Detailed Project Report (DPR) on Silicon from Rice Husk (Production Rate – 30 TPD)

SILICON FROM RICE HUSK (PRODUCTION RATE – 30 TPD) 

[EIRI/EDPR/4686] J.C.: 2903XL

Silicon is a metalloid, with the properties of both metals and non-metals. Its greatest quality is probably its ability to conduct electricity, especially at high temperatures.

Silicon is a chemical element. It is a hard, brittle crystalline solid with a blue-grey metallic luster, and is a tetravalent metalloid and semiconductor.

It is relatively unreactive. Its oxides form a family of anions known as silicates. Its melting and boiling points of 1414 °C and 3265 °C, respectively.

Silicon is the eighth most common element in the universe by mass, but very rarely occurs as the pure element in the Earth's crust.

It is widely distributed in space in cosmic dusts, planetoids, and planets as various forms of silicon dioxide (silica) or silicates.

Most silicon is used commercially without being separated, often with very little processing of the natural minerals.

On a weight basis, the abundance of silicon in the crust of Earth is exceeded only by oxygen. Estimates of the cosmic abundance of other elements often are cited in terms of the number of their atoms per 106 atoms of silicon. Only hydrogen, helium, oxygen, neon, nitrogen, and carbon exceed silicon in cosmic abundance. Silicon is believed to be a cosmic product of alpha-particle absorption, at a temperature of about 109 K, by the nuclei of carbon-12, oxygen-16, and neon-20. The energy binding the particles that form the nucleus of silicon is about 8.4 million electron volts (MeV) per nucleon (proton or neutron). Compared with the maximum of about 8.7 million electron volts for the nucleus of iron, almost twice as massive as that of silicon, this figure indicates the relative stability of the silicon nucleus.

Cycling of silica in the marine environment. Silicon commonly occurs in nature as silicon dioxide (SiO2), also called silica. It cycles through the marine environment, entering primarily through riverine runoff. Silica is removed from the ocean by organisms such as diatoms and radiolarians that use an amorphous form of silica in their cell walls. After they die, their skeletons settle through the water column, and the silica redissolves. A small number reach the ocean floor, where they either remain, forming a siliceous ooze, or dissolve and are returned to the photic zone by upwelling.

Pure silicon is too reactive to be found in nature, but it is found in practically all rocks as well as in sand, clays, and soils, combined either with oxygen as silica (SiO2, silicon dioxide) or with oxygen and other elements (e.g., aluminum, magnesium, calcium, sodium, potassium, or iron) as silicates.

In compounds, silicon dioxide occurs both in crystalline minerals and amorphous or seemingly amorphous minerals in all land areas. The natural silicates are characterized by their abundance, wide distribution, and structural and compositional complexities.

COST ESTIMATION

Plant Capacity            30 MT/Day

Land & Building (7860 sq.mt.)    Rs. 7.43 Cr

Plant & Machinery                    Rs. 21.75 Cr

Working Capital for 0.5 Months    Rs. 5.93 Cr

Total Capital Investment          Rs. 36.02 Cr

Rate of Return                          22%

Break Even Point                      65%

CONTENTS

INTRODUCTION

PROPERTIES

USES

POLYMERS OF SILICON

SILANES

SILICIDES

SILICA

HALIDES

SILICATE MINERALS

SILICIC ACIDS

MARKET OVERVIEW

SILICONE MARKET TRENDS

INCREASING USAGE IN INDUSTRIAL PROCESSES

SILICON MARKET DYNAMICS

SILICON MARKET SEGMENTATION

SILICON MARKET BY PRODUCT

SILICON MARKET BY APPLICATION

ASIA-PACIFIC REGION IS EXPECTED TO DOMINATE THE MARKET

SILICON MARKET PLAYERS

BIS SPECIFICATION

SILICON ESTIMATION

PROCESS CHEMISTRY

RICE HUSK TO SILICA

DIGESTION

PRECIPITATION

REGENERATION

CALCINATION AND SLAKING

TYPICAL PROPERTIES OF SILICA

SILICA TO SILICON

RAW MATERIAL

COMPOSITION OF RICE HUSK

FORMULATION

RAW MATERIALS SUPPLIER

SUPPLIERS OF RAW MATERIALS (GLOBAL)

SUPPLIERS OF RAW MATERIALS (INDIA)

CAUSTIC SODA

SODIUM HYDROXIDE

CALCIUM HYDROXIDE

CARBON DIOXIDE GAS

PACKAGING MATERIALS (HDPE BAGS)

MANUFACTURING PROCESS STEPS

THE SILICA PRECIPITATION STEPS ARE MENTIONED BELOW.

DIGESTION

PRECIPITATION

REGENERATION

PROCESS FLOW

REDUCTION PROCESS

PROCESS FLOW

QUALITY CONTROL

BYPRODUCTS/WASTE

TECHNOLOGY SUPPLIER

ENGINEERING DESIGN CONSIDERATIONS

PROCESS CONTROL

PLANT & MACHINERY SUPPLIERS

COMPLETE PLANT AND MACHINERY

SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)

SUPPLIERS OF PLANT AND MACHINERIES (INDIA)

COMPLETE PLANT SUPPLIERS

MUFFLE FURNACE

FILTER PRESS

BOILER

INDUSTRIAL DRYERS

STORAGE VESSEL

LABORATORY EQUIPMENTS

MATERIAL HANDLING EQUIPMENTS

INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

PACKAGING MACHINE

HORIZONTAL PLATE FILTER PRESS (SPARKLER FILTERS)

ELECTRIC ARC FURNACE

ELECTRICAL & POWER TRANSFORMERS

ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS

EFFLUENT TREATMENT PLANT

INDUSTRIAL WEIGHING SCALE

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

PROJECT IMPLEMENTATION SCHEDULE

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

CONCLUSIONS

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)