg/m3
(230x115x75) mm +/-5mm 25-30 kg/cm2 1950 Kg/m3
4 hours
2 hour 40 for 230 mm thick wall
60 for 200 mm thick wall 0.122
0.51
0.81
Normal basic size AAC BLOCKS TECHNICAL SPECIFICATIONS Thickness
Height
Length
Density
Compressive strength
3
30 - 50 kg/cm
3
30 - 50 kg/cm
3
30 - 50 kg/cm
100 mm
200 mm
600 mm
550-700 kg/m
150 mm
200 mm
600 mm
550-700 kg/m
200 mm
200 mm
600 mm
550-700 kg/m
2
2
2
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Main Technical Specifications of AAC Lightweight Block Production Line
Mainly plant capacity
Model
Capacity per Annume Per day production As per 300 day 50,000 CM 160 CM 100,000 CM 320 CM 150,000 CM 480 CM 2,00,000 CM 640 CM 3,00,000 CM 960 CM 5,00,000 CM 1600 CM
LAAC-50 LAAC-100 LAAC-150 LAAC-200 LAAC-300 LAAC-500 Cover
shed area
Model Capacity per Annume LAAC-50 50,000 CM LAAC-100 100,000 CM LAAC-150 150,000 CM Total land for building and shed , material stock 2-5 acre
Work shed cover area 20,000 Square feet 25,000 Square feet 30,000 Square feet raw material ,finish
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Raw material consumption for AAC block Ingredients Fly ash Lime Cement Anhydride Aluminioum ( metel powder )
Raw material consumption per CM of AAC block 272 KG 71 KG 95 KG 12 KG 0.46 KG
Total solid
450 KG
Water in mix ( total ,excl. steam ) Condensate which can be reused In the mix ( water consumption Above reduce correspondingly)
370 KG 90 KG
Above data is not full and final but for better understanding project is given Actual Ingredients mixing is depend on client & client technical team
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
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Energy and mass flow and balance diagram
Compressed air
Electricity
Raw material Fly ash, lime,Gypsum ,aluminium, cement
Raw material pouring & mixing
Water
New grid Moulding & cutting
Electricity
DG set Diesel Curing at autoclave
Steam
Finish product
Boiler
Fuel oil
The above figure represents the ENERGY and Mass Flow and the balance of the system and equipments include in the project activit.in the project activity electricity, steam & compressor air are the main type of energy used and main source of these energy are as follows: Electricity : from new NEgrid & DG set Steam : from boiler fuel oil combustion
Compressed air – from air compressor
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
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Page 27
Laxmi En Fab Pvt. Ltd. AUTOCLAVED AREATED CONCRETE REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097
Website : www.aacplant.co.in,www.aacautoclave.com Email:
[email protected] ,
[email protected] [email protected]
..
Laxmi En-Fab Pvt. Ltd Ahmedabad – Gujarat –India, +91 9712570097,9725012740/49
Web : www.aacplant.co.in , www.aacautoclave.com , E mail:
[email protected],
[email protected] ,
Page 28
