Detailed Project Report on Activated Carbon & Sodium Silicate from Paddy/Rice Husk
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ACTIVATED CARBON & SODIUM SILICATE FROM PADDY/RICE HUSK
[EIRI/EDPR/1082] J.C.: 9726
INTRODUCTION
Activated carbon is an inert material with a porous structure having property of absorbing organic compounds, dyes and colour bodies. It absorbs vapours and gases and gets as a catalyst or catalyst carrier in certain chemical reactions.
Activated carbon has an extensive surface area due to the porous structure, absorption quality of carbon depends upon the basic carbonaceous materials from which it is produced and the number of pores per unit area.
The activated carbon of gas and vapour absorbant type was developed during world war I as a means of defence against toxic gases used for military purposes. Since then, the application of this product has been gradually spreading to industrial activities.
Sodium silicates popularly called water glass or soluble glass are generally classified according to their SiO2, Na2O ratio, which varies between 0.5 and 4 and with various proportion of water. Based upon this ratio, a series of compounds are known ranging in properties from strongly alkaline to rarely neutral and from crystalline to glossy solids, to viscous liquids.
Sodium silicates are widely used in all types of detergents and cleaning compounds as active alkaline builders. Sodium silicate is important bonding agents in large variety of ceramics cement and refractory applications because of their heat stability and resistance to chemicals. Alkali metal silicate bonds are used in high-temperature ceramic products for the fabrication of electrical components. Soluble silicates are used widely for pellelizing, granulating and briquetting finely divided particles, eg. Ovens fertilizers and clays. Sodium silicates have been of interest for many years as bonding materials for foundary mold and care composition. The biggest use of sodium silicate is in soap and detergent industry followed by the use in adhesives for paper boards and corrugated containers Sodium Silicate is also used alone or together with many other materials as adhesive for plywood, wall board, floring and foils. Sodium silicate is also used in different places.
The important silicates are sodium Orthosilicate, Na4SiO4 Sodium metarilicate (Na2SiO3) and their hydrate and sodium sesquisilicate (Na6Si2O7) and their hydrates.
A variety of sodium silicates ranging in chemical composition from Na2O, 4 SiO2 is 2 Na2 O, SiO2 is produced by the fusion of silca or sand with soda ash. one of the most recent methods used for making Sodium Silicate is from Paddy Husk. Sodium silicate first came into existence when the sodium compound was red hot heated with the sand, after that other processes have also been evolved.
The commercial sodium silicates are amorphous vitreous or crystalline hydrated and anhydrous compounds (powder) and also liquid aquous with viscosity ranging from 0.5 to 600,000 poise at 20oC.
COST ESTIMATION
Plant Capacity 8.80 MT/Day
Land & Building (2000 sq.mt.) Rs. 1.79 Cr
Plant & Machinery Rs. 85.50 Lac
Working Capital for 2 Months Rs. 1.29 Cr
Total Capital Investment Rs. 4.26 Cr
Rate of Return 36%
Break Even Point 51%
CONTENTS
INTRODUCTION
ACTIVATED CARBON
PROPERTIES OF SODIUM SILICATE
PROPERTIES OF PRODUCTS
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
MARKET POSITION AND OTHER VALUABLE DETAILS
THREE MAIN FORMS OF ACTIVATED CARBON ARE:
HISTORY OF ACTIVATED CARBON
MANUFACTURING PROCESS
CHEMICAL ACTIVATION
ACTIVATED CARBON FROM COCONUT SHELL
ACTIVATED CARBON FROM COAL
TABLE-1: PROJECT COST OF A 10-TPD COCONUT SHELL BASED ACTIVATED CARBON PLANT
WASTE TYRE UTILISATION
REACTIVATION OF USED ACTIVATED CARBON
TABLE 2: TYPES OF ACTIVATED CARBON
PROPERTIES OF ACTIVATED CARBON
ADSORPTIVE CHARACTERISTICS
SURFACE AREA
PORE SIZE DISTRIBUTION
THE PORE SIZE IN ACTIVATED CARBONS CAN BE DIVIDED INTO.
