Industry Overview
Silica (SiO2) is a valuable inorganic multipurpose chemical compound that occurs in gel, crystalline, and amorphous forms. Conventional silica manufacturing can be energy intensive, with processes such as the reaction of sand with soda ash requiring temperatures of about 1500ºC. This project describes an alternative chemical process for producing precipitated silica using rice husk ash as the raw material.
Rice husk ash is a silica-rich agricultural residue, with silica content reported at about 90–98% after complete combustion. Rice husk is widely used as boiler fuel and power-generation fuel, generating ash that can create disposal, pollution, and health-related problems around rice mills. The proposed process converts this waste material into a valuable silica product while also enabling recovery of sodium sulphate from the effluent wash water. The sodium sulphate can be recovered through evaporation, crystallization, filtration, and drying.
The process also provides an opportunity to utilize residue ash for brick manufacturing, where retained sodium silicate can act as a binder with suitable ingredients. Rice husk is abundantly available in rice-producing countries, and its high silica content makes rice husk ash an economically attractive source for silica extraction. The project covers raw materials, product applications, specifications, manufacturing processes, alternative extraction methods, process calculations, plant and machinery requirements, technology suppliers, and related project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 5 Ton/Day |
| Land & Building (2000 sq.mt.) | Rs. 1.14 Cr |
| Plant & Machinery | Rs. 3.00 Cr |
| Working Capital for 2 Months | Rs. 1.15 Cr |
| Total Capital Investment | Rs. 5.47 Cr |
| Rate of Return | 33% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- RICE HUSK
- CHEMICAL COMPOSITION OF RHA BEFORE AND AFTER BURNING OUT AT700°C FOR 6 H
- RAW MATERIALS
- COMPOSITION OF RICE HUSK ASH
- PRECIPITATED SILICA END-USE APPLICATIONS
- USES AND APPLICATION OF PRECIPITATED SILICA
- IMPORTANT APPLICATION SECTOR
- OTHER SECTORS
- APPLICATIONS
- 1. ADHESIVE:
- 2. CHAPPALS:
- 3. CONVEYOR BELT & TRANSMISSION BELT:
- 4. PVC SHEETS:
- 5. RAILWAY PADS:
- 6. RICE ROLLERS AND RUBBER ROLLERS:
- 7. RUBBER PRODUCTS AND RUBBER HOSES:
- 8. SILICON TUBES:
- PRECIPITATED SILICA IS USED IN SILICON RUBBER FOR FOLLOWING REASONS:
- 9. RUBBER AND SOLID TYRES:
- 10. TEXTILE COTS AND APRONS:
- NON RUBBER GRADE PRECIPITATED SILICA
- APPLICATIONS
- PESTICIDES:
- PRINTING INK:
- TOOTH PASTE AND TOOTH POWDER:
- SALT:
- COATINGS:
- FIRE EXTINGUISHING POWDERS:
- ADVANTAGE OF RICE HUSK FOR PRECIPITATED SILICA
- SILICA IN RICE HUSK
- SPECIFICATION OF PRECIPITATED SILICA
- IS SPECIFICATION
- PROPERTIES OF RICE HUSK
- A. PROPERTIES OF RAW MATERIAL
- B. COMPOSITION OF RICE HUS
- C. COMPOSITION OF RICE HUSK ASH
- MARKET OVERVIEW OF PRECIPITATED SILICA
- KEY MARKET TRENDS
- INCREASING DEMAND FROM THE BUILDING AND CONSTRUCTION INDUSTRY
- THE ASIA-PACIFIC REGION IS EXPECTED TO DOMINATE THE MARKET
- INDIAN PRECIPITATED SILICA MARKET
- • LOWER ENVIRONMENTAL IMPACT AND EASY ACCESS OF RAW MATERIAL (RICE HUSK ASH)
- • SURGING DEMAND FROM END USE INDUSTRIES
- • PRESENCE OF SUBSTITUTES AND HARMFUL EFFECTS OF PRECIPITATED SILICA
- MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM RICE HUSK ASH (INDIAN INSTITUTE OF SCIENCE PRECIPITATED SILICA TECHNOLOGY) CGPL PROCESS
- DIGESTION
- PRECIPITATION
- REGENERATION
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS IN DETAILS
- CALCULATION:
- 6.4 TON RICE HUSK-> 1.6 TON RHA->1 TON SILICA
- FIGURE: PHOTOGRAPHS OF (A) RICE HUSK (B) RICE HUSK ASH (C) RICE HUSK SILICA POWDER
- FIGURE 1 FLOW CHART SHOWING THE PROCESS OF PRECIPITATED SILICA FROM RICE HUSK ASH
- DIGESTION
- PRECIPITATION
- REGENERATION
- FIGURE 2 SHOWS A PHOTOGRAPH OF THE PILOT PLANT FOR THIS PROCESS.
