Solution to the problem of flyash by way of

Manufacturing flyash bricks

In
N.C.T. Delhi.

With a short report

On
Inception of Flyash Brick Industry
In
N.C.T. Delhi.

Written by

Anil Arora
Chairman:
Center for Innovative Building Materials.India

For more clarifications/information contact at:

mjbricks@gmail.com , cibmindia@gmail.com
INTRODUCTION TO THE PROBLEM WITH BRIEF HISTORY

In India the annual production of flyash is nearly 45 million tones per

year. This is likely to increase to 70 million tons per year by 2010. At
present most of the flyash is being dumped. The disposal of the flyash is
a serious hazard to the environment that consumes millions of rupees
towards the cost of its disposal. About 14000 Hect. Of precious land
have already been used for dumping it and another thousands of Hect.
Would be required in future.

To reduce the problem of the disposal of flyash or to solve it on long

term basis, it is necessary to utilize it as a raw material for flyash based
products or for other beneficial purposes in an environmentally safe
manner. The Govt. of India is trying to achieve a significant increase in
flyash utilization in a short period of time by numerous activities.
Several Public Interest Litigation are pending for disposal with the
Hon’ble High Court of Delhi such as Center for public interest litigation
Vs U.O.I , B.L.Wadhera Vs U.O.I etc.to deal with the serious problem of
flyash disposal.

Flyash can be used for making a variety of building materials such as

Bricks, Blocks, Cellular concrete, Tiles, Portland possolana cement etc.
Flyash can also be used in road making, landscaping and in filling of low
lying areas. Its use in agriculture is also under research. Several
technologies are available to convert this major environmental problem
to productive uses. But the utilization of flyash for building purposes is
almost dismal till now. There have been attempts to make bricks by
flyash lime process using high investment oriented technology, which
have not met any commercial success. The only technology that has
succeeded is the Fal-G technology. It is also acclaimed by the HUDCO
that this low cost technology has great potential and needs promotion.
STATUS OF THE PROBLEM IN THE PRESENT SCENARIO OF
DELHI’S ENVIRONMENT.
In NCT of Delhi alone, the production of flyash is nearly 5000 tons by
the three Thermal power stations IP, Rajghat and Badarpur. In the
present status of the Environment of Delhi and these being in the hub of
Metropolitan City the problem of the disposal of flyash is aggravated.

To save the environment of Nct, Delhi, The Hon’ble Supreme Court was
pleased to pass many Envo- Friendly orders in the writ petition (civil) no
4677/85. At the time of dealing with the matter of H category brick kilns
in Nct Delhi, The Hon’ble Supreme Court, relying upon the Central
Pollution Control Board `s report on Brick kiln, stopped the traditional
method of manufacturing clay bricks. To solve the problem of flyash,
The Hon’ble Court gave liberty to brick kiln owners for switching over
to the new flyash-sand-lime technology of manufacturing bricks in NCT
Delhi. The Hon’ble Supreme court also directed Delhi Govt., to render
all possible assistance to brick kiln owners in adoption of this new flyash
technology. In another Cwp no.2145/99 Center for Public Interest
Litigation Vs U.O.I., The Hon’ble High Court of Delhi vide its order
dated 25.08.1999, directed the central government to publish the final
notification in respect of flyash on or before 26.10.1999. Therefore in
pursuance of the orders of the Hon’ble court stated above, The Govt. Of
India issued a direction on 14.09.99 can broadly be read as follows:

a) Use of flyash, bottom ash or pond ash in the manufacturing of bricks

and other construction activities.
b) Utilization of ash by thermal power plants.
c) Specification for use of ash based products.

It should be appreciated that the theme of both the directions mainly

highlights the need of the utilization of flyash through the making of
flyash bricks.
Brick is a basic need for the development works. No development is
possible in housing, public sector or private sector, without bricks. Since
the traditional kilns producing clay bricks have stopped production w.e.f
30.06.1997, there is a shortage of good quality bricks in Delhi and price
of it is escalated because of its import from neighboring states. Several
studies show that flyash brick is a far superior building material than
burnt clay brick. The use of flyash brick provides a stronger, more
durable construction that is better protected from efflorescence and
salinity with meaningful savings in construction costs. But the greater
benefit lies in controlling two major ecological problems of flyash
disposal and the reduction of cultivable land that is needed for the
production of burnt clay brick.

The role-played in Delhi, by the Flyash mission,(a technology project in

mission mode by Department of science with an object to build
confidence through demonstration projects for flyash utilization
technologies ),. Dvb , Hudco, M.o.e&F, Ntpc and other non
governmental organizations in solving the problem of the disposal of fly
ash in Delhi needs to be appreciated .DVB under the leadership of its
chairman and with the sincere efforts of its engineering staff has set an
example for other organizations by way of not only producing millions
of fly ash bricks but also being a pioneer organization for utilizing these
fly ash bricks for its own purpose of civil constructions. Cpwd and Pwd
have also incorporated the fly ash bricks in their civil schedule. The
inimitable efforts of converting this national wastage into a national
asset should be saluted. But this is just the beginning of a journey in the
national interest towards the gainful utilization of fly ash..

