Production Of Silica Gel From Rice Huskfull Txt 71205w

SGEL Manufacturing Company

MAPUA INSTITUTE OF TECHNOLOGY School of Chemical Engineering and Chemistry

A FEASIBILITY STUDY ON THE

PRODUCTION OF SILICA GEL BLUE FROM RICE HUSK

In completion to the requirements of CHFK583 Conducted By:

DE PADUA, Aileen L. VERGRA, Jonjon G. VIZCARRA, Harlene T.

Engr. Winston Flora Instructor

14 February 2004

SGEL Manufacturing Company TRANSMITTAL LETTER In partial fulfillment of the requirements for the degree in Bachelor of Science in Chemical Engineering, this study entitled “Production of Silica Gel Blue from Rice Husk”, as prepared by DE PADUA, AILEEN L. 1998113613 VERGARA, JONJON G.

1998126104

Vizcarra, HARLENE T.

1998115523

is hereby recommended for oral presentation. ________________________ ENGR. NILDA ELIQUEN Technical Adviser

______________________ ENGR.DANIEL CHENG Financial Adviser __________________________ ENGR. WINSTON B. FLORA Course Adviser

ACCEPTANCE The attached study was successfully presented June 23, 2003. It is hereby accepted as a partial requirement to the degree of Bachelor of Science in Chemical Engineering. _______________________ ENGR. NILDA ELIQUEN Technical Adviser

____________________________ ENGR. ELIZABETH ESPIRITU Faculty, School of ChE-Chm

_______________________ ENGR.DANIEL CHENG Financial Adviser

__________________________ ENGR. EDWIN OBRA Faculty, School of ChE-Chm

__________________________ ENGR. WINSTON B. FLORA Course Adviser

APPROVAL On the recommendation of the , the School of Chemical Engineering and Chemistry of the Mapua Institute of Technology accepts this study s partial fulfillment leading to a degree of Bachelor of Science in Chemical Engineering. ______________________ DEAN LUZ L. LOZANO School of ChE-Chm


Abstract

As the world chemical market sectors have become subject to increasing international competition and opportunities, the need for international information is also increasing. Many markets undergo important changes as the marketing environment and political framework conditions change. The dynamics of the market for silica gel point to continuous increase in consumption. There are opportunities that this report investigates and describes.

Silica gel has a wide range use application in many industries. The future demand will mainly depend on the growth rate of various end industries, while judging by past trends, should increase progressively over the years. Hence, there exists considerable scope for establishing a silica gel manufacturing plant in the country in order to meet rising demand, since as of today the country is totally dependent on importing silica gel from other countries. It needs to be added that silica gel has an excellent potential market overseas, particular in South East Asia.

Apart from the encouraging demand scenario, a noteworthy factor that favors the establishment of a manufacturing plant for production capacity for silica gel in the Philippines is the large availability of rice husk- the principal raw material for the production of silica gel. Being a waste of a very available crop, it makes the manufacture of silica gel on a large scale a feasible production.

Market changes may apply increasingly not only to the pharmaceutical or electrical industry but also to local markets like in the leather industry. With the world split into major consumer markets, the market for drugs and electrical equipment is becoming complex, international and competitive.

All silica gel manufacturing processes depend on the efficient accumulation of end products especially in producing high silica content of ash obtained from incinerated rice husk.

SGEL Manufacturing Company It is the objective of this study to provide clear insights into cost structure of producing silica gel and their raw materials.

This study reviews the capacity of silica gel, shows their production costs, and identifies trends in the future availability and pricing of raw materials in comparison with markets of the end products.

The study deals with the production and capacity planning, and also the strategies that should be considered in diversification into silica gel business.


PROJECT SUMMARY

Name of the Product

The company will be promoting the name SGEL BLUE for its product. It is coined from a certain type of silica gel with blue as its color. S is from the word silica followed by gel.

Name of the Enterprise

The company shall be named as SGEL Manufacturing Company. The company carries the name of its product mainly silica gel. This implies that the company transpired from team effort of an all-Filipino committee with the aspiration of utilizing their country’s own resources.

