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Preparation Date
1st March, 2011
Project Report Version: 001:001
Presented to
Shandong Dongyue Building Machines Co Ltd,
Linyi City, Shandng province, China
Prepared by
N.Gangadhar Reddy
Project Consultant,
Product Quality Reassurance Services
orissabricks@gmail.com, ngreddy2000@yahoo.com
1
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
1. Project at a Glance
1 Product Details : AAC light weight Blocks
Type : Fly Ash Based or sand based
BIS Code : IS 2185 : 1984 ..Part 3
Technology Area Infrastructure & Green-Tech
Capacity Utilization : 80%
2. Assumptions
The following assumptions have been made while preparing this Project Report.
f. 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.
2
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
3. Introduction
AAC is Autoclaved Aerated Concrete. The blocks are made to aerate by creating a
reaction between silica in base material such as fly ash or sand, active lime, and
aluminum power. The block hardness is being achieved by cement strength, and instant
curing mechanism by autoclaving. Gypsum acts as a long term strength gainer.
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 USP 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 tese
blocks reduce the dead load on the building significantly.
AAC Blocks are largely used in various constructions, such as load bearing and
pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and wherever
conventional bricks can be used. The general AAC blocks fall in the strength zone of 30-
60 Kg/Cm2, thus is having comparable strength as conventional Bricks, and hollow
concrete blocks. These Blocks gain strength over a period of time up to 2 years, where as
the conventional bricks tend to lose strength over a period of time.
These green bricks can attain very regular and uniform shapes. As no burning is
involved, so the shape also remains unchanged. As a result, the final Brick work with
these green bricks consumes less mortar to build, less mortar to plaster. Further, the AAC
being a concrete itself, it forms a more uniform bond with cement mortar, giving almost a
homogeneous structure. Not only this, even exposed brickwork (without plastering) is a
good durable structure. So people prefer to leave the Green Bricks Brickworks in garages,
boundary walls etc. un-plastered.
5. Market
Shelter is third skin, according to a German Concept, which implies its
importance next to human Skin and Clothing. This also shows the attachment of
human race to this fundamental requirement.
Add to the above fact the nearby area of this project site is undergoing a major
infrastructure revolution. As Residential, Commercial, IT companies, and Industrial
establishments are coming in, we can conclude that the Blocks unit will prosper and
flourish in this environment.
Fly Ash policy of the Government also mandates that 20% of Fly ash Generated
by a power plant must be given free of cost to SME sector on a priority basis.
4
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
AAC blocks are being seriously considered for CDM projects in India for
earning Carbon Credits. As the CER Generated is also relatively less, four or five
such units can be bundled together to make a Group CDM in the same sactors.
This project is likely to generate 1 CER per each 7 or 8 Cubic Meter of Blocks
production, depending on, and subject to the CDM methodology adopted, and the
interpretation of additionality and baseline parameters by the validating authority.
Just for a rough estimate of CERS, for an annual production of average size
AAC plant, that is 100000CM/Annum, we are likely to get around 12500 CERs on
full capacity Production. At present market rate of 11.5 Euros per CER and @ Rs. 60
per Euro, we can expect to get additional revenue on CER. But we must expect to take
a cut of around 20 to 30% of CERs, if we want to forward sell the CERs and get the
CDM part sponsored by the buyer.
5
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
Fly-Ash:
A lot has been said about this raw material in this Project Profile itself. But
this Raw material is freely available in Thermal Power plants. There are no taxes on this
item whatsoever. Transportation charges are only to be attended by the entrepreneur.
Lime:
Active powered lime is a requirement for giving the real aeration to the
product. In phase 1 we can aim to buy the active lime directly. In phase -2 we can think of
having backward integration and making a lime powering unit at site to have a more
competitive advantage, We can also think of a lime burning klin inside the factory
premises.
The project financials however have not considered the costs of powering unit, and the
lime kiln in this project.
OPC.
This Project aims to utilize OPC cement as main binder material. It will
give faster strength to the bricks, besides giving improved consistent quality. It also
ensures a better cost effectiveness for the same. Using OPC will be a standardized
practice. The other prime advantages of using OPC (compared to other binders) is its
easy availability locally through nationwide Retail Network of Cement Companies.
Gypsum:
Aluminum Power.
Finely ground Aluminum power is used in very limited quantity ( less than
0.5%), so that it reacts with active lime, and silica in base material to make the aeration,
and swell the product, making it very light weight product.
6
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
8. Process
The Process of manufacture is simple t follow, and complex to implement.