Contd.
HISTORY & EFFORTS OF OUR COMPANY TO SOLVE THIS
PROBLEM

Our company M/s M. J. Bricks Company was a manufacturer of

traditional clay bricks, in the Nct of Delhi, the production of which has
been stopped in pursuance of the direction of the Hon’ble Supreme
Court on 30.06.97..We were the first to give in writing to the Secretary
Environment, Govt. of Nct Delhi, about our intention to establish brick
kiln on flyash-sand-lime technology as per the direction of the Hon’ble
Supreme Court. Despite a clear directive from the Hon’ble Court that all
governmental agencies should assist in the changeover to adoption of
new flyash technology, The co-operation required from them and the
efforts done by us, in the capacity of the Joint secretary, Delhi Brick
Kiln Owners association and as proprietor of M/s M. J. Bricks Co can be
event wise short listed as below.

26.11.96—The Hon’ble Supreme court passed the order in writ petition

(civil) no. 4677/85 in I.A.no 22 dated 26-11-96 that can broadly be
described as under:

1.That brick kilns in Delhi should stop functioning in U.T. of Delhi by

30-6-97. The brick kilns have been given option to relocate/shift
themselves to any industrial estate in the N.C.R
.
2. IN para (9) of the said order the Hon’ble court has given the liberty to
the brick kilns to adopt the FLYASH SAND LIME technology for
manufacturing bricks and in the event that Brick kiln decides to switch
over to new technology, they may inform the Secretary Environment –
Delhi Adm. about its intention before 31st jan.1997
.
3.That Delhi Pollution Control Committee shall monitor the setting up of
the new project. After obtaining the consent and no objection from the
D.P.C.C the Brick kiln concerned are permitted to operate at the same
site with new flyash technology.
4.That the Delhi Adm. & D.P.C.C. to render all possible assistance to the
Brick kilns owner to change over to new technology.

29.01.97-- We applied to Sec. Environment Govt. Of. Nct. about our

intention to adopt this flyash technology with a request to confirm the
operation from the same existing site.

6.02.97—A meeting with the commissioner ( f&S )and DC ( Building )

to discuss the problems on adopting the new technology.

11.02.97—A request letter for seeking assistance and high lighting the
problems in adopting the new technology submitted to the commissioner
(f&S) and Development Commissioner -cum-secretary Environment,
Govt. .Of Nct.

6.03.97—A letter-requesting D.P.C.C. to render assistance and guidance

regarding new technology is submitted.

21.03.97-- A meeting was held in the chamber of Chief Secretary,

Delhi .to discuss the problems arising out of the Hon’ble court orders to
shut down/ shift brick kilns out of Delhi, on or before 30-6-97. After a
good deal of discussion, A COMMITTEE was formed to sort out the
problem likely to be faced by the brick kiln owners in adoption of new
technology. The Chief secretary also assured the brick kiln owners that
Govt. would offer full support to them in setting up the new plants in
Delhi. He also assured that proposals to grant exemption from Octroi
and Sales Tax will be examined and appropriate decisions keeping in
view the interests of brick kiln owners will be taken. Though the said
committee, as had been formed, never convened meeting despite
repeated requests made by us.

29.07.97—Proposal for industrial use of flyash generated in Delhi

Through brick making was submitted in the office of chief secretary and
Commissioner industries by us pointing out the difficulties which need
to be resolved by the Govt. authorities and the via media to overcome
those.
31.07.97—A meeting was held in the chairmanship of Additional
Secretary M.o.e.f in which we had been asked to submit our proposal to
NTPC-Badarpur thermal power station for the manufacturing of flyash
bricks.
13.08.97—A proposal for the same submitted to the Deputy General
Manager(c) BTPS.by us.
15.08.97—Due to strong persistence by us with the commissioner
( F&S) who has been designated as the chairman of the committee, a
communication was received from his office that department of
industries Govt. of NCT Delhi had been made a nodal agency and all
future communication should be addressed to commissioner of
industries.

24.09.97—A detailed project report had been submitted to the Chief

Engineer ( c ) DVB with ref. to their advertisement dated 23.08.97.

28.01.98—A meeting was attended by us discussing detailed project

report and suitable proposed technology in the office of C.E ( c ) DVB.

18.02.98—We submitted a detailed reply for certain clarifications

desired by the DVB.

9.06.98—After various representations, a meeting was held in the office

of Commissioner of Industries and a project report with proposal was
submitted by us.

3.08.98—Our application was accepted by Delhi Pollution Control

Committee for issuing Consent to Establish.

21.08.98—A meeting was called by the Chief Secretary, Govt. of N.C.T.

Delhi in which it was decided that unit would be granted permission to
establish/operate from D.P.C.C., Industrial license from Additional
Commissioner MCD and registration Under SSI would be provided by
the Department of Commissioner of Industries. It was decided that all
clearances should be given in a time bound manner by the concerned
agencies.

22.10.98 to 8.03.99—The required clearances sought, established the

unit on a war footing level and applied for consent to operate with in
time frame set by DPCC.