Logo

SG

MANUFACTURING

The name itself comes from the product we are producing, the silica gel. The diamond is for the company’s prosperity and the three lines represent steps that the company would take before they would prosper.

SGEL Manufacturing Company PLANT LOCATION1

SGEL Manufacturing Company will be situated in Barrio Wakas, Bocaue, Bulacan. The plant location was chosen because of its accessibility to most of the rice mills in Central Luzon; to other raw materials such as sulfuric acid and sodium hydroxide; and to the target markets.

1

www.bulacan.gov.ph/bocaue


COMPANY VISION SGEL shall be the local premier in the production of silica gel having the best quality by implementing the most efficient method. It will help the nation alleviate its economy by reducing the need for importation. Furthermore, the company shall be known nationwide for its firm drives for an environmentally sustainable operation.

COMPANY MISSION ! To gain economic stability to sustain future development. ! To diminish the need of importation of silica gel. ! To supply high quality and low cost silica gel to local manufacturing companies that uses silica gel as their raw material. ! To establish a strong linkage with other manufacturing industries, research institutions, foreign and local entrepreneurs and investors, and related government agencies in order to assist one another in achieving their respective goals and objectives. ! To generate profitable job opportunities for the Filipino people. ! To contribute to the provincial income of Bulacan and its development.

GUIDING PRINCIPLES SGEL Manufacturing aims to develop and manufacture product, which can be transported, used and disposed of in secure and ecologically safe way. The “responsive care” initiative adds similar programs to enable us to raise our standard well beyond the level required by current regulation. Specifically, the company will: ! Be aware of the concerns of the community regarding our products as well as operations. ! Utilize operational procedures that will protect the environment and enhance public safety. ! Provide information regarding the distribution, storage, environmental impacts, and disposal to our customers, distributors, carrier and other stockholders. ! Implement standards to safeguard the workplace, the community and the environment.


PRODUCT DESCRIPTION Silica gel is an amorphous form of silicon dioxide, which is synthetically produced in the form of hard irregular granules (having the appearance of crystals) or hard, irregular beads. A micro porous structure of interlocking cavities gives a very high surface area (800 m2 per gram). It is this structure that makes silica gel a high capacity desiccant. Water molecules adhere to the gels surface because it exhibits a lower vapor pressure than the surrounding air. When equilibrium of equal pressure is reached, no more adsorption occurs. Thus, the higher the humidity of the surrounding air, the greater the amount of water that is adsorbed before equilibrium is reached. It is in these higher humidity conditions (above 50% relative humidity) that stored or in-transit items are susceptible to damage.

The beauty of silica gel is the physical adsorption of water vapor into its internal pores. There s no chemical reaction, no by products or side effects. Even when saturated with water vapor, silica gel still has the appearance of a dry product, its shape unchanged. Advantages of Silica Gel as a Desiccant2 ! It will adsorb up to one third of its own weight in water vapor. This adsorption efficiency is approximately 35% greater than typical desiccant clays, making silica gel the preferred choice where weight and efficiency are important factors. ! It has an almost indefinite shelf life if stored in airtight conditions. ! It can be regenerated and reused if required. Gently heating silica gel will drive off the adsorbed moisture and leave it ready for reuse. ! It is a very inert material, it will not normally attack or corrode other materials and with the exception of strong alkalis and hydrofluoric acid is itself resistant to attack. ! It is non-toxic and non-flammable. ! It is most frequently and conveniently used packed in a breathable sachet or bag. These are available in a wide range of sizes suitable for use with a wide range of applications.

2

Qingdao Meigao Chemical Company, LTD.

