Code #3655
Industry Overview
Growing concerns about energy-related climate change and the increasing cost of fossil fuels have strengthened interest in renewable energy alternatives. Solar photovoltaic (PV) power generation is a proven technology, although its broader terrestrial application has been constrained by the high cost of materials used to fabricate solar cells. Silicon, in both monocrystalline and polycrystalline forms, remains the dominant semiconductor material for commercially available solar cells and modules, accounting for over 90% of the PV technology market according to the report.
Metallurgical-grade silicon is commercially produced through the carbothermic process, while electronic- or semiconductor-grade silicon is produced through the Siemens process. Metallurgical-grade silicon generally has a purity of 98–99.5% but contains electro-active impurities such as boron, phosphorus, aluminium and transition metals that can reduce the conversion efficiency of silicon solar cells and panels. Electronic-grade silicon, with total impurities below one part per billion, is considerably more expensive for large-scale solar-cell production. For efficient silicon solar-cell fabrication, the report notes that boron and phosphorus levels generally need to be reduced to below 1 ppm each, with silicon feedstock purity in the range of 5–7N.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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
This project report focuses on silicon manufacturing and purification, with particular attention to materials, technologies, and rice husk-based routes. It covers the uses and properties of silicon, silicon manufacturing technologies, metallurgical-grade and electronic-grade silicon production, purification techniques, and the comparison of silicon derived from rice husk ash and natural quartz. The report also discusses rice husk processing for silica and fluidised bed combustion studies relevant to the preparation of high-purity silica.
Silicon is important for solar photovoltaic applications because it is the dominant semiconductor material used in commercially available solar cells and modules. The report identifies monocrystalline and polycrystalline silicon as the principal forms used in PV technology. It also explains that certain impurities, particularly boron, phosphorus, aluminium and transition metals, can reduce solar-cell conversion efficiency. Consequently, silicon purification and control of impurity concentrations are important considerations when producing feedstock for efficient solar-cell fabrication.
The report discusses the manufacturing processes for metallurgical-grade silicon and electronic-grade silicon. Metallurgical-grade silicon is associated with the carbothermic process, while electronic-grade silicon is produced using the Siemens process. The report also covers silicon purification techniques, manufacturing details, flow diagrams, BIS specifications, and the Czochralski crystal-pulling process. These sections provide a broader view of the progression from silicon raw materials to higher-purity material suitable for advanced applications.
Rice husk is relevant because its ash can serve as a source of silica for further processing. The report examines the characteristics and availability of rice husks, the composition of rice husk ash, processing routes for obtaining silica, and comparisons with natural quartz. It discusses direct incineration, pre-treatment effects, hydrothermal methods, and other approaches. The report also considers fluidised bed systems for rice husk combustion and the production of amorphous silica, including pilot-scale equipment and combustion studies.
Important impurities discussed in the report include boron, phosphorus, aluminium and transition metals. Metallurgical-grade silicon typically contains higher concentrations of these impurities, and the report explains their potential effect on the efficiency of p-n junction silicon solar cells and panels. It further notes that efficient silicon solar-cell fabrication generally requires substantial reduction of boron and phosphorus concentrations. The report therefore includes sections on impurities in bulk crystalline silicon, impurity effects, metallurgical-grade silicon specifications, and silicon purification techniques.
The report covers several components of fluidised bed combustion systems used for rice husk studies. These include the fluidised bed combustor column, cyclone, screw or rice husk feeding system, compressed air supply, LPG supply, and temperature measuring systems. It also discusses thermocouple positions, data logging, flue gas sampling and oxygen measurement. Separate sections address combustion studies involving 80-mm and 210-mm inner-diameter fluidised bed combustor systems and describe their respective configurations.
The report includes project cost information along with supplier and buyer-related sections. It identifies suppliers of raw materials, plant and machinery, casting machines, material handling equipment, storage vessels, laboratory equipment, and instrumentation and process-control equipment. A buyers section is also included for silicon. Appendix A contains project-economics headings covering fixed capital, raw materials, salaries and wages, utilities and overheads, working capital, capital investment, cost of production, turnover, break-even point, financing resources, depreciation, profit analysis, and projected balance sheets.
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