First, the Fly Ash is mixed with water, and made Slurry in a slurry mixture. If
Sand is used as a base material, we need a ball mill to grind the sand to fine power. The
slurry making process is same sand.
After Slurry is made, the slurry is stored in slurry storage tank, where the slurry is
constantly agitated. Care is taken to run the slurry storage tank all the time, so that is
never settles down the particles.
Then a weigh batcher weighs the Slurry, lime, OPC, Gypsum and aluminum
power in preset quantities, and mixes thoroughly. The mixture also pours the mix into the
Mould carried n the mould cart. The full pouring of the mixture is just enough to fill
around 50% of the mould.
Then the mould is kept in a warm chamber for 2 hours, so that the aeration and the
light initial setting takes place.
Next process is the level wire cutting of the Block, while the block passes on the
cutting trolley through the series of wires. This process follows a vertical wire cutting
where as the block remains stationary, and the cutter cuts the block vertically.
The final cut blocks are Steam cured in autoclaves for 8 hours at 12 KG/Sq cm
pressure, and 200D C
Please refer the Process Flowchart Drawing, 3D Layout Drawing, and the
Pictorial Sketch Drawing given in following pages.
7
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
Main
Fly Ash Gypsum Lime OPC Raw Materials
Water
Flyash Weight Weight Batched
Slurry Batched Quantity
Batched
to mix ingredients
8
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
Please follow the real 3D graphical layout drawing, and its prospective pictorial Sketch
description
9
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
11. Photographs
Just for technical clarity some of the photos of the real working are provided here. Please
ask for a free video CD explaining complete working condition.
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Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
Almost 95% of the raw materials can be made suitable for AAC line through proper mix
design. Also we can have many different mix designs for the same denicitysame
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 input raw materials.
The following are basic guidelines (certainly not the final call) on the suitability of basic
raw materials for AAC.
2. Lime (8-25%)
Item Grade
Super Gr. 1st Gr. 2nd Gr
A(CaO+MgO) Quality 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 5-15
Digestion temperature , 60-90
Undigested residue quality fraction ,% 5 10 15
Fineness (0.080 square hole sieve left amount) % 10 15 20
3.Cement (6-15%)
SiO2 Al2O3 Fe2O3 CaO MgO C3 S C2 S C3 A C4AF
21-23 5-7 3-5 64-48 4-5 44-59 18-30 5-12 10-18
4. Gypsum/Plaster (3-5%)
CaSO4 70%
MgO 2%
Chloride 0.05%
Preferably ground residue 90m 10-15%
11
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC project profile for India
Bureau of Indian Standard Code no- 2185(Part-3):1984 discusses in details regarding the
AAC blocks specifications in India. The prime requirements for AAC blocks (of ISI
standards) in India as per the above said code are as follows.
12
Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)
Sample AAC Project for Dongyue-India Clients
50000 CM/Annum AAC Plant 718.52 0.00 0.00 718.52 60.00 778.52
100000 CM/Annum AAC Plant 732.92 133.10 0.00 866.02 60.00 926.02
150000 CM/Annum AAC Plant 747.32 133.10 133.10 1013.53 60.00 1073.53
Working Capital Rs. Lakhs If we need sand base AAC add on, we need to add a 150 KW
50000 CM/Annum AAC Plant 44.37 ball mill and a block separator Extra. Even we may need 2 more
100000 CM/Annum AAC Plant 88.75 autoclaves to reach max production of 1,5 Lakhs CM as the
150000 CM/Annum AAC Plant 133.12 steam curing period is at least 25% more
Disclaimer
This Project Profile is supplied free of cost to all prospective AAC clients
This FULL document can be distributed free of cost to any one, without any sort of permission
This Document cannot be sold to anyone for any purpose( neither soft copy nor hard copy)
This Project Profile is A GENERALISED profile and do not represent any one unit in particular.
This is for guiding prospective client, and helping them to understand the project well
This can also serve a basis for Clients Chartered Account for making a DPR for them
This template with a little variation can be used to get the DIC EM-1, Pollution control NOC, and other Docs
This document do not in any way bind, restrict or force any data on Dongyue Company or N.G.Reddy
The AAC project being Modular, there can be client specific needs, which may not be mentioned herein.
As the raw materials vary widely, so also does the mix designs we suggest. So final costing may vary.
The Price basics for China Machinery, and Indian side machinery is just for reference purpose.
