Ultra Pure Silicon from Rice Husk (Capacity: 500 kg/day)

ULTRA PURE SILICON FROM RICE HUSK

[EIRI/EDPR/4665] J.C. 2882XL

Rice husk is one of the highest produced agricultural process residues. Almost 1.2×108 tons of rice husk is generated across the globe. This huge amount of waste is an environmental nuisance. Rice husk is traditionally utilized as a fertilizer additive, as fuel and in landfill or paving applications.

India produces about 25 million tonnes of rice husk each year. When burnt, this rise husk generates ash which is a great environmental problem damaging our surroundings and land.

The rice plant absorbs silica in the form of silicic acid from the soil during its life cycle. This silica accumulates round the cellulose micro compartments and naturally exists in the form of nano particles, particles which do not permit microorganisms to enter the seed but which allow air and other gases to go in and come out. Rice husk is a natural reservoir for nano structured silica and its derivatives.  These silica nano particles can also be processed directly from rice husks. Silica obtained in this way is relatively pure and accounts for as much as 20% of the dry weight of the Rice husk. Rice husk ash also contains 60% to 80% amorphous silica which has wide spread applications in various industry. Carbon and sodium carbonate may also be gainfully extracted.

Extraction plants for batch processing of Silica are indigenously available in India. It is estimated that one tonne of paddy milled, generates 200 kg. of husk, 200 kg husk gives 50 kg Ash and the ash contains 60 to 80% silica. This would mean that about 40 kg of silica could be extracted per tonne of paddy. There are other estimates that suggest that for every 1000 Kg. of paddy milled, about 250 kg (28%) of husk is produced and when this husk is burnt in the boilers, about 70 kg (25%) of rice husk ash is generated that contains about 60 Kg silica (85-90%).

Ash generated from the combustion of rice husk for cogeneration can be reused to extract silica.

COST ESTIMATION

Plant Capacity            500 Kg./Day  

Land & Building (6000 sq.mt.)    Rs. 2.80 Cr    

Plant & Machinery                    Rs. 3.85 Cr 

Working Capital for 2 Months    Rs. 93.67 Lac 

Total Capital Investment          Rs. 7.92 Cr 

Rate of Return                          30%

Break Even Point                      59%

CONTENTS

INTRODUCTION

USES OF SILICON

PROPERTIES OF SILICON

FIGURE: DIAMOND CUBIC LATTICE OF CRYSTALLINE SILICON

FIGURE: DIAMOND CUBIC LATTICE OF CRYSTALLINE SILICON WITH INTERATOMIC SITES

FIGURE: ENERGY BAND OF CRYSTALLINE SILICON

PHYSICAL

CHEMICAL PROPERTIES

THERMAL AND MECHANICAL PROPERTIES OF SILICON

CHARACTERISTICS AND AVAILABILITY OF RICE HUSK

TABLE: TYPICAL PROXIMATE ANALYSIS OF RICE HUSKS

SILICON FROM RICE HUSK

MARKET OVERVIEW OF SILICON

MARKET DRIVERS

MARKET RESTRAINTS

MARKET OPPORTUNITIES

SILICON MARKET DYNAMICS

SILICON MARKET INSIGHTS

ASIA-PACIFIC HOLDS THE LARGEST SHARE OF THE GLOBAL SILICON MARKET

SILICON MARKET PLAYERS

B.I.S. SPECIFICATION

PRESENT MANUFACTURERS & DEALERS OF SILICON

MANUFACTURING PROCESS

PROCESS FLOW DIAGRAM

FLOW DIAGRAM

SLICON MANUFACTURING TECHNOLOGIES

PRODUCTION OF METALLURGICAL GRADE SILICON

TABLE: IMPURITIES IN METALLURGICAL GRADE SILICON

FIGURE: SCHEMATICS OF METALLURGICAL GRADE SILICON PRODUCTION PROCESS

PRODUCTION OF ELECTRONIC GRADE SILICON (EG-SI)

FIGURE: SCHEMATICS OF (A) SIEMENS REACTOR AND (B) CZOCHRALSKI CRYSTAL PULLER

SILICON PURIFICATION TECHNIQUE

SUPPLIERS OF RAW MATERIALS

ACTIVATED CARBON

HYDROCHLORIC ACID

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

FURNACES

REFRIGERATION PLANTS

DISTILLATION PLANT

SEPARATORS

STORAGE TANK

ESCALATORS

ELEVATORS, ESCALATORS, ROPEWAYS & RELATED PRODUCTS

STEAM BOILERS

GENERATOR SET

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)