Make Money from Waste. How a Rice Miller can earn Extra Income in Extraction of Sodium Silicate from Rice Husk Ash (RHA) Project
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1 Make Money from Waste. How a Rice Miller can earn Extra Income in Extraction of Sodium Silicate from Rice Husk Ash (RHA) Project
2 Introduction Rice husk ash (RHA), a by-product from the rice industry, was used as principal source of amorphous silica for the production of sodium silicate solution used for the replacement of standard commercial sodium silicate in the mix-design of metakaolin based geopolymer composites. Three initial concentrations of NaOH were considered with the aim to investigate on the optimum dissolution and formation of silica oligomers capable to act as binder during the geopolymerization. Results (FT-IR and XRD) showed that RHA-NaOH sodium silicate solutions have characteristics similar to that of standard commercial sodium silicate and the residual carbonates present in the viscous pastes can be monitored during the preparation of geopolymers using the mix-design. Combined 25Â vol% standard sodium silicate solution with vol% of RHA-NaOH based sodium silicate solution conducted to good polycondensation, densification, high flexural strength and low porosity similar to that of the standard matrix of metakaolin based composites. The new approach is found promising for the significant reduction of the Global Warming Potential of Geopolymers.
3 Rice husk / hull ash (RHA) contains: Biogenic Amorphous Silica Carbon Un-burnt rice husk / hull Sodium silicate products are manufactured as solids or thick liquids, depending on proposed use. For instance, water glass functions as a sealant in metal components. Finally, even though, sodium silicate manufacture is a mature industry, there is current research for new applications given its heat conductive properties.
4 Sodium Silicate is a colourless compound of oxides of sodium and silica. It has a range of chemical formula varying in sodium oxide (Na2O) and silicon dioxide or silica (SiO2) contents or ratios. Sodium silicate is the generic name for a series of compounds derived from soluble sodium silicate glasses. They are water solutions of sodium oxide (Na2O) and silicon dioxide (SiO2) combined in various ratios.
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6 Varying the proportions of SiO2 to Na2O and the solids content results in solutions with differing properties that have many diversified industrial applications. These are sold as 20% to 50% aqueous solutions called water glass. Rice husk a major by-product of the rice milling industry, is one of the most commonly available lignocellulosic materials that can be converted to different types of fuels and chemical feedstocks
7 through a variety of thermo chemical conversion processes. Rice husk is an agricultural residue abundantly available in rice producing countries. The husk surrounds the paddy grain. India is a major rice producing country, and the husk generated during milling is mostly used as a fuel in the boilers for processing paddy, producing energy through direct combustion and/or by gasification.
8 About 20 million tones of RHA are produced annually. This RHA is a great environment threat causing damage to the land and the surrounding area in which it is dumped. Lots of ways are being thought of for disposing them by making commercial use of this RHA. Sodium silicates are used in the composition of acid resisting and refractory cements.
9 Other uses of the silicate are as follows: as a suspension agent in are purification processes, from industrial wastes, for water proofing stone products, as a coating material in the packing materials, such as wooden panels, paper or cardboard boxes, for the insulation of electric copper wires, in the preservation of eggs. As a whole it is a good project for entrepreneurs to invest.
10 Properties of Sodium silicate Sodium silicate is a white powder that is readily soluble in water, producing an alkaline solution. It is one of a number of related compounds like, sodium ortho silicate, sodium pyro silicate, etc. All are glassy, colorless and dissolve in water. Sodium silicate is stable in neutral and alkaline. In acidic solutions, the silicate ion reacts with hydrogen ions to form silicic acid, which when heated and roasted forms silica gel, a hard, glassy substance.
11 Liquids and solids based on sodium silicate and produced by PQ Corporation have a density from 1.6g/cubic cm. to about 1.4 g/cubic cm. The future demand for sodium silicate is a function of growth of the end-user industries, mainly soap and detergent factories, pulp and paper mills, paint, pigment and adhesive factories.
12 Few Indian Major Players are as under Abhiraami Chemicals Ltd. Balls & Cylpebs Ltd. Kiran Global Chems Ltd. Shri Aster Silicates Ltd.