SGEL Manufacturing Company The most commonly known and used desiccant is silica gel which is a form of silica dioxide(SiO2), a naturally occurring mineral. It will work from below freezing point to past the boiling point of water, but performs best at room temperatures (70-90°F) and high humidity (6090%). Its performance begins to drop off over 100°F, but will continue to work until approximately 220°F. It will lower the relative humidity in a container to around 40% at any temperature in its range until it is saturated. Silica gel will absorb up to 40% of its weight in moisture. The FDA for direct food use approves some forms. It recharges easily and does not swell in size as it absorbs moisture. SELF-INDICATING (BLUE) SILICA GEL Self-indicating silica gels will absorbs moisture in exactly the same way as standard nonindicating silica gel, but they will literally indicate when they are becoming saturated by changing their color. This is useful in two ways. When the gel has changed color, it gives an immediate warning that it should be replaced. Secondly, if regenerating the silica gel, the self-indicating grade will be ready for reuse, when its original color has returned. Until recently, the only indicating silica gels used a small concentration of moisture sensitive cobalt chloride indicator, which gives blue silica gel. This changes to pink as it absorbs moisture and becomes saturated, returning to blue as it is regenerated. We will be labeling all containers of self-indicating (blue) silica gel with a TOXIC symbol and the risk Phrase “may cause cancer by inhalation’. We have produced a Material Safety Data Sheet for information. s are advised to ‘avoid raising dust’ and to use ‘a suitable, effective dust mask’ when handling the material, it will also be classed as a special waste and need to be disposed of accordingly.

Please note the following points: ! ! !

Self-indicating (blue) silica gel is the same as it has been for 60 years there has been no change in its formulation or composition. Self-indicating (blue) silica gel has not been banned from use. The term hazardous apply to cobalt chloride not silica gel, so they do not apply to selfindicating (blue) silica gel


PRODUCT PROPERTIES

Physical Properties There are three types of silica gel:3

1. Regular density gel ! High surface area of 750-800 m2 per gram ! Average pore diameter of 2.2-2.6 nm ! Pore volume is 0.37-0.40 ml per gram ! Contains 6% weight as surface hydroxyl group, which imparts a high capacity for water adsorption of other popular molecules ! High selectivity for polar molecules ! Large percentage of small pores

2. Intermediate density silica gel ! Surface area of 300-350 m2 per gram ! Pore volume of 0.9-1.10ml/g ! Average pore size is 12-16 nm in diameter ! Particles are larger than those of regular density gel ! Has a high capacity for water adsorption at high humidity ! Porosity can be controlled

3. Low density silica gel ! Surface area of 100-200 m2/g ! Pore diameter of 18-22 nm ! Pore volume of 1.4-2.0 ml/g

3

Chemical Engineering Encyclopedia (1997) p. 765


Chemical Properties4 ! Molecular weight is 60.06 kg/mole ! Freezing temperature is 1883.00 K ! Boiling temperature is 2503.20 K ! Critical temperature of 4076.87 K ! Critical pressure is 336.18 bar ! Critical volume is 302.5 cm3/mol ! Critical density is 0.1986 ! Accentric factor is 0.719 ! @ 25ºC is 43.137 j/mol ! Enthalpy of fusion @ TF = 1883.00 kcal/mol is 8.514 kj/mol ! Enthalpy of formation @ 298 K is –910.70 kj/mol ! Thermal conductivity @ 25ºC is 1.458 W/m @ 273 K is 1.487 W/m @ 1400 K is 5.961 W/m

4

Carl L. Yaws, Chemical Properties Handbook (United States of America: Mc Graw Hills Companies, 1999) P. 550


PRODUCT USES AND APPLICATIONS

! Silica gel prevents moisture related problems before they begin by creating a protective shield of dry air within any enclosed storage area. ! In leather products and goods, it can limit the growth of mold and reduce spoilage. ! In electronics, it prevents condensation, which might damage the electronics. ! It can be used as a dehydrating refinement of organic products. ! Used in beer purification. ! Used as a carrier of catalysis. ! It can be used in cooling systems for saving energy. The desiccant can remove moisture from the air, which releases heat and increases the air temperature. ! It is also used as a base catalyst to increase the viscosity and thixotropy; for surfactants and optical effects; as a source of reactive silica; for cloud seeding; in chromatographic column packing; as an anti-caking agent; and in paper coating. ! Takes the function of grading, concentrating, water adsorption, and oil adsorption in the process of toothpaste and cosmetic manufacture.

