Detailed Project Report (DPR) on silicone from rice husk

SILICONE FROM RICE HUSK [CODE NO.3655]

Worldwide concerns over energy related climate change coupled with spiraling cost of fossil fuels in recent years has increased interests in renewable energy alternatives. Although solar photovoltaic power generation is a proven technology, especially in the space industry, development of this technology to meet terrestrial energy demands has been limited. One of the issues that have limited the widespread use of solar photovoltaic power has been the high cost associated with the materials used in fabricating the solar cells. Currently silicon in both monocrystalline and polycrystalline form is the dominant semiconductor material used in the fabrication of most commercially available solar cells or modules, commanding over 90% of the market share of all PV technologies.

Metallurgical grade and electronic or semiconductor grade silicon are produced on commercial scale by the carbothermic and Siemens process respectively. Metallurgical grade silicon is typically 98-99.5% and contains high content of electro-active impurities such as B(5-70 ppm), P(5-100ppm), Al(3000-5000 ppm) and transition metals which are recognized to reduce the conversion efficiencies of p-n junction silicon solar cells and panels. Electronic grade silicon on the other hand which has total impurities less than one part per billion (< 1ppb) is too expensive for large scale production of solar cells. For fabrication of efficient silicon solar cells it is generally recognized the B and P levels have to be reduced to less than 1ppm each and with an overall silicon feedstock purity in the range of 5-7N.


COST ESTIMATION

Plant Capacity            5 MT/Day       
Land & Building (1500 sq.mt.)      Rs. 2.15 Cr         
Plant & Machinery                      Rs. 2.10 Cr     
Working Capital for 1 Month     Rs. 83 Lac
Total Capital Investment              Rs. 5.28 Cr
Rate of Return            20%                   
Break Even Point             63%                

