Detailed Project Report on Sodium Silicate from Rice Husk

SODIUM SILICATE FROM RICE HUSK

[EIRI/EDPR/1460] J.C. 239

INTRODUCTION

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  mearly  neutral and from crystalline to glossy solids, to viscous liguids.

Sodium silicates are widely used in all types of detergents and cleaning compounds as active alkaline builders. Sodium silicate is important bonding agents in targe variety of ceramics cement and refractory applications  because  of  their  heat stability and resistance to chemicals. Ankalimetal silicate  bonds are used in high-temperature ceramic products for the  fabrication of  electrical components. Soluble silicates are used widely  for pelletizing,  granvlating   and  briquetting   finely   divided particles, eg. Ovens fertilizers and clays. Sodium silicates have been  of interest formany years as bonding materials for  foundry 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, flooring  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.

COST ESTIMATION

Plant Capacity            15 MT/Day

Land & Building (5000 sq.mt.)    Rs. 6.66 Cr

Plant & Machinery                    Rs. 1.33 Cr

Working Capital for 2 Months    Rs. 1.07 Cr

Total Capital Investment          Rs. 9.68 Cr

Rate of Return                          14%

Break Even Point                      64%

CONTENTS

INTRODUCTION

PROPERTIES OF SODIUM SILICATE

THE TYPICAL PROPERTIES OF SODIUM SILICATE ARE AS FOLLOWS.

USES AND APPLICATION

DETERGENT AND CLEANING COMPOUND

DEFLOCULATION

ADHESIVE AND CEMENTS

BONDING AGENTS

COATINGS

SOLS & GELS

OTHER IMPORTANT APPLICATIONS OF SODIUM SILICATE

B.I.S. SPECIFICATION

MARKET SURVEY

SODIUM SILICATE IMPORTS DATA & IMPORT STATISTICS IN INDIA

SODIUM SILICATE EXPORT DATA & EXPORT SHIPMENT DATA OF INDIA

PHYSICO - CHEMICAL CHARACTERISTICS OF RICE HUSK ASH

RESULTS AND DISCUSSION

METHODS FOR REMOVAL OF IMPURITIES

CHEMICAL COMPOSITION OF RICE HUSK ASHES

SURFACE AREA AND AMORPHOUS NATURE

CONCLUSIONS

PROCESS OF MANUFACTURE

GENERALLY POWDERED IS PACKED AS FOLLOWS:

ANALYSIS OF SODA SILICATE

DETERMINATION OF MATTER INSOLUBLE IN WATER

DETERMINATION OF SPECIFIC GRAVITY

DETERMINATION OF TOTAL SOLUBLE SILICA (AS SIO2)

DETERMINATION OF TOTAL ALKALI AS NA2O

1. METHOD:

II METHOD:

DETERMINATION OF LOSS ON IGNITION

PRESENT MANUFACTURERS OF SODIUM SILICATE

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

OTHER RELATED INFORMATIONS

CONVERSION OF RICE HULL ASH INTO SOLUBLE SODIUM SILICATE

MATERIALS AND METHODS

FIGURE 1 PRESENTS THE FLOW DIAGRAM FOR PRODUCTION OF SOLUBLE SODIUM SILICATE.

RESULTS AND DISCUSSION

FIGURE 2 PRESENTS A SAMPLE OF RHA, AS RECEIVED.

METHOD OF PRODUCING ACTIVE RICE HUSK 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

PRINCIPLES OF PLANT LAYOUT

4. ADEQUATE SPUR FACILITIES

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS

SUPPLIERS OF PLANT & MACHINERY

ROTARY KILNS

VIBRATING SCREENS

CHILLED CONVEYOR

HIGH SPEED DISSOLVER MANUFACTURERS

BALL MILLS FROM INDIA

MILLING AND GRINDING TOOLS & MACHINERY

TRAY DRYER FROM INDIA

BOILERS

GENERATOR SET FROM INDIA

ELEVATORS & ESCALATORS

PACKAGING & LAMINATION MACHINERY

MANUFACTURERS/SUPPLIERS OF RAW MATERIALS

RICE HUSK ASH

SODA ASH FROM INDIA

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)