Silica Recovery from Rice Husk Ash (Production Rate - 30000 TPA)

SILICA RECOVERY FROM RICE HUSK ASH (PRODUCTION RATE - 30000 TPA) 

[EIRI/EDPR/4764] J.C.: 2984XL

INTRODUCTION

Silica (SiO2) is one of the valuable inorganic multipurpose chemical compounds. It can exist in gel, crystalline and amorphous forms. It is the most abandon material on the earth’s crust. However, manufacture of pure silica is energy intensive. A variety of industrial process, involving conventional raw materials require high furnace temperatures (more than 700 degree C). In our Project, a simple chemical process is described which uses a non-conventional raw material rice husk ash for extraction of silica. Rice Husk ash is one of the most silica rich raw materials containing about 90-98% silica (after complete combustion) among the family of other agro-wastes. Rice husk is a popular boiler fuel and the ash generated usually creates disposal problems. The chemical process discussed not only provides a solution for waste disposal but also recovers a valuable silica product, together with certain useful associate recoveries. The other associate recovery is sodium sulphate. Effluent wash water obtained after washing precipitated silica (wet impure silica) contains sodium sulphate. By evaporation of water in multiple effect evaporators, followed by crystallization, filtration and drying, crystals of sodium sulphate are obtained. The residue ash in sodium silica production can be utilized for making good quality bricks. Retained sodium silicate in residue ash acts as a binder and with incorporation of suitable ingredients high quality bricks can be manufactured. From rough estimation the production of paddy in the country about twenty five million tons of rice husk is obtained from rice mills. This is usually burnt resulting in mounts of ash in and around the mills, causing major health problem and pollution. Using rice husk as the raw material two million tons of pure high-grade silica can be produced to meet the high demand of various industries that are using it. The main states with large number of rice mills are Andhra Pradesh, Tamil Nadu, Karnataka, and Kerala etc.

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. Process is 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            100 MT/Day

Land & Building    Rs. 19.26 Cr

Plant & Machinery                    Rs. 36.13 Cr

Working Capital for 0.5 Months    Rs. 6.17 Cr

Total Capital Investment          Rs. 63.58 Cr

Rate of Return                          43%

Break Even Point                      44%

CONTENTS

INTRODUCTION

RICE HUSK

PROPERTIES

PRECIPITATED SILICA

USES/APPLICATIONS

IMPORTANT APPLICATION SECTOR

APPLICATIONS

ADHESIVE

CHAPPALS

CONVEYOR BELT & TRANSMISSION BELT:

PVC SHEETS

RAILWAY PADS

PRECIPITATED SILICA IS USED FOR THE FOLLOWING REASONS IN RAILWAY PADS:

RICE ROLLERS AND RUBBER ROLLERS

PRECIPITATED SILICA IS USED IN RUBBER ROLLERS AND RICE ROLLERS FOR FOLLOWING REASONS:

RUBBER PRODUCTS AND RUBBER HOSES

PRECIPITATED SILICA IS USED IN SILICON RUBBER FOR FOLLOWING REASONS:

RUBBER AND SOLID TYRES

TEXTILE COTS AND APRONS

ADVANTAGES

MARKET OVERVIEW

APPLICATION INSIGHTS

REGIONAL INSIGHTS

KEY COMPANIES & MARKET SHARE INSIGHTS

SPECIFICATION – SILICA (PRECIPITATED)

RAW MATERIAL – RICE HUSK

RAW MATERIALS SUPPLIER

SUPPLIERS OF RAW MATERIALS (GLOBAL)

SUPPLIERS OF RAW MATERIALS (INDIA)

CAUSTIC SODA

SODIUM HYDROXIDE

CALCIUM HYDROXIDE

CARBON DIOXIDE GAS

PACKAGING MATERIALS (HDPE BAGS)

PROCESS CHEMISTRY

RICE HUSK TO SILICA

DIGESTION

PRECIPITATION

REGENERATION

CALCINATION AND SLAKING

TYPICAL PROPERTIES OF SILICA

FORMULATION

MANUFACTURING PROCESS STEPS

DIGESTION

PRECIPITATION

REGENERATION

PROCESS FLOW

TECHNOLOGY SUPPLIER

ENGINEERING DESIGN CONSIDERATIONS

PROCESS CONTROL

PLANT & MACHINERY SUPPLIERS

COMPLETE PLANT AND MACHINERY

SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)

SUPPLIERS OF PLANT AND MACHINERIES (INDIA)

COMPLETE PLANT SUPPLIERS

MUFFLE FURNACE

FILTER PRESS

BOILER

INDUSTRIAL DRYERS

STORAGE VESSEL

LABORATORY EQUIPMENTS

MATERIAL HANDLING EQUIPMENTS

INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

PACKAGING MACHINE

HORIZONTAL PLATE FILTER PRESS (SPARKLER FILTERS)

ELECTRIC ARC FURNACE

ELECTRICAL & POWER TRANSFORMERS

ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS

COOLING TOWERS

EFFLUENT TREATMENT PLANT

INDUSTRIAL WEIGHING SCALE

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

ANNUAL PRODUCTION: 30000 TPA

PROJECT IMPLEMENTATION SCHEDULE

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PRELIMINARY PLANT LAYOUT

CONCLUSIONS

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)