       
INTRODUCTION    
USES OF SILICON    
PROPERTIES OF SILICON    
FIGURE: DIAMOND CUBIC LATTICE OF CRYSTALLINE SILICON    
FIGURE: DIAMOND CUBIC LATTICE OF CRYSTALLINE SILICON WITH INTERATOMIC SITES    
FIGURE: ENERGY BAND OF CRYSTALLINE SILICON    
FIGURE: FREE ENERGY OF FORMATION OF OXIDES OF ELEMENTS    
TABLE: THERMAL AND MECHANICAL PROPERTIES OF SILICON    
PROPERTIES    
CHEMICAL PROPERTIES    
CHARACTERISTICS AND AVAILABILITY OF RICE HUSKS    
TABLE. 1 TYPICAL PROXIMATE ANALYSIS OF RICE HUSKS    
COMPOSITION OF RICE HUSK ASH ON DRY BESIS    
MARKET OVERVIEW OF SILICON    
INCREASING DEMAND FOR ALUMINUM SILICON ALLOY    
ALUMINUM ALLOYS ACCOUNT FOR THE LARGEST SHARE    
ASIA-PACIFIC TO DOMINATE THE MARKET    
NOTABLE DEVELOPMENTS IN THE MARKET    
IMPURITIES IN BULK CRYSTALLINE SILICON    
FIGURE: EFFECT OF METAL ATOM IMPURITIES ON P-TYPE SOLAR
   CELLS EFFICIENCY    
SOURCES OF SILICON RAW MATERIALS    
SILICON MANUFACTURING TECHNOLOGIES    
MANUFACTURING PROCESS OF METALLURGICAL GRADE SILICON (MG-SI)    
TABLE: IMPURITIES IN METALLURGICAL GRADE SILICON    
FIGURE: SCHEMATICS OF METALLURGICAL GRADE SILICON
  PRODUCTION PROCESS    
MANUFACTURING PROCESS OF ELECTRONIC GRADE SILICON (EG-SI)    
FIGURE: SCHEMATICS OF (A) SIEMENS REACTOR AND
   (B) CZOCHRALSKI CRYSTAL PULLER    
SILICON PURIFICATION TECHNIQUES    
MANUFACTURING PROCESS IN DETAILS    
FLOW DIAGRAM    
B.I.S. SPECIFICATION    
COMPARISON OF SILICON FROM RICE HUSK ASH AND NATURAL QUARTZ    
MATERIALS AND METHODS    
TABLE: ELEMENTAL COMPOSITION OF RHA AND NATURAL QUARTZ
   BEFORE AND AFTER MAGNESIUM REDUCTION    
COMPOSITION OF RICE HUSK ASH    
TABLE. COMPOSITION OF RICE HUSK ASH BY GEOGRAPHICAL LOCATION    
PROCESSING OF RICE HUSK FOR SILICA    
DIRECT INCINERATION WITHOUT PRE-TREATMENTS    
FIGURE 1. RICE HUSK (A); CARBONIZED RICE HUSK
   (B); COMPLETELY INCINERATED RICE HUSK (C)    
FIGURE 2. A PILOT PLANT FOR RICE HUSK INCINERATION IN INDIA    
PRE-TREATMENT EFFECTS ON SILICA PRODUCTION FROM RICE HUSK    
HYDROTHERMAL METHOD    
OTHER METHODS    
BEHAVIOUR OF RICE HUSK ASH FOR PREPARATION OF HIGH PURITY SILICA
THEORETICAL CONSIDERATIONS    
CURRENT RESEARCH AND DEVELOPMENT IN THE PRODUCTION OF RICE HUSK SILICA    
PRODUCTION OF AMORPHOUS SILICA FROM RICE HUSK IN FLUIDISED
  BED SYSTEM    
PILOT-SCALE FLUIDISED BED COMBUSTOR SET-UP    
FLUIDISED BED COMBUSTOR    
CYCLONE    
FLUIDISING AND PNEUMATIC AIR FEEDING SYSTEM    
COMBUSTOR START-UP    
RICE HUSK FEEDING SYSTEM    
FIGURE-3: FEEDING SYSTEM OF PILOT-SCALE FLUIDISED BED COMBUSTOR
TEMPERATURE MEASUREMENT    
FIGURE-4: SCHEMATIC DIAGRAM OF THERMOCOUPLE POSITION IN
   A PILOT-SCALE FLUIDISED    
BED COMBUSTOR    
FLUE GAS SAMPLING AND ANALYSIS    
MEASURING PRINCIPLE    
FIGURE -6: OXYGEN MEASUREMENT PRINCIPLE    
RESULTS AND DISCUSSIONS    
BED PRE-HEATING AND STARTING OF COMBUSTOR    
FIGURE -7: TEMPERATURE PROFILE DURING BED PRE-HEATING    
EFFECT OF FLUIDIZING VELOCITY ON RICE HUSK COMBUSTION
FIGURE -8: REAL TIME TEMPERATURE PROFILE OF RICE HUSK
   COMBUSTION AT 4, 5 AND 6 UMF AND B) 7 UMF FLUIDIZING VELOCITY    
CONCLUSIONS    
COMBUSTION STUDY IN 80-MM (INNER DIAMETER) FLUIDISED BED    
COMBUSTOR SYSTEM    
I) FLUIDISED BED COMBUSTOR COLUMN    
II) CYCLONE    
III) SCREW FEEDING SYSTEM    
IV) COMPRESSED AIR SUPPLY    
V) LPG SUPPLY    
VI) TEMPERATURE MEASURING SYSTEM    
PLATE -1: THE 80-MM INNER DIAMETER FLUIDISED BED
  COMBUSTOR SYSTEM    
COMBUSTION STUDY IN 210-MM (INNER DIAMETER) FLUIDISED BED    
COMBUSTOR SYSTEM    
I) FLUIDISED BED COMBUSTOR COLUMN    
II) CYCLONE    
III) COMPRESSED AIR SUPPLY    
IV) LPG SUPPLY    
V) RICE HUSK FEEDING SYSTEM    
VI) TEMPERATURE MEASURING SYSTEM (THERMOCOUPLES
   AND DATA LOGGER)    
FIGURE -1: POSITIONS OF THERMOCOUPLES (T1 – T6), FEEDING PORT
  AND VIEWING    
PORT AT THE 210-MM INNER DIAMETER FLUIDISED BED COMBUSTOR    
FIGURE -2: OVERALL SCHEMATIC DIAGRAM OF THE 210-MM INNER DIAMETER FLUIDISED    
BED COMBUSTOR SYSTEM    
PLATE-2: THE 210-MM INNER DIAMETER FLUIDISED BED
   COMBUSTOR SYSTEM (SHOWN    
WITHOUT INSULATION MATERIAL)    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF CASTING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)    
SUPPLIERS OF LABORATORY EQUIPMENTS    
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
BUYER'S OF SILICON    
    
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)