Make Money From Rice Husk Ash. Converting Waste Agricultural Biomass into a Resource.
Rice husk, an agro waste material, contains about 20% ash which can be retrieved as amorphous, chemically reactive silica. This silica finds wide applications as filler, catalyst support, adsorbent and a source for synthesizing high performance silicon and its compounds. Various metal ions and unburned carbon influence the purity and color of the ash. Controlled burning of the husk after removing these ions can produce white silica of high purity. India produces around 25 million tons of rice husks (widely available waste). 78% of weight as rice, broken rice and bran, rest 22% of weight of paddy as husk. 75% of organic volatile matter and 25% of weight is converted as Rice Husk Ash (RHA) during firing process. Husk contains 17%-20% silica in complex form and RHA contains 85%-95% amorphous silica. RHA is a great environment threat causing damage to the land and the surrounding area in which it is dumped.
Precipitated silica can be prepared by treating rice husk with Sodium sulphate to produce Sodium silicate, which is then dissolved in water and reacted with Sulphuric acid to get Precipitated silica.Rice husk is treated with Sodium sulphate to produce Sodium silicate. Sodium silicate obtained is diluted with water. The diluted Sodium silicate solution is brought to a certain temperature and Sulphuric acid of appropriate dilution is added in controlled condition. The resultant product is Precipitated silica, which is washed in a washing tank. The washed Precipitated silica is filtered, dried and pulverised to required mesh size.
Precipitated Silica Production
Silica is not a new commodity in the plastics market. Its usage as extenders and reinforcing fillers, as pozzolanic material and as glass microspheres for specific engineering applications are well known in the market. Because of its high silica and lignin content, rice husk is tough, woody and abrasive in nature with low nutritive properties and resistance to weathering. With growing environmental concern, open burning has been outlawed in many major rice-producing countries. 18% of the rice husk can be retrieved as ash after the gasification process. Silica content in ash is almost 90% and the rate of recovery of precipitated silica is 90-95% from the rice husk ash if the conversion efficiency is more than 70%. Rice hull ash (RHA) contains over 60% of silica which can be an economically viable raw material for the production of silica based products.
Silica generation is a separate independent process not dependent on electricity generation, although the input ash is dependent on gasification process. Provision will be taken in the design so that external ash is used also as input thus increase silica production.
Liquid sodium silicate is processed with acid and filtered. The filter separates a diluted sodium sulfate (Glauber’s salt solution) and the wet silica product. The salt solution can be evaporated or fed to a reverse osmosis and solid salt is produced as valuable by-product. The wet filter cake is finally washed and fed to the drying unit. With special dryers a precipitated silica product with about 8% water content is produced. The precipitated amorphous silica powder is screened and stored in storage silos. For distribution of silica products packaging in bags of various sizes is executed in the packing unit.
Uses of Precipitated Silica
- Rubber industry – as a reinforcing agent
- Cosmetics
- Tooth pastes – as a cleansing agent
- Food industry – as an anti-caking agent.
- Paints – as a filler
Silica is the major constituent of the rice husk ash. So precipitated silica production will not only provide value addition but also solve the problem of large amount of ash disposal generated from gasification process. With such a large ash content & silica content in the ash it becomes economical to extract silica from the ash, which has wide market & also takes care of ash disposal. Precipitated Silica (also called particulate silica) is composed of aggregates of ultimate particles of colloidal size that have not become linked in massive gel network during the preparation process. It is an amorphous form of silica; the word amorphous denotes a lack or crystal structure, as defined by x ray diffraction. Early interest in amorphous silica was purely academic. The ash produced after the husks have been burned is high in silica. RHA can be used in a variety of application like: green concrete, high performance concrete, ceramic glaze, water proofing chemicals, roofing shingles, insulator, specialty paints, flame retardants, carrier for pesticides, insecticides & bio fertilizers etc. Precipitated silica is also used as filler for paper & rubber, as a carrier & diluents for agricultural chemicals, as an anti-caking agent, to control viscosity & thickness and as a cleansing agent in toothpastes & in cosmetics. The distinguishing feature of the growth of precipitated silica industry in India is that it has classifiably flourished in the small scale sector. Readily available new materials low capital investment & high rates of return offer a distinct advantage to the small scale manufacturers to venture into this field. There is a very good scope in
Project at a Glance
Capacity: 4500 MT/Annum
Plant & Machinery: Rs. 28 Lakhs
Cost of Project: Rs. 129 Lakhs
Rate of Return: 46%
Break Even Point: 38%
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