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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