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