Detailed Project Report on extracting silica from rice husk ash

EXTRACTING SILICA FROM RICE HUSK ASH
[CODE NO.3694]  

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            2 Ton/Day       
Land & Building (2000 sq.mt.)      Rs. 2.17 Cr         
Plant & Machinery                      Rs. 1.50 Cr     
Working Capital for 2 Months     Rs. 59 Lac
Total Capital Investment              Rs. 4.41 Cr
Rate of Return            21%                   
Break Even Point             62%            
         
           
 
INTRODUCTION    
RICE HUSK    
USES AND APPLICATION OF PRECIPITATED SILICA    
IMPORTANT APPLICATION SECTOR    
OTHER SECTORS    
APPLICATIONS    
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    
PRINTING INK:    
SALT:    
COATINGS:    
FIRE EXTINGUISHING POWDERS:    
ADVANTAGE OF RICE HUSK FOR PRECIPITATED SILICA    
SILICA IN RICE HUSK    
SPECIFICATION OF PRECIPITATED SILICA    
IS SPECIFICATION    
OVERVIEW OF PRECIPITATED SILICA IN INDIA    
MARKET SURVEY    
PATTERN OF REGION WISE GLOBAL DEMAND    
GLOBAL DEMAND SUPPLY SCENARIO    
PATTERN OF CONSUMPTION    
COUNTRY WISE EXPORTS OF PRECIPITATED SILICON    
KEY MARKET DEVELOPMENTS    
TABLE-2    
GLOBAL SUPPLY AND EXPANSIONS    
US DEMAND    
PRECIPITATED SILICA TO REMAIN LARGEST SEGMENT    
SPECIALTY SILICA    
FUMED SILICA    
SILICA GEL    
FUTURE OUTLOOK    
SPECIALTY SILICAS IN ASIA    
RAPID GROWTH OF CONSUMPTION    
INDIAN INSTALLED CAPACITY OF PRECIPITATED SILICA    
CONSOLIDATED DEMAND FOR PRECIPITATED SILICA    
PATTERN OF CONSUMPTION    
GROWTH RATE    
GLOBAL MARKET POSITION OF PRECIPITATED SILICA    
MANUFACTURERS/SUPPLIERS OF PRECIPITATED SILICA    
MANUFACTURING PROCESS    
CALCULATION:    
DIGESTION    
PRECIPITATION    
REGENERATION    
TYPICAL PROPERTIES OF PRECIPITATED SILICA    
EXPERIMENTAL WORK & RESULTS    
DIGESTION    
PRECIPITATION    
SALIENT FEATURES OF THE TECHNOLOGY    
NOVEL PROCESS FOR SILICA PRECIPITATION    
A. DIGESTION:    
DIGESTION:    
PRECIPITATION:    
PRODUCTION OF PURE SILICA FROM RICE HUSK ASH WITH PARAMETER    
PROCESS FLOW DIAGRAM    
EXTRACTING AMORPHOUS SILICA FROM RICE HUSK    
ASSOCIATED RECOVERIES    
GENERAL MATERIAL BALANCE    
RESULTS    
PROCESSING DETAILS OF PRECIPITATED SILICA    
USING RICE HUSK ASH    
DIGESTION    
PRECIPITATION    
REGENERATION    
CALCINATION AND SLAKING    
DIGESTION    
PRECIPITATION    
THE TWO MAIN REQUIREMENTS OR CONTROLLING FACTORS
   FOR THE SILICA PRODUCED ARE    
1. SURFACE AREA    
2. TAP DENSITY    
REGENERATION    
CALCINATION AND SLAKING    
ALTERNATIVE PROCESS TO MANUFACTURE PRECIPITATED SILICA    
PROCESS DESCRIPTION    
THE REACTION IS AS FOLLOWS:    
MATERIAL SAFETY DATA SHEET OF DRY PRECIPITATED SILICA    
HAZARDS IDENTIFICATION    
POTENTIAL HEALTH EFFECTS    
COMPOSITION/INFORMATION ON INGREDIENTS    
FIRST AID MEASURES    
FIRE-FIGHTING MEASURES    
ACCIDENTAL RELEASE MEASURES    
HANDLING AND STORAGE    
EXPOSURE CONTROLS/PERSONAL PROTECTION    
PERSONAL PROTECTIVE EQUIPMENT    
RESPIRATORY PROTECTION    
PHYSICAL AND CHEMICAL PROPERTIES    
A REVIEW STUDY OF PRECIPITATED SILICA    
HISTORY OF CONTRIBUTION/BACKGROUND    
SUPPLIERS OF PLANT AND MACHINERIES    
COMPLETE PLANT SUPPLIERS    
MUFFLE FURNACE    
FILTER PRESS    
MINI BOILER    
INDUSTRIAL DRYERS    
STORAGE VESSEL    
LABORATORY EQUIPMENTS    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS    
PACKAGING MACHINE    
HORIZONTAL PLATE FILTER PRESS (SPARKLER FILTERS)    
SUPPLIERS OF RAW MATERIALS    
RICE HUSK    
CAUSTIC SODA    
SODIUM HYDROXIDE    
CALCIUM HYDROXIDE    
CARBON DIOXIDE GAS    
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)