Industry Overview
Precipitated silica is a versatile inorganic chemical primarily composed of silicon dioxide (SiO2) and is available in gel, crystalline, and amorphous forms. Although silica is one of the most abundant materials in the Earth's crust, producing high-purity silica through conventional methods is energy intensive, typically requiring the reaction of sand with soda ash at temperatures of approximately 1500°C.
This project presents an alternative manufacturing process that utilizes rice husk ash, an agricultural by-product containing approximately 90–98% silica after complete combustion. Rice husk ash is generated in large quantities from rice mills where rice husk is commonly used as boiler fuel, creating significant disposal and environmental challenges. The proposed chemical process converts this waste material into valuable precipitated silica by reacting the ash with caustic soda, offering a more energy-efficient and cost-effective alternative to conventional silica production.
In addition to producing precipitated silica, the process enables the recovery of sodium sulphate from wash water through evaporation, crystallization, filtration, and drying. The remaining residue can also be utilized in manufacturing quality bricks, improving overall resource utilization and minimizing waste generation. Rice husk is abundantly available in rice-producing regions, making it an economical raw material with strong industrial potential. The process supports sustainable manufacturing by reducing agricultural waste, lowering energy consumption, and supplying high-quality silica for a wide range of industrial applications while contributing to environmental protection.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 100 MT/Day |
| Land & Building | Rs. 19.26 Cr |
| Plant & Machinery | Rs. 36.13 Cr |
| Working Capital for 0.5 Months | Rs. 6.17 Cr |
| Total Capital Investment | Rs. 63.58 Cr |
| Rate of Return | 43% |
| Break Even Point | 44% |
Content Index
- INTRODUCTION
- RICE HUSK
- PROPERTIES
- PRECIPITATED SILICA
- USES/APPLICATIONS
- IMPORTANT APPLICATION SECTOR
- APPLICATIONS
- ADHESIVE
- CHAPPALS
- CONVEYOR BELT & TRANSMISSION BELT:
- PVC SHEETS
- RAILWAY PADS
- PRECIPITATED SILICA IS USED FOR THE FOLLOWING REASONS IN RAILWAY PADS:
- RICE ROLLERS AND RUBBER ROLLERS
- PRECIPITATED SILICA IS USED IN RUBBER ROLLERS AND RICE ROLLERS FOR FOLLOWING REASONS:
- RUBBER PRODUCTS AND RUBBER HOSES
- PRECIPITATED SILICA IS USED IN SILICON RUBBER FOR FOLLOWING REASONS:
- RUBBER AND SOLID TYRES
- TEXTILE COTS AND APRONS
- ADVANTAGES
- MARKET OVERVIEW
- APPLICATION INSIGHTS
- REGIONAL INSIGHTS
- KEY COMPANIES & MARKET SHARE INSIGHTS
- SPECIFICATION – SILICA (PRECIPITATED)
- RAW MATERIAL – RICE HUSK
- 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)
- PROCESS CHEMISTRY
- RICE HUSK TO SILICA
- DIGESTION
- PRECIPITATION
- REGENERATION
- CALCINATION AND SLAKING
- TYPICAL PROPERTIES OF SILICA
- FORMULATION
- MANUFACTURING PROCESS STEPS
- DIGESTION
- PRECIPITATION
- REGENERATION
- PROCESS FLOW
- 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
- COOLING TOWERS
- 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:
- ANTICIPATED ENVIRONMENTAL IMPACTS
- CONSTRUCTION PHASE
- OPERATION PHASE
- MITIGATION MEASURES (PROPOSED)
- HEALTH SAFETY & ENVIRONMENT
- PROJECT FINANCIALS
- BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
- ANNUAL PRODUCTION: 30000 TPA
- PROJECT IMPLEMENTATION SCHEDULE
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- PRELIMINARY PLANT LAYOUT
- CONCLUSIONS
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
Precipitated silica is a high-purity form of silicon dioxide produced by chemically extracting silica from rice husk ash.
The process converts silica-rich agricultural waste into a valuable industrial material using chemical treatment rather than conventional high-temperature melting. This approach improves resource utilization, reduces waste disposal problems, and supplies silica suitable for applications such as rubber, adhesives, plastics, and other industrial products.
Rice husk ash is used because it contains a very high concentration of silica and is widely available.
As a by-product of rice milling and biomass combustion, rice husk ash is inexpensive and often creates disposal challenges. Recovering silica from this material supports sustainable manufacturing by reducing waste while producing a commercially valuable chemical product through an energy-efficient process.
The proposed process replaces high-temperature sand processing with chemical extraction from rice husk ash.
Traditional silica production typically requires very high furnace temperatures, making it energy intensive. The alternative process uses rice husk ash and caustic soda to recover silica, lowering energy requirements while utilizing an agricultural residue that would otherwise contribute to environmental pollution.
The process also recovers sodium sulphate and generates residue that can be utilized in brick manufacturing.
Sodium sulphate is obtained by evaporating and crystallizing the wash water generated during silica production. The remaining residue contains sodium silicate, which can act as a binder for producing quality bricks, helping improve overall process efficiency and minimizing waste.
Precipitated silica is widely used in rubber, adhesives, plastics, footwear, conveyor belts, PVC products, and related industrial applications.
Its reinforcing, thickening, and performance-enhancing properties make it valuable across numerous manufacturing sectors. The report also highlights applications in railway pads, rubber rollers, solid tyres, textile cots, aprons, and various engineered rubber products.
The process converts agricultural waste into a valuable industrial product while reducing pollution and improving resource efficiency.
Using rice husk ash helps address waste disposal issues associated with rice mills, reduces dependence on energy-intensive conventional production methods, enables recovery of useful by-products, and supports a more sustainable circular economy for agricultural residues.
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