Even the quantity of items is approximate, and can vary from case to case basis
The civil costs can vary depending location, and the clients rapport and grasp on the field
The fabrication costs can depend a lot on clients ability to handle the things on his own, and Steel Prices
The speed of execution of project totally depends on Clients skills to Coordinate the Indian suppliers
We can take up the client specific Project profile on a Nominal Payment basis
We are attempting to get the AAC units bundled in a group for CDM benefit to earn Carbon Credits
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1 Pre curing Room 24.00 16.50 3960
2 Mould Turning Ares 6.00 16.50 990
3 Cutting Area 18.00 16.50 2970
4 Boiler Area 16.00 8.00 1280
5 Total Mandatory workshed Areas 9200
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7.a For 50000 CM/annum plant 30.00 8.00 2400
7.b For 100000 CM/annum plant 30.00 14.00 4200
7.c For 150000 CM/annum plant 30.00 20.00 6000
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2. Minimum Area for 100000CM Plant 3.00 15400 23800
3. Minimum Area for 150000CM Plant 3.50 17200 29200
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C Installation Schedule
Installation Schedule for 150000 CM/Year capacity AAC plant on autoclaves & Major Items
Sl. No Items Phase-1 Phase-2 Phase-3
Autoclaves Complete Kit along with
1 Body, Steam Pipes, Cyllinder and 2 2 2
Insulation, safety devices, Rails
2 Moulds 12 4 4
3 Side Pallets 50 50 50
4 Steam Traullies 25 25 25
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Details of Machinary From (Both India and China ) Installation in a 3 Phase Split
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* India Side Procurement includes Boiler, Autoclaves, Surrry Tank Body, Loader, Forklift, and Other unfabricated MS items
3 Stores & workShed 17200 sft @ Rs.800/- 137.60 30.00 41.28 96.32
4 office 1000 sft 8.00 30.00 2.40 5.60
5 500 sft x 3 floor rcc or MS struct 15.00 30.00 4.50 10.50
6 Mis fixed assets 5.00 40.00 2.00 3.00
Transformer/geneset/Electric Installations
7 & charges 50.00 25.00 12.50 37.50
8 Water Source--Boor Well with Pump 2.00 25.00 0.50 1.50
Plant & Machinary(with Installation)-
9 Phase-1 (1st Year) 549.72 25.00 137.43 412.29
Plant & Machinary(with Installation)-
10 Phase-2 (2nd yr) 133.10 25.00 33.28 99.83
Plant & Machinary(with Installation)-
11 Phase-3 (3nd yr) 133.10 25.00 33.28 99.83
12 Prilimnary exp 5.00 40.00 2.00 3.00
13 Preoperative 15.00 40.00 6.00 9.00
14 Contingency 5.00 40.00 2.00 3.00
15 Total 1073.53 284.66 788.87
5 Insuraance per Month ( at 0.3% per annum ) Rs. 20,182.99 Rs. 20,182.99
6 Maintainance per Month ( at 2% per annum ) Rs. 91,619.96 Rs. 91,619.96
7 Office Overheads(Post+phone+Net+travel+stanry) @ Rs. 25/CM Rs. 83,333.33 Rs. 83,333.33
8 Total Expences per Month Rs. 4,437,277.95
H DEPREATIATION
Item 1st Yr 2nd year 3rd Year 4th Year 5th Year Remarks
1 Block Land & Building 165.60 149.04 134.14 120.72 108.65
2 Added Land & Buildi ngs 0.00 0.00 0.00 0.00 0.00
Depreaciation on building/shed and other
3 constructions except land 10% 16.56 14.90 13.41 12.07 10.87
4 Year end Block 149.04 134.14 120.72 108.65 97.79
3 Depreaciation on machinary & equipments 15% 90.26 76.72 85.18 92.37 78.51
4 Year end Block 511.46 567.85 615.77 523.41 444.90
J3 Sales per year @ Rs. 2500/CM 1000.00 2000.00 3000.00 3250.00 3500.00
Note : Sales inclusive of VAT & Excise 2808.00
Expected CER Generated 5000.00 10000.00 15000.00 16250.00 17500.00
J4 Carbon Credit Revenue (Apprx) 25.88 51.75 77.63 84.09 90.56
CERs @8 CM=1 CER, 50000 25% of CERs deducted as transactional and operational costs. CER
Note : CM=6666 CER @ 11.5 Euros@60 revenues for Guidelines only. Not computed in Profitability of this
INR report
Analisis
J10 Break Even Point (B.E.P) 49.33 31.66 22.28 21.01 19.41 %
Note :
1 Net Profit Ratio = (Net Profit / Net Sales) x100
2 Rate of Return on Investment = (Net Profit / Project Cost) x 100
3 Break Even Point ( B.O.P )= (Fixed Cost / (Fixed Cost + Net Profit)) x 100