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)
