Foundry Slag Waste to Building Material

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Promotion of Technology for Utilization of Slag Waste from

Foundries in

Paver Block Making Kolkata

20 January 2016

NSTEDBDepartment of Science & Technology Government of India

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NSTEDBDepartment of Science & Technology Government of India

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Secondary Raw MaterialsWASTE MATERIALS

oIndustrialoAshoMarble SludgeoFoundry WasteoEtc.

POTENTIAL USE

Material Process End Use

Plain Concrete Crushed Aggregate

Fresh Concrete

Washed to remove cement & recover aggregate

Aggregate

Reinforced Concrete

Crushed & Steel bars removedSteel recycled

CrushedConcrete reused as aggregate

NSTEDBDepartment of Science & Technology Government of India

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What is foundry slag waste?

NSTEDBDepartment of Science & Technology Government of India

o The slag is a non-metallic inert by-product primarily consists of silicates, alumina silicates and calcium alumina-silicates produced during production of iron and steel in foundry units

Batala

JalandharLudhiana

DelhiAgra

IndoreHowrahRajkot

Ajmer

MumbaiKolhapur

Chennai

Jaipur

Ahmedabad Bhopal

Bhavnagar

BelgaumCoimbatore

There are approx 5,500 units in the Country located in the areas marked in the map engaged in various types of metal castings

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Indian foundry sector… at a glance

NSTEDBDepartment of Science & Technology Government of India

Casting production- Fourth largest casting producer in world- Annual production – 10 million tonnes (approx.)

Decentralized unorganized production- Decentralized production > 5,500 units- Annual turnover – Rs. 400 billion- Employment to 0.5 million workers (direct) and 1.5 million workers (indirect)

Resource intensive process- 90% small to medium using cupola technology- Low productivity and high energy consumption- No pollution control measure

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Indian foundry sector… at a glance

NSTEDBDepartment of Science & Technology Government of India

Slag generated is approximately 10% of the total production

#source-The Institute of Indian Foundrymen

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Challenge identified

NSTEDBDepartment of Science & Technology Government of India

Waste generation- Slag waste generation – 5 lakh tonnes/ annum (approx.)

Use- Slag dumped in open field, barren land

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NSTEDBDepartment of Science & Technology Government of India

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NSTEDBDepartment of Science & Technology Government of India

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Howrah foundry sector… at a glance

NSTEDBDepartment of Science & Technology Government of India

Technology used- DB Cupola furnace

Production- No. of units > 200 units

Raw materials- High ash coke, metal and limestone

Slag generated*- 60,000 metric tonnes/ year

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Current Building Material Technology

Scarcity of natural sand/ aggregate

Soil and land pollutionHigh cost of

building material

Introduction of New Technology

Project Intervention

Reduced PollutionReduced Cost of Building Material

Dissemination

Co-Benefits for Environment, Business

& People

Dissemination

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NSTEDBDepartment of Science & Technology Government of India

Innovative Solutions

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Technology developed

NSTEDBDepartment of Science & Technology Government of India

• Methodology developed for replacement of coarse and fine aggregates, used in conventional production of Paver Blocks

• Paving blocks produced by completely replacing 6-8 mm aggregate with Foundry Slag

• A lab scale plant set up at Datia, Madhya Pradesh

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NSTEDBDepartment of Science & Technology Government of India

Foundry Slag Grinding

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NSTEDBDepartment of Science & Technology Government of India

8 – 10 mm foundry slag aggregate

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NSTEDBDepartment of Science & Technology Government of India

Foundry Slag Based Paver Block Production Unit

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Foundry Slag Waste UtilizationEnterprise details

• Micro enterprise ~ Rs. 25 lakhs investment• Product - Paving block (can be expanded to other

building materials with low CAPEX)

• Working days - 300 in a year• Production capacity - 1500 blocks per dayFoundry slag waste requirement• Paving block - Approximate 5 kg weight (hexagonal)• Composition - 1:4:4 (M30 grade)• Raw materials - Cement, sand, foundry slag waste aggregate• Annual consumption - 1,000 Tons per enterprise