30.11.98—We received a call from DVB for setting up a flyash brick-

manufacturing unit at Rajghat with certain conditions.
14.12.98—A reply was sent accordingly with acceptance of offer with
suitable amendments.
14.12.98 to 4.03.99—We held three meetings regarding further
clarifications and acceptance of our approval with the Dvb.

8.03.99 to 23.12.99—We held, with DPCC and with other concerned

offices and ministries, several meetings with a prayer to expedite the
grant of consent to operate, to our pioneer unit for the sake of developing
the flyash brick industry.

10.05.99—We received a letter conveying our selection for

manufacturing of flyash bricks at Rajghat from DVB.

21.09.99—A letter of intent to convey the acceptance of our offer to

install a flyash brick-manufacturing unit at rajghat had been issued by
the DVB.

22.10.99—A contract agreement, to manufacture 8000 bricks per day,

was made by us with the DVB to start the Production of Flyash bricks.

15.12.99—The production of our unit at Rajghat had been started to

strengthen the hands of DVB in the utilization of flyash.

23.12.99—In spite of our several letters and meetings, time to time,

showing proof that the surrender of land is not applicable on our unit as
per the Hon’ble Supreme court direction dated 26.11.96, our consent to
operate, for our earlier established unit at VPO-Chandpur, was refused
on the same ground.

08.02.00—To pray for Justice, an application for impleadment u/s 151

Cpc intervening in Cwp no.2145/99 was filed in the Hon’ble High Court
of Delhi by us which was allowed on 16.02.00.

17.02.00—We filed an appeal u/s 31 of Air prevention & control act

before the Appellate authority constituted under the act. But the said
authority took the view to maintain the status quo as the matter was
pending disposal with The Hon’ble Supreme Court.

24.04.00—We filed an IA 1246 in IA 22 in Cwp 4677/85 in The

Hon’ble Supreme Court for the clarification of Dpcc stand.
08.08.00—The Hon’ble High court ordered Dpcc to grant the consent to
operate to our most envo-friendly unit.

29.08.00—The Hon’ble Supreme Court clarified that land surrender is

not applicable to the brick kiln owners and also said that the technology
adopted by us is environment friendly.

11.09.00—We had been asked by the DPCC to file a new application

for consent to operate that was filed accordingly with required fees.

27.10.00—We received consent to operate for the first most environ-

friendly unit of manufacturing flyash bricks in NCT, Delhi and the
production of flyash bricks & tiles was started.
SCOPE FOR LARGE SCALE UTILIZATION OF FLYASH IN
DELHI

An annual estimated demand of bricks in Delhi is around 2500 million

per year, this needs about 2000 hectares of topsoil to be removed leading
to ecological degradation . Thermal Power Station in Delhi (I.P, Rajghat,
Badarpur) generates about 5000 tons per day or 1.5 million tons per
year. Being in the hub of Metropolitan City, the problem of fly ash has
aggravated.

Alternatively, if total fly ash generated in Delhi, i.e., about 1.5 million
tons is converted into fly ash bricks, it will produce only 750 millions
which is about 30 % of the Delhi requirement. Fly ash brick is, therefore,
not a threat to the existing burnt clay brick industry.

By converting this huge national wastage into a national asset, we will

not be able to solve the problem of its being an environmental hazard but
also be able to save the revenue towards the cost of its disposal in
millions. (If a ton of fly ash consumes Rs 40 towards its disposal then
the valuable 60 million Rs yearly can be saved). The disposal of flyash,
which gobbles up the precious large tracts of land, can be restricted.

The only alternative for elimination of flyash based pollution is its full
utilization in the manufacturing of the building materials.

Advantages of flyash bricks over clay bricks:

1) Growing cold crushing strength

2) No efflorescence
3) Compact construction & Consistent quality
4) Better thermal insulation properties
5) Availability through out the year.
6) Better shape & finish
7) Rationalization of Mortar With optional need of Plaster.
Constraints need to be removed for large scale utilization of flyash

Absence of fair co-operation by the user in Public sector/Government

agencies for promotion of flyash brick in their own construction.

Lack of awareness among general public towards flyash based products.

Need to transport flyash over long distance for use, escalates the cost of
the finished product.

Support measures required for promotion of flyash bricks

There is a need to advertise the qualities of Eco-Friendly flyash based

products as it has been done in the case of banning the Polybags.

Like other states some fiscal benefits should be provided to attract the
entrepreneurs as well as the users.

Excise/sales tax should be exempted for initial five years, as it has been
guidelined by The M.o.e.& F in their letter dated 27.05.1996.

An early approval of flyash based manufacturing unit through a single

window facility should be granted.

Power should be given to those units, manufacturing flyash-based

products, on concessional terms.

Financial assistance from governmental institutions at subsidized rates

of interest should be made available.
An urgent needs to set up a committee to play the role of nodal agency
with following objectives.

a) To handle the problems faced by the manufacturers and users of

flyash based products.
b) To develop well planned programs for proper management of flyash.
c) To enhance the use of flyash bricks in various building activities.
d) To develop other uses of flyash.

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