SILICA FROM RICE HUSK ASH (PRECIPITATED SILICA, CELLULOSE FIBRE, LIGNIN PELLETS, SODIUM SULPHATE) (CAP: 5 TPD)

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Silica from Rice Husk Ash Project Report HTML

Industry Overview

Silica (SiO₂) is a valuable inorganic multipurpose chemical compound that occurs in gel, crystalline, and amorphous forms. Conventional silica manufacturing can be energy intensive and may require high furnace temperatures. This project describes a chemical process for producing precipitated silica using rice husk ash as a non-conventional raw material. Rice husk ash, obtained from the combustion of rice husk commonly used as boiler fuel, contains about 90–98% silica after complete combustion and can otherwise create significant disposal and pollution concerns.

The process provides a route for recovering valuable silica while also obtaining sodium sulphate as an associated product. Sodium sulphate can be recovered from the effluent wash water generated during precipitated silica production through evaporation, crystallization, filtration, and drying. Residual ash containing sodium silicate may also be utilized in brick manufacturing. The report notes that rice husk is available in substantial quantities from rice mills and identifies Andhra Pradesh, Tamil Nadu, Karnataka, and Kerala among the states with large numbers of rice mills.

Compared with the conventional process of reacting sand with soda ash at about 1500ºC, the project uses rice husk ash and caustic soda, offering an energy-efficient approach based on a low-cost raw material that would otherwise contribute to environmental pollution.

Cost Estimation

Particulars	Details
Plant Capacity	5.00 MT/day
Land & Building ( 3 Acres)	Rs. 39.00 Lacs
Plant & Machinery	Rs. 1.63 Cr
Working Capital for 1 Month	Rs. 9.50 Lacs
Total Capital Investment	Rs. 2.19 Cr
Rate of Return	9%
Break Even Point	80%

Content Index

INTRODUCTION
BENEFITS OF PRECIPITATED SILICA FROM RHA
NON RUBBER GRADE PRECIPITATED SILICA
MARKET OVERVIEW OF PRECIPITATED SILICA
PROPERTIES OF RICE HUSK
MANUFACTURING PROCESS OF PRECIPITATED SILICA FROM RICE HUSK ASH (INDIAN INSTITUTE OF SCIENCE PRECIPITATED SILICA TECHNOLOGY) CGPL PROCESS
SEQUENCES IN SILICA MANUFACTURE
ALTERNATE PROCESS OF SILICA MANUFACTURE
TECHNICAL DETAILS OF SILICA MANUFACTURE
COMPLETE PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF FILTER PRESS
SUPPLIERS OF MINI BOILER
SUPPLIERS OF INDUSTRIAL DRYERS
SUPPLIERS OF STORAGE VESSEL
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PACKAGING MACHINE
HORIZONTAL PLATE FILTER PRESS (SPARKLER FILTERS)
SUPPLIERS OF RAW MATERIALS (GLOBAL
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF RICE HUSK ASH
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF SODIUM HYDROXIDE
SUPPLIERS OF CALCIUM HYDROXIDE
SUPPLIERS OF CARBON DIOXIDE GAS
SUPPLIERS OF PACKAGING MATERIALS (HDPE BAGS)
SUPPLIERS OF REACTORS
SUPPLIERS OF BOILERS
SUPPLIERS OF CONDENSER
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
ELECRICAL GOOD & SWITCH MANUFACTURE
LABORATORTY EQUIPMENTS MANUFACTURERS
CONVEYOR BELT
BUCKET ELEVATORS
BAG SEALING MACHINE
D.G. SET MANUFACTURERS & SUPPLIERS
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
ZLD PLANT & MACHINERY MANUFACTURER /SUPPLIERS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
UTILITIES
QUALITY CONTROL AND TESTING EQUIPMENTS
QUALITY CONTROL PROCEDURE/ PARAMETERS
DOCUMENTS REQUIRED FOR LICENSES
PROCESSES AND COMPLIANCES
SETTING UP BUSINESS IN INDIA- COMPARATIVE ANALYSIS
SETTING UP BUSINESS IN INDIA-
PROCESSES/COMPLIANCES
ORGANIZATION CHART
PLANT LAYOUT
KEY INDUSTRY REGULATIONS AND POLICIES
SWOT ANALYSIS
IMPLEMENTATION SCHEDULE
PROPOSED IMPLEMENTATION SCHEDULE 12 MONTHS

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 from rice husk ash is silica recovered through a chemical process using silica-rich rice husk ash as the raw material. Rice husk ash can contain about 90–98% silica after complete combustion, according to the project report. The process described uses rice husk ash and caustic soda rather than the conventional reaction of sand with soda ash at about 1500ºC. This approach also addresses the disposal of rice husk ash generated by rice mills while recovering a commercially useful inorganic material.

Rice husk ash is used because it is a silica-rich agro-waste material that can otherwise create disposal and pollution problems. The report describes rice husk as a popular boiler fuel and notes that the resulting ash can accumulate around rice mills. Recovering silica from this ash converts a waste stream into a useful industrial raw material. The project also indicates that using rice husk ash can require lower energy than an alternative process involving the fusion of selected-quality sand.

The project describes precipitated silica as the principal recovered product and sodium sulphate as an associated recovery. Sodium sulphate is obtained from the effluent wash water generated after washing precipitated silica. The described recovery route involves evaporation of water in multiple-effect evaporators, followed by crystallization, filtration, and drying. The report also states that residue ash from sodium silica production can be used for manufacturing bricks because retained sodium silicate can act as a binder when suitable ingredients are incorporated.

Equipment requirements depend on the selected process and plant design, but the report specifically includes suppliers and sections covering filter presses, mini boilers, industrial dryers, storage vessels, material handling equipment, packaging machines, reactors, boilers, condensers, conveyors, bucket elevators, bag sealing machines, and ZLD plant and machinery. The report also includes horizontal plate filter press information and quality-control and testing equipment. Detailed equipment selection should follow the process sequence, material characteristics, production requirements, utilities, and applicable plant-design considerations.

Rice husk ash and caustic soda are central raw materials identified in the project description for the silica manufacturing process. The content index also includes supplier sections for rice husk ash, caustic soda, sodium hydroxide, calcium hydroxide, carbon dioxide gas, and packaging materials such as HDPE bags. The exact raw-material specifications, quantities, and process requirements should be taken from the detailed technical sections of the project report rather than assumed from general industry practice.

A rice husk ash silica plant requires consideration of raw-material availability, process selection, plant location, equipment, utilities, quality control, environmental management, and regulatory compliance. The report includes dedicated sections on plant layout principles, plant location factors, utilities, quality control and testing, documents required for licenses, processes and compliances, key industry regulations and policies, and implementation scheduling. Reliable access to rice husk ash and appropriate arrangements for handling process effluents and recovered materials are also important aspects of project planning.

The project report covers substantially more than the manufacturing process. It includes market and technical information, properties of rice husk, equipment and raw-material supplier sections, plant layout and location considerations, utilities, quality control, licensing documentation, processes and compliances, organization structure, regulations and policies, SWOT analysis, and implementation scheduling. Its appendix further covers plant economics, fixed capital, raw materials, working capital, cost of production, turnover, break-even point, finance resources, depreciation, profit analysis, and a projected balance sheet for five years.

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Detailed Project Report (DPR) on SILICA FROM RICE HUSK ASH (PRECIPITATED SILICA, CELLULOSE FIBRE, LIGNIN PELLETS, SODIUM SULPHATE) (CAP: 5 TPD)

Industry Overview

Cost Estimation

Content Index

Appendix