Detailed Project Report (DPR) on Activated Carbon & Sodium Silicate from Paddy/Rice Husk

ACTIVATED CARBON & SODIUM SILICATE FROM PADDY/RICE HUSK

[EIRI/EDPR/1082] J.C.: 9726

INTRODUCTION

Activated carbon is an inert material with a porous structure having property of absorbing organic compounds, dyes and colour bodies. It absorbs vapours and gases and gets as a catalyst or catalyst carrier in certain chemical reactions.

Activated carbon has an extensive surface area due to the porous structure, absorption quality of carbon depends upon the basic carbonaceous materials from which it is produced and the number of pores per unit area.

The activated carbon of gas and vapour absorbant type was developed during world war I as a means of defence against toxic gases used for military purposes. Since then, the application of this product has been gradually spreading to industrial activities. 

Sodium silicates popularly called water glass or soluble glass are generally classified according to their SiO2, Na2O ratio, which varies between 0.5 and 4 and with various proportion of water. Based upon this ratio, a series of compounds are known ranging in properties from strongly alkaline to rarely neutral and from crystalline to glossy solids, to viscous liquids.

Sodium silicates are widely used in all types of detergents and cleaning compounds as active alkaline builders. Sodium silicate is important bonding agents in large variety of ceramics cement and refractory applications because of their heat stability and resistance to chemicals. Alkali metal silicate bonds are used in high-temperature ceramic products for the fabrication of electrical components. Soluble silicates are used widely for pellelizing, granulating and briquetting finely divided particles, eg. Ovens fertilizers and clays. Sodium silicates have been of interest for many years as bonding materials for foundary mold and care composition. The biggest use of sodium silicate is in soap and detergent industry followed by the use in adhesives for paper boards and corrugated containers Sodium Silicate is also used alone or together with many other materials as adhesive for plywood, wall board, floring and foils. Sodium silicate is also used in different places.

The important silicates are sodium Orthosilicate, Na4SiO4 Sodium metarilicate (Na2SiO3) and their hydrate and sodium sesquisilicate (Na6Si2O7) and their hydrates.

A variety of sodium silicates ranging in chemical composition from Na2O, 4 SiO2 is 2 Na2 O, SiO2 is produced by the fusion of silca or sand with soda ash. one of the most recent methods used for making Sodium Silicate is from Paddy Husk. Sodium silicate first came into existence when the sodium compound was red hot heated with the sand, after that other processes have also been evolved.

The commercial sodium silicates are amorphous vitreous or crystalline hydrated and anhydrous compounds (powder) and also liquid aquous with viscosity ranging from 0.5 to 600,000 poise at 20oC.

COST ESTIMATION

Plant Capacity            8.80 MT/Day

Land & Building (2000 sq.mt.)    Rs. 1.79 Cr

Plant & Machinery                    Rs. 85.50 Lac

Working Capital for 2 Months    Rs. 1.29 Cr

Total Capital Investment          Rs. 4.26 Cr

Rate of Return                          36%

Break Even Point                      51%

CONTENTS

INTRODUCTION

ACTIVATED CARBON

PROPERTIES OF SODIUM SILICATE

PROPERTIES OF PRODUCTS

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

MARKET POSITION AND OTHER VALUABLE DETAILS

THREE MAIN FORMS OF ACTIVATED CARBON ARE:

HISTORY OF ACTIVATED CARBON

MANUFACTURING PROCESS

CHEMICAL ACTIVATION

ACTIVATED CARBON FROM COCONUT SHELL

ACTIVATED CARBON FROM COAL

TABLE-1: PROJECT COST OF A 10-TPD COCONUT SHELL BASED ACTIVATED CARBON PLANT

WASTE TYRE UTILISATION

REACTIVATION OF USED ACTIVATED CARBON

TABLE 2: TYPES OF ACTIVATED CARBON

PROPERTIES OF ACTIVATED CARBON

ADSORPTIVE CHARACTERISTICS

SURFACE AREA

PORE SIZE DISTRIBUTION

THE PORE SIZE IN ACTIVATED CARBONS CAN BE DIVIDED INTO.

