Autotherm -AAC Plant Project Report- Simple

7/23/2019 Autotherm -AAC Plant Project Report- Simple

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A Simple Project Report on AAC Block Plant :

Project at a Glance Capacity 50000 CBM (in shape of blocks of 0.75 density and size

600mmx200mmx200mm) Equivalent to 2.5 crores ordinary brick of density 1.9 sizes

230mmx110mmx75mm

S.No Description Estimated Cost (Rupees in

Crores) 1. Land 3 acres 1.50

2. Plant Machinery and Building including 5

delivery vehicles

11.00

2.a.

2.b.2 c.

3.

Plant Machinery,

(Mobile & Loading Equipments)

Building UtilitiesDelivery Vehicle

Working Capital 5000 CBM/Month

@Rs1800/Per CBM

8.50Cr.

1.75 Cr.0.75 Cr.

0.90

Total Capital Employed 13.10 Statement Showing Projected Profit & Loss Account Based on Production of

45000CBM/Annum Fly Ash Route

Particulars Per CBM Total (Rs. In Crores) Sales 3200 14.40

Variable Cost

Flyash 500 Kg.Lime (CaO) 100 Kg.

Cement 80 Kg.

Gypsum 75 Kg.

350350

480

150

1.581.58

2.16

0.67



Aluminum Powder

Power & Fuel

Electricity

Coal

Direct Wages

Total Variable CostContribution

Fixed Cost Salary and Wages

Annual Maintenance

Other Factory Over-Head

Sales Expenses

Total Fixed Cost

Total Cost of Sales

50

90

250

80

18001400

133

156

22

53

364

2164

0.22

0.40

1.13

0.36

8.106.30

0.60

0.70

0.10

0.24

1.64

9.74

Gross Profit Before Interest and

Depreciation 1036 4.66

Break Even Sales (Rs. In Crs.)

Break Even Sales (Qty.)

Break Even Sales (in %)

9.74

30600CBM/Yr.

68%

Sand Route

Particulars Per CBM Total(Rs. In Crores) Sales 3200 14.40

Variable Cost

Flyash 500 Kg.Lime (CaO) 100 Kg.

Cement 80 Kg.

Gypsum 75 Kg.

Aluminum Powder

Power & Fuel

Electricity

Coal

Direct Wages

Total Variable Cost

Contribution

Fixed Cost Salary and Wages

Annual Maintenance

Other Factory Over-Head

Sales Expenses

Total Fixed Cost

Total Cost of Sales

175350

480

150

50

90

250

80

1625

1575

133

156

22

53

364

1989

0.781.58

2.16

0.67

0.22

0.40

1.13

0.36

7.31

7.09

0.60

0.70

0.10

0.24

1.64

8.95

Gross Profit Before Interest and

Depreciation 1211 5.45

Break Even Sales (Rs. In Crs.)Break Even Sales (Qty.)

Break Even Sales (in %)

8.9527900CBM/Yr

62%



Process :



Equipments:



Market :



Comparison between Autoclaved Aerated Concrete (AAC) blocks and clay

bricks:

Sl.No.

Parameter AAC Blocks Clay Bricks

1 Soil Consumption Uses fly ash which is athermal power plant wasteproduct & thus noconsumption of top soil

One sq ft of carpet areawith clay brick walling willconsume 25.5 kg of topsoil

2 Fuel Consumption One sq ft of carpet areawith AAC blocks willconsume 1 kg of coal

One sq ft of carpet areawith clay bricks willconsume 8 kg of coal

3 CO2 Emission One sq ft of carpet areawill emit 2.2 kg of CO2

One sq ft of carpet areawill emit 17.6 kg of CO2

4 Labour Organized sector withproper HR practices

Unorganized sector withrampant use of child

labour5 Production Facility State-of-the-art factory

facilityUnhealthy workingconditions due to toxicgases

6 Tax Contribution Contributes to governmenttaxes in form of CentralExcise, VAT and Octroi

Does not contribute togovernment exchequer

7 Size 625 mm x 240 mm x 100-300 mm

225 mm x 100 mm x 65mm

8 Variation in Size 1.5 mm (+/-) 5 mm (+/-)

9 Compressive Strength 3.5-4 N/m2 2.5-3 N/m2

10 Dry Density 550-700 kg/m3 1800 kg/ m3

11 Fire Resistance (8" wall) Up to 7 hours Around 2 hours

12 Cost Benefit Reduction in dead weight

leading to savings in steeland concrete

None

13 Energy Saving Approximately 30% forheating and cooling

None

Consumption & Energy of Raw Material Comparison:



EquipmentsEquipment is depend of selection of process , base material , selection of automization etc.below is given general baseequipment

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:• Main Slurry mixer –fly ash

• Main Mixer desert mortar after Cutting

• Weighted / batch slurry mixer • 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

Cutting processing equipment:

• Hoist for mould move • Hoist for semi finish product

•Tractor

•Horizontal cutting machine with Arrangement

• Vertical 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



Energy & Mass Flow Diagram :

Layout:



For More Details Contact Us:

Autotherm Equipments Corporation, S.F. No: 284, Vellan Thottam,Ganesh Nager, Malumichampatti, Coimbatore - 641 021,Tamilnadu,India. Email : [email protected]

[email protected]

Skype : albinindiaWebsite : www.autotherm.in

www.autothermindia.com Hand Phone : +91 98 948 96 996Telefax : +91 422 267 0004

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Autotherm -AAC Plant Project Report- Simple