13 Project at a Glance PROJECT AT A GLANCE (USD in Thousands) COST OF PROJECT MEANS OF FINANCE Particulars Existing Proposed Total Particulars Existing Proposed Total Land & Site Development Exp Capital Buildings Share Premium Plant & Machineries Other Type Share Capital Motor Vehicles Reserves & Surplus Office Automation Equipments Cash Subsidy Technical Knowhow Fees & Exp Internal Cash Accruals Long/Medium Term Franchise & Other Deposits Borrowings Preliminary& Pre-operative Exp Debentures / Bonds Provision for Contingencies Unsecured Loans/Deposits Margin Money - Working Capital TOTAL TOTAL
14 Project at a Glance Year Annualised Book Value Debt Dividend Retained Earnings Payout Probable Market Price P/E Ratio Yield Price/ Book Value No.of Times EPS CEPS Per Share Per Share Per Share Rs Rs Rs Rs Rs % Rs % Rs %
15 Project at a Glance Year D. S. C. R. Debt / - Deposits Debt Equity as- Equity Total Net Worth Return on Net Worth Profitability Ratio Assets Turnover Ratio Current Ratio Individual Cumulativ e Overall GPM PBT PAT Net P/V Ratio Contribu tion (Number of times) (Number of times) % % % % % % Initial % 6.70% 5.34% % % 14.36% 9.65% % % 19.64% 12.69% % % 23.29% 14.83% % % 25.77% 16.31% %
16 Project at a Glance BEP BEP - Maximum Utilisation Year 5 Cash BEP (% of Installed Capacity) 65.81% Total BEP (% of Installed Capacity) 69.31% IRR, PAYBACK and FACR Internal Rate of Return.. ( In %age ) 20.82% Payback Period of the Project is ( In Years ) 2 Years 9 Months Fixed Assets Coverage Ratio ( No. of times ) 4.146
17 Major Queries/Questions Answered in the Report? 1. What is Sodium Silicate from Rice Husk Ash industry? 2. How has the Sodium Silicate from Rice Husk Ash industry performed so far and how will it perform in the coming years? 3. What is the Project Feasibility of Sodium Silicate from Rice Husk Ash Plant? 4. What are the requirements of Working Capital for setting up Sodium Silicate from Rice Husk Ash plant?
18 5. What is the structure of the Sodium Silicate from Rice Husk Ash Business and who are the key/major players? 6. What is the total project cost for setting up Sodium Silicate from Rice Husk Ash plant? 7. What are the operating costs for setting up Sodium Silicate from Rice Husk Ash plant? 8. What are the machinery and equipment requirements for setting up Sodium Silicate from Rice Husk Ash plant?
19 9. Who are the Suppliers and Manufacturers of Plant & Machinery for setting up Sodium Silicate from Rice Husk Ash plant? 10. What are the requirements of raw material for setting up Sodium Silicate from Rice Husk Ash plant? 11. Who are the Suppliers and Manufacturers of Raw materials for setting up Sodium Silicate from Rice Husk Ash plant? 12. What is the Manufacturing Process and Formulations of Sodium Silicate from Rice Husk Ash plant?
20 13. What is the total size of land required for setting up Sodium Silicate from Rice Husk Ash plant? 14. What will be the income and expenditures for Sodium Silicate from Rice Husk Ash plant? 15. What are the Projected Balance Sheets of Sodium Silicate from Rice Husk Ash plant? 16. What are the requirement of utilities and overheads for setting up Sodium Silicate from Rice Husk Ash plant? 17. What is the Built up Area Requirement and cost for setting up Sodium Silicate from Rice Husk Ash Business?
21 18. What are the Personnel (Manpower) Requirements for setting up Sodium Silicate from Rice Husk Ash Business? 19.What are Statistics of Import & Export for Sodium Silicate from Rice Husk Ash? 20. What is the time required to break-even? 21.What is the Break-Even Analysis of Sodium Silicate from Rice Husk Ash plant? 22.What are the Project financials of Single Sodium Silicate from Rice Husk Ash plant?
22 23. What are the Profitability Ratios of Sodium Silicate from Rice Husk Ash plant? 24. What is the Sensitivity Analysis-Price/Volume of Sodium Silicate from Rice Husk Ash plant? 25. What are the Projected Pay-Back Period and IRR of Sodium Silicate from Rice Husk Ash plant? 26. What is the Process Flow Sheet Diagram of Sodium Silicate from Rice Husk Ash project?
23 27. What are the Market Opportunities for setting up Sodium Silicate from Rice Husk Ash plant? 28. What is the Market Study and Assessment for setting up Sodium Silicate from Rice Husk Ash plant? 29. What is the Plant Layout for setting up Sodium Silicate from Rice Husk Ash Business?