PHYSICAL CHARACTERISTICS
TABLE 3: TYPICAL PROPERTIES OF ACTIVATED CARBON
PARTICLE SIZE DISTRIBUTION
APPLICATION
OTHER APPLICATIONS OF ACTIVATED CARBON INCLUDE:
TABLE 4: APPLICATIONS OF ACTIVATED CARBON
TABLE 5: APPLICATIONS IN THE CHEMICAL INDUSTRY
MERCURY REMOVAL
TABLE 6: EPA PROJECTED CONTROL TECHNOLOGIES
TABLE 7: MAJOR INTERNATIONAL MANUFACTURERS OF ACTIVATED CARBON
ARSENIC REMOVAL
MARKET TRENDS
POTENTIAL NEW MARKETS EMERGE
TABLE 8: MAJOR MANUFACTURERS OF ACTIVATED CARBON IN CHINA
NEW PROJECTS
TABLE 9: SOME INDIAN MANUFACTURERS OF ACTIVATED CARBON
TABLE 10: DEMAND FOR ACTIVATED CARBON IN INDIA BY END USE
TABLE 11: INDIAN DEMAND SUPPLY SCENARIO FOR ACTIVATED CARBON
TABLE 12: IMPORTS AND EXPORTS OF ACTIVATED CARBON FROM INDIA
TABLE 13: TOP-10 SUPPLIERS OF ACTIVATED CARBON INTO INDIA
TABLE 14: TOP-10 DESTINATIONS FOR EXPORTS OF ACTIVATED CARBON FROM INDIA
RISING PRICES
INDIAN SCENARIO
DEMAND SUPPLY TRENDS
CONSUMERS OF ACTIVATED CARBON
USES & APPLICATIONS
ACTIVATED CARBON:-
3. USES DEPENDING UPON ITS CHEMICAL PROPERTIES:
BUREAU OF INDIAN STANDARDS SPECIFICATION
1. SCOPE:
2. TYPES:
REQUIREMENTS:
3.1 DESCRIPTION:
3. 3 ADDITIONAL REQUIREMENTS:
4. PACKING MARKING AND STORAGE:
PACKING:
MARKING:
4.3 STORAGE:
SODIUM SILICATE
ACTIVATED CARBON:
MANUFACTURING PROCESS OF ACTIVATED CARBON FROM RICE HUCK
RAW MATERIALS REQUIREMENTS
THE MAJOR STEPS INVOLVED IN THIS PROCESS ARE:
NEW RICE HUSK PROCESSING TECHNOLOGY
GREEN TECHNOLOGY
FEEDSTOCK
PREPARATION OF FEEDSTOCK
RICE HUSK PROCESSING PLANT:
COMBUSTION AND POWER GENERATION UNIT
LIQUID SODIUM SILICATE AND ACTIVATED CARBON PRODUCTION
PRECIPITATED SILICA PRODUCTION
MAIN APPLICATIONS OF THE PRODUCTS
PRECIPITATED SILICA:
TYPICAL PROPERTIES OF OUR PRODUCTS:
ACTIVATED CARBON:
LIQUID SODIUM SILCATES:
METHOD OF PRODUCING ACTIVE RICE HUSK ASH
METHOD OF PRODUCING AN ADSORBENT FROM RICE HULL ASH
PROCESS FOR PREPARING A SODIUM SILICATE FROM RICE HULL ASH
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
EXAMPLE 6
EXAMPLE 7
EXAMPLE 8
EXAMPLE 9
EXAMPLE 10
EXAMPLE 11
EXAMPLE 12
EXAMPLE 13
EXAMPLE 14
EXAMPLE 15
MANUFACTURE OF SODIUM SILICATE AND ACTIVATED CARBON
FLOW SHEET FOR MANUFACTURING ACTIVATED CARBON
PLANT LAY OUT FOR MANUFACTURE OF ACTIVATED CARBON FROM RICE HUSK
PRESENT MANUFACTURERS ACTIVATED CARBON
SODIUM SILICATE
SUPPLIERS OF PLANT AND EQUIPMENTS
ROTARY KILNS
VIBRATING SCREENS
FILTER PRESS
TRAY DRYER
PULVERIZERS
PELLETIZING MACHINE
BUCKET ELEVATOR
BOILERS
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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