Welcome to

Sr. Executives of Ministry of Environment & Forests, Govt. of Bangladesh,

Faculty of BUET, Members of BBMOA and Other Distinguished Delegates

To the Technical Presentation on:

FaL-G Bricks-A Resource-efficient Environment-friendly Construction Material

Multi Stakeholders’ Workshop

25 February 2016

Status of Clay brick Industry in Bangladesh

There are over 5700 clay brick units in the country producing about 8.66 billion bricks annually. Technology is nowhere an exception to Indian brick kilns continuing with age-old practices even today. Though brick is supposed to be of 250*125*75 mm, popularly produced size is 240*115*70 & 230*110*70 mm rendering around 15 MPa strength.

In view of high strength, brick is broken into pieces and used as coarse aggregate in concrete, addressing the constraints in availability of stone within the country.

Bangladesh is keen to promote coal based power plants. Different plants with aggregate capacity of 15,000 MW are in the pipeline that would generate over 15 to 22.5 million tons of fly ash every year.

Bangladesh government is concerned to conserve their top soil which is rampantly used for clay brick production. To serve this objective Government is keen to take advantage of fly ash generation. In this context Institute for Industrial Productivity (IIP), an US based NGO, has identified FaL-G technology as the viable solution and recommended to Bangladesh.

What is FaL-G:

FaL-G is the patented technology (Patent No. 198639) developed by Dr N Bhanumathidas & N Kalidas in India, for the production of fly ash Bricks and blocks.

Fly ash (the residue of coal combustion in boilers of thermal plants and other process industries) is blended with lime/cement and Gypsum to get FaL-G. Sand or stone dust is added as filler.

This technology is being promoted by Institute for Solid Waste Research & Ecological Balance (INSWAREB) and, as of now, over 18,000 micro plants are working with an aggregate out put of over 54 billion bricks (or equal volume of blocks) and turnover of approx. Rs. 21,600 crores.

FaL-G: Technology features

Raw Materials :

Basic raw materials are:

• Fly ash from super thermal plants as pozzolan and filler • OPC as cementitious media and also as source of lime • Anhydrite gypsum, as setting and strength accelerator • Stone dust (from crushers) as filler; alternate: River sand

FaL-G: Technology features

What is fly ash:

Fly ash is nothing but the clayish impurity that remains in coal during its formation, and gets burnt in furnace.

Fly ash basically contains SiO2, Al2O3, Fe2O3, Na2O, K2O and other micro elements, both in reactive and unreactive state.

Reactive phases associate with lime forming lime based Hydrated mineralogy akin to that of OPC.

Experience of FaL-G Bricks in India:

In the absence of consumer awareness and market support, the technology which was introduced in India in 1990 took 10 years to raise to 700 units. There upon 11 years to touch12,000 mark and 15 years in proliferating to 18,000 units.

By replacing the application of clay bricks in the

construction segment, both in housing and infrastructure, FaL-G bricks/blocks serve the market with more vividity.

Contributions of FaL-G Technology in National Perspective

Ministry

concerned

Activity

Ministry of Rural

Dev.

Conservation of fertile top soil;

protecting land for agriculture.

Ministry of Power Conservation of coal.

To make use of huze quantities of fly

ash.

Ministry of

Environment &

Forests

Abatement of Pollution.

Abatement of CO2 emission.

Ministry of Poverty

allieviation

Creation of year-long employment to

rural folks.

Benefits to Bangladesh:

High strength bricks with perfect edges and superior engineering properties would usher in revolutionising brick industry.

Benefits to Bangladesh:

High strength FaL-G blocks would pave the way for execution of high quality pavements in Khadanza pattern with 100-years of service life at least.

Benefits to Bangladesh:

High strength FaL-G bricks help to render high strength aggregate to the concrete industry, minimising import bill on aggregate.

As a prelude, to facilitate transfer of FaL-G technology to Bangladesh, IIP has organised a Round Table Meet at Dhaka on 3rd May 2015.

Senior officers of Ministry of Environment and captains of clay brick industry from Bangladesh have attended this meet where INSWAREB has presented technicalities and socio-economic dimensions of this activity, based on extensive proliferation of this technology in India.

This has enthused brick manufacturers to undertake a visit to India for witnessing the activity at field level.

Subsequent to the visit of members of BBMOA to India in June 2015, one more Delegation consisting of senior officials of Ministry of Environment and other concerned Departments visited India in August 2015 and seen some operating plants in Coimbatore. Further interaction among IIP, BBMOA and Govt. of Bangladesh has culminated into this stakeholders meeting Today.

Experiments with textile-sludge from Bangladesh: INSWAREB has tried to put the textile-sludge to use in FaL-G Brick production and conducted some preliminary Investigations. Constituents of any sludge do participate in chemistry if they are reactive and remain as filler if they are unreactive. But investigations revealed that the constituents of textile sludge have detrimental role in spoiling the cement chemistry and thus not suitable for FaL-G brick.

FURTHER ACTION: It is desirable that a pilot plant be set up in Bangladesh for conducting trial production in order to give feel of the products through field demonstrations by executing walls, pavements and providing aggregate. This pilot plant would also be used to train some of the workers on production techniques.

There upon it is at the discretion of clay brick manufacturers in Bangladesh to set up FaL-G Brick plants and practice the technology.

Association of Bangladesh University of Engineering and Technology (BUET):

It is happy note to learn that BUET would absorb FaL-G technology, validate the same under local conditions and guide BBMOA , as Knowledge- Dissemination Body, in association with INSWAREB.

As the seat of learning and research, BUET is welcome to study the total scope of FaL-G technology for tapping its potential not only as brick, but also as coarse aggregate and concrete.

Indicators of

Sustainable Development

Per million

bricks

At country level of 5000

units

Conservation of top soil for replacing clay bricks

Prevention of denudation

4,500 tons

67.5 mn.tons

4218 acres

Utilisation of fly ash

(@ 1.0 kg/brick)

1,000 tons 15 mn. tons

Conservation of coal 250 tons 3.75 mn. tons

Abatement of CO2 240 tons

(380-140)

3.6 mn. tons

Employment potential 75,000

At a conservative annual capacity of 3 million bricks/unit

Fal-G: The Unique E4 Technology

INSWAREB is ready to serve BBMOA in deriving the benefit of carbon credits, when Their members migrate to FaL-G technology.

Due to service to ecology and community welfare, FaL-G qualifies for Gold Standard for fetching handsome rates in carbon credit market.

New Industrial Policy-2016 approved yesterday Categorized high priority industries as the sectors that create large scale employment through speedy expansion and earn substantial sums of export earning. These industries get Priority in receiving government incentives for rapid development.

FaL-G brick saves coal and thus saves huze foreign exchange reserves, simultaneously giving employment, thus qualify for incentives.

APPEAL to GOVERNMENT

It is judicious to sanction a few millions worth of incentives for green products such as fly ash bricks, against losing several billions and trillions of cost towards repair of Environment and Ecology.

-INSWAREB- 25 February 2016

Dhaka

Thank you for your Kind Attention