SGEL Manufacturing Company MATERIAL SAFETY DATA SHEET5

1. Product Identification Synonyms: Silica, amorphous; Silica, precipitated and gel (CAS # 112926-00-8) (OSHA). Chemical Formula: SiO2. XH20 + CoC12

Composition/Information on Ingredients Ingredient CAS No Percent Hazardous --------------------------------------------------------- --------------------Silica Gel

63231-67-4

> 97%

yes

Cobalt Chloride

7646-79-9

< 3%

yes

R Phrases ------------------

R22,R36,R42/43

Hazards Identification Emergency Overview -------------------------TOXIC (see hazard warning label) SAFETY DATA Ratings (Provided here for your convenience) -------------------------------------------------------------------------------------Health Rating: - Moderate Flammability Rating: - None Reactivity Rating: - None Rating: Slight Lab Protective Equip: GOGGLES; LAB COAT; VENT HOOD; PROPER GLOVES Storage Colour code: Orange (General Storage) Potential Health Effects ------------------------------This product contains synthetic amorphous silica; not to be confused with crystalline silica such as quartz, cristobalite or tridymite or with diatomaceous earth or other naturally occurring forms of amorphous silica that frequently contain crystalline forms. Inhalation: May cause dryness and irritation to mucous membranes, nose, and throat. Symptoms may include coughing, sore throat, and wheezing. Ingestion: 5

http://www.envirogel.co.uk/material_safety_datasheet_blue.htm

SGEL Manufacturing Company No adverse effects expected. Skin : May cause irritation with dryness and abrasion. Eye : May cause irritation, redness and pain. Chronic Exposure: Repeated exposure may cause symptoms similar to those listed for acute effects. Synthetic amorphous silica does not produce silicosis> Prolonged exposure to cobalt has been shown to cause cancer in laboratory animals. Aggravation of Pre-existing Conditions: No information found. First Aid Measures Inhalation: Remove to fresh air. Get medical attention for any breathing difficulty. Ingestion: Give several glasses of water to drink to dilute. If large amounts were swallowed, get medical advice. Skin : Immediately flush skin with plenty of soap and water for at least 15 minutes. Remove contaminated clothing and shoes. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention if irritation develops. Eye : Immediately flush eyes with plenty of water for at least 15 minutes, lifting upper and lower eyelids occasionally. Get medical attention if irritation persists. Fire Fighting Measures Fire: Not considered to be a fire hazard. Explosion; Not considered to be explosion hazard. Fire Extinguishing Media: Use any means suitable for extinguishing surrounding fire. Special Information: Use protective clothing and breathing equipment appropriate for the surrounding fire. Accidental Release Measure Ventilate area of leak or spill. Wear appropriate personal protective equipment as specified in Section 8. Spills: Sweep up and containerise for reclamation or disposal. Vacuuming or wet sweeping may be used to avoid dust dispersal. Regulations require reporting spills and releases to soil, water and air in excess of reportable quantities. Handling and Storage


Keep in a tightly closed container, stored in a cool, dry, ventilated area and labelled accordingly. Protect against physical damage. When pouring into a container of flammable liquid, ground both containers electrically to prevent a static electric spark. Containers of this material may be hazardous when empty since they retain product residues (dust, solids); observe all warnings and precautions listed for the product. Exposure Controls/Personal Protection Airborne Exposure Limits: Silica (synthetic, amorphous): - OSHA Permissible Exposure Limit (PEL) - 80/(%SiO2) mg/m3 (TWA) for amorphous silica, including natural diatomaceous earth. - ACGIH Threshold Limit Value (TLV) 10 mg/m3 (TWA) for amorphous precipitated silica and amorphous silica gel. For Inorganic Cobalt Compounds: - ACGIH Threshold Limit Value (TLV) 0.02 mg/m3 (TWA) as Co, A3: Animal carcinogen. Ventilation Systems: A system of local and/or general exhaust is recommended to keep employee exposures below the Airborne Exposure Limits. Local exhaust ventilation is generally preferred because it can control the emissions of the contaminant at its source, preventing dispersion of it into the general work area. Please refer to the ACGIH document, Industrial ventilation, A Manual of Recommended practices, most recent edition, for details. Personal Respirators: If the exposure limit is exceeded, a half-face dust/mist respirator must be worn suitable for the exposure limit or the maximum use concentration specified by the appropriate regulatory agency or respirator supplier, whichever is lowest. WARNING: Air-purifying respirators do not protect workers in oxygen-deficient atmospheres. Respirators must meet the requirements of European Standard EN149 FF3SL. Suitable for use under COSHH, CAW, CLAW and IRR. Skin Protection: Wear protective gloves and clean body-covering clothing.