- TYPICAL PROPERTIES OF PRECIPITATED SILICA
- PROCESS FOR SILICA PRECIPITATION IN DETAILS
- A. DIGESTION:
- DIGESTION:
- ENERGY
- PRECIPITATION:
- ENERGY
- CONVENTIONAL PROCESS OF EXTRACTION OF SILICA FROM RICE HUSK ASH
- PRECIPITATED SILICA USING RICE HUSK ASH
- 4.1 DIGESTION
- 4.2 PRECIPITATION
- 4.3 REGENERATION
- 4.4 CALCINATION AND SLAKING
- 4.1 DIGESTION
- 4.2 PRECIPITATION
- 1. SURFACE AREA
- 2. TAP DENSITY
- 4.3 REGENERATION
- 4.4 CALCINATION AND SLAKING
- TYPICAL PROPERTIES OF SILICA PRECIPITATED
- EXTRACTION METHOD OF SILICA
- THE REACTION IS:
- THE REACTION IS:
- MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM QUART SAND
- STEP 1: PRECIPITATION
- STEP 2: WASHING
- STEP 3: DRYING
- STEP 4: FINISHING AND PACKAGING
- TYPICAL SILICA MANUFACTURING PROCESS
- ALTERNATE PROCESS OF SILICA MANUFACTURE
- A. CONVENTIONAL
- B. RICE HUSK, SUPERHEATED STEAM
- C. RICE HUSK, HF, NH3
- D. PROPOSED PROCESS
- B. PROCESS DESCRIPTION
- C. EXPERIMENTAL PROCEDURE
- EXTRACTION OF SILICA FROM RH/RHA
- COMBUSTION METHOD
- CHEMICAL METHOD
- EXTRACTION METHOD OF SILICA FROM RHA
- TECHNOLOGY SUPPLIERS FOR PRECIPITATED SILICA FROM RICE HUSK
- COMPLETE PLANT AND MACHINERY SUPPLIERS
- SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
- SUPPLIERS OF PLANT AND MACHINERIES
- COMPLETE PLANT SUPPLIERS
- SUPPLIERS OF MUFFLE FURNACE
- 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
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF SODIUM HYDROXIDE
- SUPPLIERS OF CALCIUM HYDROXIDE
- SUPPLIERS OF CARBON DIOXIDE GAS
- SUPPLIERS OF PACKAGING MATERIALS (HDPE BAGS)
Appendix
- APPENDIX – A:
- 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 from rice husk ash is produced by chemically extracting silica from the ash and subsequently precipitating it as a silica product. Rice husk ash is particularly suitable because it contains a high proportion of silica after controlled combustion. The process described in the project uses caustic soda during digestion, followed by precipitation and regeneration steps. This approach converts an agricultural residue into a commercially useful inorganic material while providing a potential route for utilizing ash that would otherwise require disposal.
Rice husk ash is considered suitable because it is abundantly available and contains a high concentration of silica. Rice husk is an agricultural residue generated during rice milling and is also used as fuel in boilers and power-generation applications. Its combustion produces ash with substantial silica content. Recovering silica from this ash can reduce waste-disposal requirements and create value from a low-value residue. The approach is therefore relevant to both resource recovery and the production of silica for industrial applications.
Precipitated silica is used across rubber, footwear, adhesives, coatings, printing inks, pesticides, oral-care products, and other industrial applications. The project specifically discusses uses in conveyor and transmission belts, PVC sheets, railway pads, rice and rubber rollers, rubber products and hoses, silicon tubes, tyres, textile cots and aprons, as well as non-rubber applications. Its suitability for different applications depends on properties such as surface area, particle characteristics, purity, structure, and other product specifications.
Silica is extracted from rice husk ash through a sequence of chemical processing steps that includes digestion, precipitation, regeneration, and associated separation operations. In the process described in the project, rice husk is first converted into ash containing concentrated silica. The ash is then treated with caustic soda to form a soluble silicate, after which silica is precipitated under controlled conditions. Washing, filtration, drying, and other finishing operations can then be applied to obtain the required silica product.
The major difference is the source of silica and the energy requirement of the processing route. The conventional process described in the report involves reacting sand with soda ash at about 1500ºC, whereas the proposed route uses rice husk ash and caustic soda through a chemical extraction and precipitation process. Rice husk ash is an agricultural residue with high silica content and can be available at relatively low cost. The proposed approach can therefore provide a route to silica recovery while addressing rice husk ash disposal and reducing reliance on high-temperature processing.
Equipment requirements depend on the selected process and plant configuration, but the project identifies several major equipment categories for a rice husk ash-based silica facility. These include muffle furnaces, filter presses, mini boilers, industrial dryers, storage vessels, laboratory equipment, material handling systems, instrumentation and process control equipment, and packaging machinery. A horizontal plate filter press is also specifically identified. The complete equipment arrangement should be finalized according to process design, material balance, product specifications, operating conditions, and required production capacity.
The process provides opportunities to recover sodium sulphate and utilize residual ash in addition to producing precipitated silica. Sodium sulphate is present in the effluent wash water obtained after washing precipitated silica and can be recovered through evaporation, crystallization, filtration, and drying. The report also describes using residue ash for brick manufacturing, with retained sodium silicate serving as a binder when suitable ingredients are incorporated. These recovery and utilization routes can improve overall resource efficiency and reduce the quantity of solid and liquid residues requiring disposal.
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