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)
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