Impacts• Jobs created - 6-8 persons• Waste utilized - 1,000 Tons per year• Business generated - Rs. 72 lakhs/ year (Rs. 16 per block)

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Product certification

NSTEDBDepartment of Science & Technology Government of India

The paving blocks produced by using the foundry slag were tested by the NIT Bhopal and Shriram Institute for Industrial Research, New Delhi

The results up till M30 grade blocks were found to be very positive and duly complying to IS 15658:2006

The Compressive Strength test results of M30/ M40 grade blocks were found to be higher than those manufactured by using aggregate

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Product certification

NSTEDBDepartment of Science & Technology Government of India

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NSTEDBDepartment of Science & Technology Government of India

The Technology Packageo Processing of foundry slag waste through medium duty jaw crushers

o Use of OPC grade cement

o Mixing of concrete through ordinary concrete mixers

o Production through vibration in table vibrators

o PVC moulds for shaping

o Open atmosphere curing for 7 days

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Market opportunity

NSTEDBDepartment of Science & Technology Government of India

• Howrah district• Rural road – 948.68 kms**

• Pavers required – 960 lakhs numbers*• Metro rail• Private housing• Shopping mall• Petrol pump• Tourism park

Sources:* http://dcmsme.gov.in/dips/HOWRAH_wb.pdf

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The business

NSTEDBDepartment of Science & Technology Government of India

CAPEX (CAPITAL COSTS)Vibrating table - Rs. 3 lakhsMoulds (2000 nos.)- Rs. 6 lakhsJaw crusher - Rs. 3 lakhsConcrete mixer - Rs. 1 lakhsMiscellaneous - Rs. 1 lakhsInfrastructure (shed, office, electricity etc.) - Rs. 6 lakhsTotal investment - Rs. 20 lakhs

OPEX (WORKING CAPITAL)For a period of 1 month including raw material, labour, electricity etc. - Rs. 10 lakhsTotal investment ~ Rs. 30 lakhs (approx.)(excluding land)

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The business

NSTEDBDepartment of Science & Technology Government of India

ASSUMPTIONSSelling price of a hexagonal paving block - Rs. 15 per blockProduction period - 300 daysNo. of units per day - 1500 nos.Total production per year – 4,50,000 units

Existing production technologyRaw material

Cement 3.60Stone aggregate 4.35

Sand 2.15

Manpower 1.50Energy 0.95Overheads 1.30

TOTAL 13.85

Slag based technologyRaw material

Cement 3.60Foundry slag 2.60

Sand 2.15

Manpower 1.50Energy 0.95Overheads 1.30

TOTAL 12.10

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The business

NSTEDBDepartment of Science & Technology Government of India

ASSUMPTIONSSelling price of a hexagonal paving block - Rs. 16 per blockProduction period - 300 daysNo. of units per day - 1500 nos.Total production per year – 4,50,000 units

PROFITABILITY IN EXISTING PAVING BLOCK PRODUCTION (FROM SINGLE MACHINE)

Production cost - Rs. 13.85 per block(including expenses and bank loan returns) Profitability - Rs. 9.5 lakhs per year

PROFITABILITY IN FOUNDRY SLAG WASTE BASED PAVING BLOCK PRODUCTION (FROM SINGLE MACHINE)

Production cost - Rs. 12 per block(including expenses and bank loan returns) Profitability - Rs. 18 lakhs per year

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The enterprise establishment cost

NSTEDBDepartment of Science & Technology Government of India

The establishment of an enterprise can be financed through the PMEGP scheme of the Ministry of MSME

Total project cost – Rs. 25 lakhs• Entrepreneur’s contribution – 2.5 lakhs• Term loan (from Banks) – 15.75 lakhs• Govt. of India subsidy – 6.75 lakhs

PMEGP (Prime Minister’s Employment Generation Programme) scheme (KVIC)• General Category

• Urban – 15%• Rural – 25%• Entrepreneur’s contribution – 10%

• Special Category• Urban – 25%• Rural – 35%• Entrepreneur’s contribution – 5%

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NSTEDBDepartment of Science & Technology Government of India

Thanks