Physical and Chemical Properties


Appearance: Blue crystals. Odour: Odourless. Solubility: Silica gel base is insoluble in water; cobalt chloride may leach out. Specific Gravity: 2.1 PH: 5.5-9.0 (in 5% slurry)% Volatiles by volume @ 21ºC (70ºF): 0 Boiling Point: No information found. Melting Point: No information found. Vapour Density (Air=1): No information found. Vapour Pressure (mm Hg): No information found. Evaporation Rate (BuAc=1): No information found. Stability and Reactivity Stability: Stable under ordinary conditions of use and storage. Hazardous Decomposition Products: Oxides of carbon and silicone may be formed when heated to decomposition. Hazardous Polymerisation: Will not occur. Incompatibility: Reacts with hydrogen fluoride, fluorine, oxygen difluoride, chlorine trifluoride, strong acids, strong bases, and oxidizers. Conditions to Avoid: Moisture, extreme heat, and incompatibles. Toxicological Information Toxicological Data: No LD50/LC50 information found relating to normal routes of occupational exposure. Carcinogenicity: Cobalt and its compounds have been shown to cause cancer in laboratory animals. Ecological Information Environmental Fate: For Silica Gel (synthetic amorphous): When released into the soil, this material is not

SGEL Manufacturing Company expected to biodegrade. When released into water, this material is not expected to biodegrade. Environmental Toxicity: For Silica Gel (synthetic amorphous): This material is not expected to be toxic to aquatic life. Disposal Considerations Whatever cannot be saved for recovery or recycling should be managed in an appropriate and approved waste disposal facility. Processing, use or contamination of this product may change the waste management options. Local disposal regulations may differ from national disposal regulations. your local Environmental Agency for closest Waste Management site. Dispose of container and unused contents in accordance with national and local regulations. Transport Information Not regulated. Regulatory Information -----------\ Chemical Inventory Status - Part 1 \----------Ingredient EC Silica Gel (63231-67-4) Cobalt (II) Chloride (7646-79-9)

No No

-----------\ Federal, State & International Regulations - Part 1 \----------Ingredient

--SARA 302-RQ TPQ

Silica Gel (63231-67-4) Cobalt (II) Chloride (7646-79-9)

No No

No No

-----SARA 313----List Chemical Catg. No No

No Cobalt compound

-----------\ Federal, State & International Regulations - Part 2 \----------Ingredient Silica Gel (63231-67-4) Cobalt (II) Chloride (7646-79-9)

CERCLA

--RCRA-261.33

--TSCA-8 (d)

No 1

No No

No No

Poison Schedule: No information found. This MSDS has been prepared according to the hazard criteria of the Controlled Products Regulations (R) and the MSDS contains all of the information required by the R. EC Classification: Carcinogenic

SGEL Manufacturing Company R Phrases

R49 May cause cancer by inhalation R42/43 may cause sensitisation by inhalation and skin . S Phrases S22 Do not breathe dust. S53 Avoid exposure - obtain special instructions before use. S45 In case of accident or if you feel unwell, seek medical advise. S60 This material and/or its container must be disposed of as hazardous waste. S2 Keep out of reach of children. EINECS Listing Preparation - all components listed.

Other Information Label Hazard Warning: TOXIC Label Precautions: Avoid with eyes, skin and clothing. Avoid breathing dust. Keep container closed. Use with adequate ventilation. Wash Thoroughly after handling. Label First Aid: If inhaled, remove to fresh air. Get medical attention for any breathing difficulty. In case of , immediately flush eyes or skin with plenty of water for at least 15 minutes. Get medical attention if irritation develops or persists. Product Use: Transformer Breathers, Tank Vent Dryers, Drum Vent Dryers, Air Drying Applications and Laboratory Reagent.



