Detailed Project Report on precipitated silica from rice husk for 20 tpd by iisc/cgpp technology process

PRECIPITATED SILICA FROM RICE HUSK FOR 20 TPD BY IISC/CGPP TECHNOLOGY PROCESS [3736]

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. Rice is the seed of the monocot plants Oryza sativa (Asian rice) or Oryza glaberrima (African rice). It is normally grown as an annual plant, although in tropical areas it can survive as a perennial and can produce aratoon crop for up to 30 years. Since a large portion of maize crops are grown for purposes other than human consumption, rice is the most important grain with regard to human nutrition and caloric intake, providing more than one fifth of the calories consumed worldwide by the human species.

The rice plant can grow to 1–1.8 m (3.3–5.9 ft) tall, occasionally more depending on the variety and soil fertility. It has long, slender leaves 50–100 cm (20–39 in) long and 2–2.5 cm (0.79–0.98 in) broad. The small wind-pollinated flowers are produced in a branched arching to pendulous inflorescence 30–50 cm (12–20 in) long. The edible seed is a grain (caryopsis) 5–12 mm (0.20–0.47 in) long and 2–3 mm (0.079–0.12 in) thick. Rice is the staple food of over half the world's population. It is the predominant dietary energy source for 17 countries in Asia and the Pacific, 9 countries in North and South America and 8 countries in Africa. Rice provides 20% of the world’s dietary energy supply, while wheat supplies 19% and maize 5%. Rice husks are the hard protecting covering of grains of rice. Rice hulls are the coating for the seeds, or grains, of the rice plant. To protect the seed during the growing season, the hull forms from hard materials, including opaline silica and lignin. One practice, started in the seventeenth century, to separate the rice from hulls, it to put the whole rice into a pan and throw it into the air while the wind blows.

The hulls are blown away while the rice fell back into the pan. This happens because the hull isn't nearly as dense as the rice. These steps are known as winnowing. Later pestles and a simple machine called a rice pounder were developed to remove hulls. In 1885 the modern rice hulling machine was invented in Brazil. During the milling processes, the hulls are removed from the raw grain to reveal whole brown rice, which may then sometimes be milled further to remove the bran layer, resulting in white rice. Rice husk is a by-product of the rice milling industry. It is a unique crop residue with uniform size and high content of ash (14–25%). The silica content of the rice husk ash (RHA) can be as high as 90–98% . This husk can be used as a fertilizer in agriculture or as an additive for cement and concrete fabrication. Due to its high silicon content, rice husk has become a source for preparation of elementary silicon and a number of silicon compounds especially silica silicon carbide and silicon nitride . India is a major producer of rice and finding ways to put the husk to use is imminent.

The high silica content in the rice husk ash has attracted interest in discovering ways to use it commercially. Although silica occurs as a component of cells or cell walls in virtually all arial parts of the rice plant, it is most abundant in the husk. Owing to their small diameter, many technological applications, such as thermal insulators, composite fillers, etc., use ultrafine silica powders .We have investigated the possibility of producing high purity silicon from rice husk by purifying the rice husk silica followed by pelletizing and reduction in a modified electric arc furnace. The pelletizing was carried using carbon black as a reductant and sucrose as a binder.

COST ESTIMATION

Plant Capacity     20 MT/Day  
Land & Building (1.5 Acre)  Rs. 2.60 Cr.    
Plant & Machinery                    Rs. 8 Cr.
Working Capital for 1 Month   Rs. 1.88 Cr.
Total Capital Investment          Rs. 12.80 Cr.
Rate of Return                         34%
Break Even Point                     55%



INTRODUCTION    
RICE HUSK    
CHEMICAL COMPOSITION OF RHA BEFORE AND AFTER BURNING
OUT AT700°C FOR 6 H    
SILICA    
RAW MATERIALS    
COMPOSITION OF RICE HUSK ASH    
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:    
ADVANTAGE OF RICE HUSK FOR PRECIPITATED SILICA    
SILICA IN RICE HUSK    
SPECIFICATION OF PRECIPITATED SILICA    
IS SPECIFICATION    
MARKET OVERVIEW OF PRECIPITATED SILICA    
PATTERN OF REGION WISE GLOBAL DEMAND    
GLOBAL DEMAND SUPPLY SCENARIO    
PATTERN OF CONSUMPTION    
COUNTRY WISE EXPORTS OF PRECIPITATED SILICON    
KEY MARKET DEVELOPMENTS    
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    
U.S PRECIPITATED SILICA MARKET REVENUE, BY APPLICATION,
   2012 - 2022 (USD MILLION)    
GLOBAL DEMAND OF PRECIPITATED SILICA    
MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM RICE HUSK
ASH (INDIAN INSTITUTE OF SCIENCE PRECIPITATED SILICA TECHNOLOGY) CGPL PROCESS    
DIGESTION    
PRECIPITATION    
REGENERATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS IN DETAILS    
CALCULATION:    
6.4 TON RICE HUSK-> 1.6 TON RHA->1 TON SILICA    
FIGURE: PHOTOGRAPHS OF (A) RICE HUSK (B) RICE HUSK ASH (C)
   RICE HUSK SILICA POWDER    
FIGURE 1 FLOW CHART SHOWING THE PROCESS OF PRECIPITATED
   SILICA FROM RICE HUSK ASH    
DIGESTION    
PRECIPITATION    
REGENERATION    
FIGURE 2 SHOWS A PHOTOGRAPH OF THE PILOT PLANT FOR THIS PROCESS.    
TYPICAL PROPERTIES OF PRECIPITATED SILICA    
FIGURE 3 THE SEM PICTURE OF THE SILICA OBTAINED WITH THE PROCESS    
FIGURE: X-RAY DIFFRACTION PATTERN OF SILICA PRODUCED FROM RHA.    
FIGURE: FOURIER TRANSFORM INFRARED SPECTRA OF SILICA PRODUCED
  FROM RHA    
EXPERIMENTAL WORK & RESULTS    
DIGESTION    
PRECIPITATION    
SALIENT FEATURES OF THE TECHNOLOGY    
PROCESS FOR SILICA PRECIPITATION IN DETAILS    
A. DIGESTION:    
DIGESTION:    
PRECIPITATION:    
CONVENTIONAL PROCESS OF EXTRACTION OF SILICA FROM RICE HUSK ASH    
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    
EXTRACTION METHOD OF SILICA    
MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM QUART SAND    
STEP 1: PRECIPITATION    
STEP 2: WASHING    
STEP 3: DRYING    
STEP 4: FINISHING AND PACKAGING    
TYPICAL SILICA MANUFACTURING PROCESS    
OTHER PROCESS OF PRECIPITATED SILICA    
THE KIND OF PROCESS    
A. WET PROCESS    
1. ACIDIFICATION SILICATE    
DRY PROCESS    
1. THE USEFULNESS OF PRODUCTS    
THE PROCESS STAGES:    
1. THE PRODUCT FORMATION    
2. THE PURITY PRODUCTS    
ALTERNATIVE PROCESS TO MANUFACTURE PRECIPITATED SILICA    
PROCESS DESCRIPTION    
THE REACTION IS AS FOLLOWS:    
A REVIEW STUDY OF PRECIPITATED SILICA    
TABLE: A TYPICAL COMPOSITION OF RICE HUSK    
HISTORY OF CONTRIBUTION/BACKGROUND    
TECHNOLOGY SUPPLIERS FOR PRECIPITATED SILICA FROM RICE HUSK    
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)    
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 (GLOBAL)    
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)