SILICA FROM RICE HUSK ASH

[EIRI/EDPR/4460]

The conventional process of manufacturing silica is the reaction of sand with soda ash at about 1500ºC. In our project, a new method of manufacturing silica by reacting rice husk ash with caustic soda is developed.

In Advantage of using rice husk as raw material for precipitated silica are superior and cost effective compared to present technology of producing Silica from quartz. Starts from a raw material of little or no cost and value, which otherwise would cause environmental pollution. Processis energy efficient and also consumes much lower energy compared to an alternative process involving fusion of selected quality of sand.

Rice husk or paddy husk - an agricultural residue is available abundantly in rice producing countries. India alone produces approximately 12 million tons of rice husk annually. Rice husk is generally not advocated as cattle feed because of low cellulose and other sugar contents in it. Furfural and rice bran oil are extracted from rice husk. Rice husk is used by industries as fuel in boilers and for power generation. Rick husk has a high ash content varying from 18-20%. Silica is the major constituent of rice husk ash. High silica (SiO2) content in rice husk ash is economically feasible to extract silica, which has wide market.

COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (6000 sq.mt.) Rs. 3.43 Cr

Plant & Machinery Rs. 8.50 Cr

Working Capital for 2 Months Rs. 2.36 Cr

Total Capital Investment Rs. 14.54 Cr

Rate of Return 26%

Break Even Point 58%

CONTENTS

INTRODUCTION

RICE HUSK

CHEMICAL COMPOSITION OF RHA BEFORE AND AFTER BURNING

OUT AT 700°C FOR 6 H

BENEFITS OF PRECIPITATED SILICA FROM RHA

RAW MATERIALS

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:

MARKET OVERVIEW OF PRECIPITATED SILICA

KEY TAKEAWAYS

INDIAN PRECIPITATED SILICA MARKET DRIVERS

LOWER ENVIRONMENTAL IMPACT AND EASY ACCESS OF RAW

MATERIAL (RICE HUSK ASH)

SURGING DEMAND FROM END USE INDUSTRIES

INDIAN PRECIPITATED SILICA MARKET CHALLENGES

PRESENCE OF SUBSTITUTES AND HARMFUL EFFECTS OF

PRECIPITATED SILICA

MARKET LANDSCAPE

GLOBAL MARKET OF PRECIPITATED SILICA

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

MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM RICE

HUSK ASH (INDIAN INSTITUTE OF SCIENCE PRECIPITATED SILICA

TECHNOLOGY) CGPL PROCESS

DIGESTION

PRECIPITATION

REGENERATION

PROCESS FLOW DIAGRAM

SEQUENCES IN SILICA MANUFACTURE

CALCULATION:

FIGURE: PHOTOGRAPHS OF (A) RICE HUSK (B) RICE HUSK ASH (C) RICE

HUSK SILICA POWDER

DIGESTION

PRECIPITATION

REGENERATION

TYPICAL PROPERTIES OF PRECIPITATED SILICA

PROCESS FOR SILICA PRECIPITATION IN DETAILS

A. DIGESTION:

DIGESTION:

ENERGY

PRECIPITATION:

ENERGY

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

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

TECHNICAL DETAILS OF SILICA MANUFACTURE

DETAILED DESCRIPTION OF THE PROCESS IS AS FOLLOWS:

1. THE PRODUCT FORMATION

2. THE PURITY PRODUCTS

TECHNOLOGY SUPPLIERS FOR PRECIPITATED SILICA FROM RICE HUSK

COMPLETE PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF PLANT AND MACHINERIES

COMPLETE PLANT SUPPLIERS

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 – 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)

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