Industry Overview
Rice husk, also known as paddy husk, is an abundant agricultural residue generated in rice-producing countries. India alone produces approximately 12 million tons of rice husk annually. Due to its low cellulose and sugar content, rice husk is generally not advocated as cattle feed. It has several industrial applications, including use as boiler fuel and for power generation, while furfural and rice bran oil can also be extracted from rice husk.
Rice husk contains a high proportion of ash, generally ranging from 18–20%, with silica being its major constituent. The high silica (SiO2) content of rice husk ash makes the recovery and production of silica economically feasible. Precipitated silica produced from rice husk ash has applications across rubber products, tyres, conveyor and transmission belts, PVC sheets, railway pads, rollers, silicon rubber, printing inks, salt, coatings and fire-extinguishing powders. The project report covers the raw material characteristics, applications, market scenario, manufacturing processes, material balance, technology, safety requirements, plant and machinery, raw-material suppliers and project economics associated with precipitated silica production from rice husk ash.
Cost Estimation
| Particulars | Details |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Precipitated silica can be produced by recovering silica from rice husk ash through chemical processing and precipitation. Rice husk contains a substantial amount of silica, which remains concentrated in the ash after controlled processing. The report describes processes involving digestion, precipitation, regeneration, calcination and slaking. Process conditions influence important product characteristics such as surface area and tap density, which are relevant to the intended application and product specifications.
Rice husk is suitable because its ash contains silica as a major constituent. Rice husk is also an abundant agricultural residue in rice-producing regions, providing a potential raw-material source for silica recovery. The report notes that rice husk ash generally contains 18–20% ash and that its high silica content makes silica extraction economically feasible. Converting this residue into an industrial material can also provide an additional application for an agricultural by-product.
Precipitated silica is used in rubber, tyres, silicon rubber, conveyor belts, transmission belts and various other industrial products. The report also identifies applications in PVC sheets, railway pads, rice and rubber rollers, rubber hoses, silicon tubes, textile cots and aprons. Non-rubber applications covered include printing inks, salt, coatings and fire-extinguishing powders. The suitability of a particular silica grade depends on its physical and chemical properties and the requirements of the application.
The main stages described in the report include digestion, precipitation, regeneration, and calcination and slaking. Depending on the selected process route, rice husk ash is chemically processed to recover silica-containing material, followed by precipitation and subsequent treatment to achieve the required product characteristics. The report also discusses alternative manufacturing processes, material balance, process flow, experimental work and associated recoveries. Process control is important because properties such as surface area and tap density affect the resulting precipitated silica.
Equipment requirements depend on the selected manufacturing process and production scale. The report identifies equipment categories including muffle furnaces, filter presses, mini boilers, industrial dryers, storage vessels, laboratory equipment, material-handling equipment, instrumentation and process-control equipment, packaging machines and horizontal plate filter presses. Equipment selection should consider process requirements, material characteristics, product specifications, safety provisions and the desired operating capacity.
Rice husk is the principal agricultural raw material identified in the report, while several chemical and supporting materials are also listed. These include caustic soda, sodium hydroxide, calcium hydroxide and carbon dioxide gas. Packaging materials such as HDPE bags are also included among the listed requirements. The actual material requirements depend on the selected process route, product specifications, operating conditions and production system used for recovering and processing silica from rice husk ash.
Safety management should address chemical handling, dust exposure, storage, personal protective equipment and emergency response. The report includes a Material Safety Data Sheet section covering hazards identification, potential health effects, first aid, fire-fighting measures, accidental release measures, handling and storage, exposure controls and respiratory protection. Appropriate engineering controls, workplace procedures, protective equipment and process-specific safety measures should be established according to the chemicals, equipment and operating conditions used in the plant.
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