PRECIPITATED SILICA PRODUCTION FROM RICE HUSK ASH (RHA) ACID PRECIPITATION PROCESS (H₂SO₄ / HCL ROUTE)
(EIRI/EDPR/4870)
Industry Overview
Precipitated silica (SiO2) is a versatile inorganic chemical available in gel, crystalline, and amorphous forms, with applications across the rubber, plastics, adhesives, personal care, food, pharmaceutical, and industrial sectors. Conventional silica production typically involves reacting sand with soda ash at temperatures of around 1500°C, making the process highly energy intensive. This project presents an alternative manufacturing route that utilizes rice husk ash (RHA), an agricultural by-product containing approximately 90–98% silica after complete combustion, as the primary raw material.
The process offers a practical solution for managing rice husk ash generated by rice mills while recovering high-purity silica through a comparatively energy-efficient chemical process using caustic soda. In addition to silica, the process enables recovery of sodium sulphate from the wash water through evaporation, crystallization, filtration, and drying. The remaining residue can also be utilized in the manufacture of quality bricks, improving overall resource utilization and reducing waste.
Rice husk is abundantly available in major rice-producing regions and has limited value as animal feed because of its low cellulose content. Its high silica concentration makes it an attractive raw material for silica production. The report highlights growing demand from rubber and non-rubber applications, including tires, shoe soles, PVC products, adhesives, food additives, toothpaste, cosmetics, filtration media, dehumidifying agents, and thermal insulation materials. It also notes projected growth in the Indian precipitated silica market, supported by expanding industrial applications, increasing demand from agrochemical and personal care sectors, technological developments such as nanotechnology, and government initiatives encouraging electric vehicle manufacturing, while acknowledging the temporary slowdown experienced during 2020–2021 due to the COVID-19 outbreak.
Cost Estimation
| Particular | Value |
|---|---|
| Rated Plant capacity | 10.00 MT/Day |
| Land & Building (6000 Sq.Mtr) | Rs. 4.37 Cr |
| Plant & Machinery | Rs. 3.26 Cr |
| Working Capital for 2 Month | Rs. 1.60 Cr |
| Total Capital Investment | Rs. 9.38 Cr |
| Rate of Return | 22% |
| Break Even Point | 58% |
Content Index
- INTRODUCTION
- BENEFITS OF PRECIPITATED SILICA FROM RHA
- RAW MATERIALS
- PRECIPITATED SILICA END-USE APPLICATIONS
- USES AND APPLICATION OF PRECIPITATED SILICA
- NON RUBBER GRADE PRECIPITATED SILICA
- MARKET OVERVIEW OF PRECIPITATED SILICA
- GLOBAL MARKET OF PRECIPITATED SILICA
- PROPERTIES OF RICE HUSK
- ALTERNATE PROCESS OF SILICA MANUFACTURE
- TECHNICAL DETAILS OF SILICA MANUFACTURE
- COMPLETE PLANT AND MACHINERY SUPPLIERS
- SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
- SUPPLIERS OF PLANT AND MACHINERIES
- SUPPLIERS OF FILTER PRESS
- SUPPLIERS OF MINI BOILER
- SUPPLIERS OF INDUSTRIAL DRYERS
- SUPPLIERS OF STORAGE VESSEL
- SUPPLIERS OF LABORATORY EQUIPMENTS
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
- SUPPLIERS OF PACKAGING MACHINE
- HORIZONTAL PLATE FILTER PRESS
- (SPARKLER FILTERS)
- SUPPLIERS OF RAW MATERIALS (GLOBAL)
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF RICE HUSK ASH
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF SODIUM HYDROXIDE
- SUPPLIERS OF CALCIUM HYDROXIDE
- SUPPLIERS OF CARBON DIOXIDE GAS
- SUPPLIERS OF PACKAGING MATERIALS (HDPE BAGS)
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Precipitated silica is a high-purity amorphous silica produced by chemically extracting silica from rice husk ash. Rice husk ash is rich in silica after complete combustion, making it an effective alternative to conventional silica raw materials. The process converts an agricultural waste into a valuable industrial product while reducing disposal problems and improving resource utilization.
Rice husk ash offers a cost-effective and energy-efficient source of silica. Unlike conventional production from sand, which requires very high furnace temperatures, the reported process uses a chemical extraction route. It also utilizes a low-value agricultural by-product, helping reduce environmental pollution while recovering commercially valuable materials.
Precipitated silica is widely used in rubber and non-rubber industries. Common applications include tires, shoe soles, silicone rubber, PVC products, adhesives, sealants, toothpaste, cosmetics, food products, pharmaceuticals, anti-caking agents, filtration, dehumidification, thermal insulation, and other specialty industrial products where reinforcement, adsorption, or flow improvement is required.
Yes, the process allows recovery of additional useful products. Sodium sulphate can be recovered from the process wash water through evaporation and crystallization. The remaining residue ash can also be utilized in brick manufacturing because retained sodium silicate acts as a binder when combined with suitable materials.
The rubber industry is the primary consumer, supported by several non-rubber sectors. Demand comes from manufacturers of tires, industrial rubber products, footwear, PVC materials, adhesives, food products, agrochemicals, personal care products, pharmaceuticals, paints, coatings, battery separators, and specialty chemical formulations.
The process converts agricultural waste into valuable industrial products while reducing pollution. Instead of allowing rice husk ash to accumulate around rice mills, it is used as a raw material for silica production. This approach minimizes waste disposal issues, promotes resource recovery, and improves overall sustainability by making productive use of an abundant agricultural residue.
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