PRECIPITATED SILICA PRODUCTION FROM RICE HUSK ASH (RHA) ACID PRECIPITATION PROCESS (H₂SO₄ / HCL ROUTE)

PRECIPITATED SILICA PRODUCTION FROM RICE HUSK ASH (RHA) ACID PRECIPITATION PROCESS (H₂SO₄ / HCL ROUTE)

 [EIRI/EDPR/4870] J.C.: 3091

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

Rated Plant capacity         =          10.00 MT/Day   

Land & Building (6000 Sq.Mtr)  Rs. 4.37  Cr    

Plant & Machinery                    Rs. 3.26  Cr 

Working Capital for 2 Month    Rs. 1.60   Cr 

Total Capital Investment          Rs. 9.38  Cr 

Rate of Return                          22%

Break Even Point                      58%

CONTENTS

INTRODUCTION

BENEFITS OF PRECIPITATED SILICA FROM RHA

RAW MATERIALS

PRECIPITATED SILICA END-USE APPLICATIONS

USES AND APPLICATION OF PRECIPITATED SILICA

NON RUBBER GRADE PRECIPITATED SILICA

MARKET OVERVIEW OF PRECIPITATED SILICA

GLOBAL MARKET OF PRECIPITATED SILICA

PROPERTIES OF RICE HUSK

ALTERNATE PROCESS OF SILICA MANUFACTURE

TECHNICAL DETAILS OF SILICA MANUFACTURE

COMPLETE PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)

SUPPLIERS OF PLANT AND MACHINERIES

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)