silica from rice husk ash 20 mt/day

SILICA FROM RICE HUSK ASH 20 MT/Day  

 [CODE NO.4460] 

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.

 COST ESTIMATION

Plant Cpacity                            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%

• INTRODUCTION
  
• RICE HUSK
• CHEMICAL COMPOSITION OF RHA BEFORE AND AFTER BURNING OUT AT700°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)