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    Silica produced from Rice Husk Ash RHA (Capacity: 20 MT/Day) {Plant Machinery INR 8.50 Crores approx}

    Silica produced from Rice Husk Ash RHA (Capacity: 20 MT/Day) {Plant Machinery INR 8.50 Crores approx}
    Silica produced from Rice Husk Ash RHA (Capacity: 20 MT/Day) {Plant Machinery INR 8.50 Crores approx}
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      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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