24 Table of Contents of the Project Report
25 1. Project Location 1.1. District Profile & Geotechnical Site Characterization General Location & Geographical Area Topography Administrative set up Map Industry at a Glance 2. Introduction
26 3. Uses & Application 3.1. Typical Industries Using Sodium Silicates 3.2. Sodium Silicate 4. Properties of Sodium Silicate 4.1. Sodium Silicate 5. Grades & Types of Sodium Silicate 5.1. Sodium Silicate (Neutral Grade Liquid) 5.2. Technical Specification
27 5.3. Sodium Silicate (Alkaline Grade) 5.4. Technical Specification: 6. Market Survey 7. Financials & Comparison Of Major Indian Players/Companies 7.1. About Financial Statements Of Cmie Database 7.2. Profits & Appropriations 7.3. Total Liabilities 7.4. Total Assets
28 7.5. Net Cash Flow From Operating Activities 7.6. Section I Name of the company with contact details Name of Director(S) Plant Capacity Location of Plant Name of Raw Material(S) Consumed With Quantity & Cost 7.7. Section II Assets Cash Flow Cost as % Ge of Sales Forex Transaction Growth in Assets & Liabilities
29 Growth in Income & Expenditure Income & Expenditure Liabilities Liquidity Ratios Profitability Ratio Profits Return Ratios Structure of Assets & Liabilities (%) Working Capital & Turnover Ratios 8. Export & Import Statistics Data Of India 8.1. Export Statistics Data On Sodium Silicate 8.2. Import Statistics Data On Sodium Silicate
30 9. Methods Of Analysis 10. Safety Procedures In Handling Sodium Silicates Liquid Silicates Storage And Handling Pumps, Valves And Piping Methods Of Analysis 11. Raw Material Details Main Characteristics Of Rice Husk
31 11.2. Chemical Analysis Of Rice Husk On Dry Basis Rice Husk Ash Composition Of Rice Husk Ash On Dry Basis 12. Production Methods Of Rice Husk Ash 13. Manufacturing Process 14. Process Flow Diagram
32 15. Material Safety Data Sheet (Msds) For Sodium Silicate Hazards Identification Major Health Hazards Precautionary Statements Potential Health Effects First Aid Measures Fire-fighting Measures Accidental Release Measures Handling And Storage Personal Protective Equipment 16. Suppliers Of Plant & Machinery Complete Machinery Suppliers
33 17. Suppliers Of Raw Materials 18. Machinery, Raw Material & Product Photographs Machinery Photographs Raw Material Photographs Product Photographs 19. Plant Layout 20. Quotation Of Plant, Machinery And Equipments From Supplier
34 Project Financials Project at a Glance Annexure Assumptions for Profitability workings..1 Plant Economics..2 Production Schedule 3 Land & Building. 4 Factory Land & Building Site Development Expenses
35 Plant & Machinery....5 Indigenous Machineries Other Machineries (Miscellaneous, Laboratory etc.) Other Fixed Assets Furniture & Fixtures Pre-operative and Preliminary Expenses Technical Knowhow Provision of Contingencies Working Capital Requirement Per Month. 7 Raw Material Packing Material Lab & ETP Chemical Cost Consumable Store
36 Overheads Required Per Month and Per Annum.. 8 Utilities & Overheads (Power, Water and Fuel Expenses etc.) Royalty and Other Charges Selling and Distribution Expenses Salary and Wages Turnover Per Annum Share Capital...11 Equity Capital Preference Share Capital
37 Annexure 1 :: Cost of Project and Means of Finance Annexure 2 :: Profitability and Net Cash Accruals Revenue/Income/Realisation Expenses/Cost of Products/Services/Items Gross Profit Financial Charges Total Cost of Sales Net Profit After Taxes Net Cash Accruals
38 Annexure 3 :: Assessment of Working Capital requirements Current Assets Gross Working Capital Current Liabilities Net Working Capital Working Note for Calculation of Work-inprocess Annexure 4 :: Sources and Disposition of Funds
39 Annexure 5 :: Projected Balance Sheets ROI (Average of Fixed Assets) RONW (Average of Share Capital) ROI (Average of Total Assets) Annexure 6 :: Profitability Ratios D.S.C.R Earnings Per Share (EPS) Debt Equity Ratio
40 Annexure 7 :: Break-Even Analysis Variable Cost & Expenses Semi-Variable/Semi-Fixed Expenses Profit Volume Ratio (PVR) Fixed Expenses / Cost B.E.P
41 Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume Resultant N.P.B.T Resultant D.S.C.R Resultant PV Ratio Resultant DER Resultant ROI Resultant BEP
42 Annexure 12 :: Shareholding Pattern and Stake Status Equity Capital Preference Share Capital Annexure 13 :: Quantitative Details-Output/Sales/Stocks Determined Capacity P.A of Products/Services Achievable Efficiency/Yield % of Products/Services/Items Net Usable Load/Capacity of Products/Services/Items Expected Sales/ Revenue/ Income of Products/ Services/ Items
43 Annexure 14 :: Product wise Domestic Sales Realisation Annexure 15 :: Total Raw Material Cost Annexure 16 :: Raw Material Cost per unit Annexure 17 :: Total Lab & ETP Chemical Cost Annexure 18 :: Consumables, Store etc. Annexure 19 :: Packing Material Cost Annexure 20 :: Packing Material Cost Per Unit
44 Annexure 21 :: Employees Expenses Annexure 22 :: Fuel Expenses Annexure 23 :: Power/Electricity Expenses Annexure 24 :: Royalty & Other Charges Annexure 25 :: Repairs & Maintenance Expenses Annexure 26 :: Other Manufacturing Expenses Annexure 27 :: Administration Expenses Annexure 28 :: Selling Expenses
45 Annexure 29 :: Depreciation Charges as per Books (Total) Annexure 30 :: Depreciation Charges as per Books (P & M) Annexure 31 :: Depreciation Charges - as per IT Act WDV (Total) Annexure 32 :: Depreciation Charges - as per IT Act WDV (P & M) Annexure 33 :: Interest and Repayment - Term Loans Annexure 34 :: Tax on Profits Annexure 35 :: Projected Pay-Back Period and IRR
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