Project funded by National Science & Technology Entrepreneurship Development Board (NSTEDB)
Department of Science and Technology, Government of India
Foundry slag replaces the 8-12mm aggregate that are used in the conventional production of paving blocks. DA research facility at TARAgram in Orchha, Madhya Pradesh has set up a pilot plant for producing paver blocks using foundry slag. This slag paver block manufacturing plant produces paver blogs using slag reducing the cost and replaces the aggregate in all values. The quality of the slag paver blocks are tested at the Advanced Materials Processing & Research Institute (AMPRI) – CSIR Lab at Bhopal. The results were very positive and are higher than those manufactured by using aggregate. They comply with the standards of IS 15658:2006.
Foundry slag paver blocks are the solution to the problems that the environment and the slag dumpers are acing for decades. This innovative and economical production of pavers from slag benefits the slag users by reducing their cost and the environment.
Due to its benefits and success, the project was able to link up with the Department of Science and Technology (DST), the Government of India. In September 2015, it started a scheme to establish enterprises to develop paver blocks from foundry slag. The foundry wastes which are dumped in open space are used for manufacturing paver blocks under the ‘Promoting Sustainable and inclusive growth by Enterprise creation through Science and technology-based Innovative solutions (Sub-Sector-Foundry)’. This project encourages the investors by conveniently forming an enterprise that manufacturers paver blocks from foundry slag.
Foundry manufacturers generate slag after the extraction of metals.
Sizing of foundy slag waste by jaw crusher.
Sieving to get appropriate slag aggregates (10-12 mm)
Mixing of sand + cement + slag aggregate through ordinary concrete mixers.
Use of appropriate admixtures for controling water mixutres to cement ratio.
Moulding and compaction of mix through either vibration or hydraulic technique (equipment).
Water curing for 14 days with subsequent atmospheric curing for 7 days.
Finally, we get paver blocks ready.
The stakeholders will be adequately informed about the opportunities available in manufacturing and selling the paver blocks made from slag. The precise business proposition and the available support system will be made conscious among the stakeholders including the existing brick manufacturers. They will also be connected to sources of equipment, processes, technical specifications, and service providers who can supply the same are not readily available in the market.
Slag paver blocks and bricks are created using the slag and the burnt sand devised by Development Alternatives with TARA. The confidence of stakeholders will be strengthened through test results of slag pavers from reliable institutions. After the manufacturing process, the end products i.e. slag paver blocks /bricks are tested at NIT, Bhopal to compare their quality with conventional paver blocks/bricks.
A customized business plan is developed for all the enterprises that are to be formed or developed under this project. The plan includes the total asset needed, based on the standardized machinery, operating costs and other resources required in establishing paver block/brick manufacturing plant from foundry slag. The business plan will contain the details like different types of value-added products that can be manufactured, investment required, per brick/paver block costing, sources of raw materials, plant layout, infrastructure and financial requirements, calculations of return on investment and payback period, potential market segmentation and overall market analysis, areas of product diffusion etc. The model business plan will then be shared with potential/ targeted entrepreneurs and enterprises to acquire their confidence.
Foundry owners who has a land and uses it to dump the slags from the foundry units can easily setup a paver block manufacturing unit . The accumulation of slag in their foundry enterprise for years and sub-urban foundry enterprises can provide adequate raw material to their new paver block manufacturing unit. They can setup a paver block manufacturing unit and utilizes the slag dump. This unit can separate around 5% of the metal from the foundry slag through the crushing and magnetic separation process in manufacturing the paver blocks/bricks. The extracted metal can again be reused. Transporters (Trolly-Wallas) who dump the foundry slags in empty fields can also be one of the very likely investors.
A community-owned enterprise can be a cost-effective solution. Apart from sharing the investment, it also gives a sense of ownership to the community and also the community will work together for the up-keeping of plant. The local assiciations, BMOs, a group of enterprises, SPVs, and local institutions will be approached for the awareness of benefits of such a preposition.
The existing manufacturers will also be approached for investment in this proposition. Since the process doesn’t involve a heavy restructuring of the paver blocks/bricks, our proposals to the manufacturers will be proved as even more beneficial.