Organization of production for the processing of ash and slag waste

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Organization of production for the processing of ash and slag waste
FINANCIAL INDICATORS of PROJECT
PROJECT COST
6503735 thousand tenge
IMPLEMENTATION DATE
2019-2027 year

Project Description

OBJECTIVE OF THE PROJECT

Organization of production for processing ash and slag waste in the city of Pavlodar.

It is proposed to organize the production of silicate bricks from sand, lime, ash and slag from the ash dumps of CHP based on the acquisition and installation of a technological line with a finished capacity of 100 million pcs. conditional brick.

Economic:

  • increase in GRP (KZT 3540 million);
  • increase in budget revenues resulting from the opening of a new production entity (488 million tenge per year);
  • production of domestic, competitive product.

Social:

  • job creation (241 people);
  • improvement of the welfare of workers and their families (average wage 110 thousand tenge);
  • growth of social and economic activity of the population.

Ecological:

  • Improvement of the regional ecological environment due to the reduction of ash dumps (500 million tons of ash and slag materials were accumulated in the Republic of Kazakhstan);
  • release of land occupied by ash dumps.
CURRENT SITUATION

The Pavlodar region imports bricks in the amount of $ 17.5 million, mainly from Russia for $ 12.5 million and China for $ 4.5 million.

PRODUCT CHARACTERISTICS

The main activity of the enterprise will be the manufacture of silicate bricks.

Standard silicate brick 250 * 120 * 65 mm, as well as 250 * 120 * 88, 250 * 120 * 138 incl. hollow and silicate tongue-and-groove wall materials according to GOST 379-95. Grade wall materials M100 – M300.

In the manufacture of silica brick material basis for 60% is ash.

Silicate brick with the addition of ash and fuel slag hardens in autoclaves at a pressure of saturated steam of 0.8-1.6 MPa. The recommended shutter speed is 4-8 hours. The resulting material is water and frost-resistant than ordinary silicate brick, has lower water absorption and water permeability values, better appearance.

CONSUMERS
  • organizations involved in the improvement of settlements
  • construction organizations
  • building trade organizations
  • individuals
PRODUCT PROMOTION
  • placement and publication of teasers and presentations in the guidebooks of investors;
  • use of modern Internet technologies for creating websites;
  • broadcasting advertising informational messages through media;
  • participation in industry exhibition campaigns to promote and become familiar with products
KEY FINANCIAL AND ECONOMIC INDICATORS

Investment stage of the project – 2019-2027;
CMP 2019-2020 (including commissioning), as well as commissioning;
The maximum capacity of the plant is 100 million units of conventional bricks. The design volume of production is 90 million units of conventional brick, taking into account the risks of equipment downtime and other force majeure and other factors;
The cost of the project is 6503735 thousand tenge (private and public investment);
Sales from 2020-2027: 28320 million tenge;
Net income from 2020-2027: 5184 million tenge;
Tax revenues to the budget: 488 718 thousand tenge per year;
Project IRR: 8%;
Payback period: 8 years;
Break-even level – 1 457 348 624 tenge (36 989 thousand units);
The unit cost of production – 40 tenge;
The number of employees – 241 (including workers – 209)
Annual revenue – 3 540 000 thousand tenge;
Product profitability – 47%
Return on sales – 18.3%.

COMPETITORS
  • Brick factory ESKOR Semey

The plant is equipped with Czech technological equipment under license from German manufacturers of brick products. Brick ceramic front one-and-a-half hollow M-100, M-125, M-150 Semey city

  • SILIKAT LLP

Production and sale of white and colored silicate bricks. The plant also produces lime and sand construction. Shipment is carried out by railway transport to any region of the republic or pickup Semey.

  • ARCHIPRESS

The plant produces and sells hyper-pressed facing bricks with a brand of strength from M-250, frost resistance F100. Pavlodar

PRODUCT COMPETITIVENESS

It is possible to make ash brick from ashes (both corpulent and with voids). Compared with ceramic and silicate bricks, it has lower thermal conductivity and cost. If you look at the technical and economic indicators of ash brick with voids and cellular concrete, which is now popular, it will turn out that with a lower density of concrete 1.4 – 2 times, the strength of a brick is 5 – 8 times higher. If ash and slag waste is used for the production of silicate bricks, lime consumption is reduced by 10–50%, and sand by 20–30%. This brick has a lower density than normal.
The advantage of a brick of a zilosilicate mixture of composition is lower than that of a usual average density (1700–1400 kg / m3 against 1900–2000 kg / m3). Using ashes of thermal power station, it is possible to receive a porous silicate brick with such properties: density 1250 – 1400 kg / m3; strength of 10 – 17.5 MPa, porosity of 27 – 28%, frost resistance 15 – 35 cycles. Its use allows to reduce the thickness of the outer walls by 20, and the mass – by 40% and significantly reduce heat consumption for heating buildings.

SWOT ANALYSIS

Strengths:
1. Meeting the internal needs of Pavlodar region and other regions in building materials.
2. Improving the environmental situation in the region.
3. Release of land from ash dumps.
4. Tax revenues to the budget for the further development of the industry and “green” energy.
5. Creation of new jobs.

Weak sides:
1. High entry barriers, namely large investment in the project.
2. New production technology, lack of experience in this matter.
3. Lack of qualified personnel.
4. Lack of motivation CHP.
5. Lack of promising partnership agreements for sales.

Opportunities:
1. Organization of a full-scale project for the development of innovative products.
2. Obtaining state support on the terms of PPP (financing, preferences, tax benefits) and other state. programs.
3. Additional revenues from the sale of bricks and reducing the cost of organizing the functioning of ash dumps.
4. Reduction of payments for environmental payments.
5. Increase the value chain.

Threats:
1. Perhaps the introduction of any new government restrictions on the market.
2. Decrease in consumer demand.
3. New competitors may appear on the market due to faster and cheaper introduction of innovative technologies and expansion of production volumes.
4. Recession in the economy
5. Lack of coordination of interested state bodies and CHP for joint implementation of an integrated approach and processing of ash and slag waste.

Organization of production for the processing of ash and slag waste 0 Organization of production for the processing of ash and slag waste 1 Organization of production for the processing of ash and slag waste 2

Project Performance Indicators

SV
28320 million tenge
NP
5184 million tenge
IRR
8%
PP
8 years
BEP
1,457,348,624 tg (36,989 thousand units)
ROS
18,3%