PHYSICAL CHARACTERISTICS

TABLE 3: TYPICAL PROPERTIES OF ACTIVATED CARBON

PARTICLE SIZE DISTRIBUTION

APPLICATION

OTHER APPLICATIONS OF ACTIVATED CARBON INCLUDE:

TABLE 4: APPLICATIONS OF ACTIVATED CARBON

TABLE 5: APPLICATIONS IN THE CHEMICAL INDUSTRY

MERCURY REMOVAL

TABLE 6: EPA PROJECTED CONTROL TECHNOLOGIES

TABLE 7: MAJOR INTERNATIONAL MANUFACTURERS OF ACTIVATED CARBON

ARSENIC REMOVAL

MARKET TRENDS

POTENTIAL NEW MARKETS EMERGE

TABLE 8: MAJOR MANUFACTURERS OF ACTIVATED CARBON IN CHINA

NEW PROJECTS

TABLE 9: SOME INDIAN MANUFACTURERS OF ACTIVATED CARBON

TABLE 10: DEMAND FOR ACTIVATED CARBON IN INDIA BY END USE

TABLE 11: INDIAN DEMAND SUPPLY SCENARIO FOR ACTIVATED CARBON

TABLE 12: IMPORTS AND EXPORTS OF ACTIVATED CARBON FROM INDIA

TABLE 13: TOP-10 SUPPLIERS OF ACTIVATED CARBON INTO INDIA

TABLE 14: TOP-10 DESTINATIONS FOR EXPORTS OF ACTIVATED CARBON FROM INDIA

RISING PRICES

INDIAN SCENARIO

DEMAND SUPPLY TRENDS

CONSUMERS OF ACTIVATED CARBON

USES & APPLICATIONS

ACTIVATED CARBON:-

3. USES DEPENDING UPON ITS CHEMICAL PROPERTIES:

BUREAU OF INDIAN STANDARDS SPECIFICATION

1. SCOPE:

2. TYPES:

REQUIREMENTS:

3.1 DESCRIPTION:

3. 3 ADDITIONAL REQUIREMENTS:

4. PACKING MARKING AND STORAGE:

PACKING:

MARKING:

4.3 STORAGE:

SODIUM SILICATE

ACTIVATED CARBON:

MANUFACTURING PROCESS OF ACTIVATED CARBON FROM RICE HUCK

RAW MATERIALS REQUIREMENTS

THE MAJOR STEPS INVOLVED IN THIS PROCESS ARE:

NEW RICE HUSK PROCESSING TECHNOLOGY

GREEN TECHNOLOGY

FEEDSTOCK

PREPARATION OF FEEDSTOCK

RICE HUSK PROCESSING PLANT:

COMBUSTION AND POWER GENERATION UNIT

LIQUID SODIUM SILICATE AND ACTIVATED CARBON PRODUCTION

PRECIPITATED SILICA PRODUCTION

MAIN APPLICATIONS OF THE PRODUCTS

PRECIPITATED SILICA:

TYPICAL PROPERTIES OF OUR PRODUCTS:

ACTIVATED CARBON:

LIQUID SODIUM SILCATES:

METHOD OF PRODUCING ACTIVE RICE HUSK ASH

METHOD OF PRODUCING AN ADSORBENT FROM RICE HULL ASH

PROCESS FOR PREPARING A SODIUM SILICATE FROM RICE HULL ASH

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

EXAMPLE 7

EXAMPLE 8

EXAMPLE 9

EXAMPLE 10

EXAMPLE 11

EXAMPLE 12

EXAMPLE 13

EXAMPLE 14

EXAMPLE 15

MANUFACTURE OF SODIUM SILICATE AND ACTIVATED CARBON

FLOW SHEET FOR MANUFACTURING ACTIVATED CARBON

PLANT LAY OUT FOR MANUFACTURE OF ACTIVATED CARBON FROM RICE HUSK

PRESENT MANUFACTURERS ACTIVATED CARBON

SODIUM SILICATE

SUPPLIERS OF PLANT AND EQUIPMENTS

ROTARY KILNS

VIBRATING SCREENS

FILTER PRESS

TRAY DRYER

PULVERIZERS

PELLETIZING MACHINE

BUCKET ELEVATOR

BOILERS

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)