Historical Demand

The importation of silica gel of the Philippines had endured considerable increases. From 1995 to 1999, 2000 to 2003, there was an increase in the demand of silica gel. There had been some fluctuations that are caused by unexpected political instability, which inevitably scared most foreign investors. The result leads to an economic instability. Fortunately, such event did not affect much of the demand pattern of silica gel. One reason is the fact that silica gel is a constituent important for the manufacture of pharmaceutical products and as well as to electrical industries, thus silica gel is always in great demand. Another cause of the growing demand in the country is the continuous rise of the population.

It can be observed that there is no local production that exists in the country, yet there are some years when the country had a small amount exported to other neighboring Asian countries. The reason for this is that some of our local traders who import silica also export some of it to countries where there is no sufficient supply of silica gel. In short, they used to “buy and sell” silica gel. The demand for silica gel is expected to increase in the subsequent years based from the historical demand of the product. This is ed by the computed projected demand of silica gel for the next ten years. The demand profile obtained is very encouraging. The study shows the consumption of silica gel in the Philippines is increasing with a growth rate averaging 6.62% a year. This is due to the rapid expansion of pharmaceutical; soap and detergent industries are major consumers, which have triggered the importation of this product. Furthermore, the major , pharmaceutical is one of the most stable markets. The demand picture, from the point of view of new producers, is encouraging and tempting enough to be invested upon a profitable business area. Whenever the demand is great the supply must be able to match the situation. So far, there is no local manufacturer. Therefore, the absence of any local producer of silica gel will give the new manufacturer less problem in entering the local market. Based on the local market segmentation, pharmaceutical industry consumes 60% of the total supply. Thus, it is very encouraging to choose this segment as the company’s target market.

SGEL Manufacturing Company The demand of the pharmaceutical industry will always be high because it could also be considered as a necessity of every individual. As the population continuously rises, the consumption of silica gel will also rise, even though political turmoil and economic fluctuations takes place. Since there is no existing local manufacturer of silica gel in the Philippines, our company will focus first on domestic market. For the succeeding years, we plan to participate in the exportation of the product most likely in the Asian region. There is no local manufacturer of silica gel in the country. The companies listed above are just traders that import silica gel from other countries. They already had added to their price the cost of importing their supply. Hence, the price of silica gel in the country is much higher than in the market of those countries that produce their own silica gel. The SGEL Manufacturing Company will produce a high quality and competitively priced silica gel so that companies that will use our products will continue to patronize us. Rational and economic manufacture of high quality products on a large scale is not feasible without advanced process and extensive process control technology. Through the application of the advanced manufacturing process and its first class management, SGEL Manufacturing will keep with its high production safety, continuously optimizing its production to upgrade the quality of its products. The quality system consists of advanced instruments in QC and QA, well-established quality mechanism, which is continuously modified and upgrade by quality management. The quality system facilitates the product quality management at high standard.


SWOT ANALYSIS STRENGTH ! SGEL, being a local manufacturer of silica gel provides competitive price. ! Investors would back up SGEL Manufacturing Company. ! Since our raw material will be coming locally from Bulacan and will be acquired at a very low price, the product will be offered at a low price with satisfying profit. ! We will be established in the market since our product will be offered at a low price. WEAKNESS ! SGEL, being a new player in the industry, has no permanent share in the market yet. ! Initial investment would be very costly and returns would not be sufficient to pay for the next few years. ! Importers of silica gel might not be convinced with the quality of our product. ! SGEL might not get sufficient from the government in our campaign for local patrons. OPPORTUNITIES ! The market for desiccants is increasing and current manufacturers might not be able to produce enough products to suffice the demand. ! Plant location is near the source of the raw materials so transportation and its cost will not be a problem. ! We can target a larger market since the exportation is low and importation is high and we can convince the importers that they can save money by patronizing local and economical product such as ours. ! Because silica gel has many uses, we can be competitive compared with other products manufactured locally. THREAT ! Importers of silica gel may not be convinced by the ments of our company since they have relied on imported silica gel. ! The demand for silica gel is fluctuating. There may be sometime that the company will face difficulty due to decreased demand. ! Changing weather conditions affects the production of rice husk.


MARKETING MIX ANALYSIS

PRODUCT 80% of SGEL Blue will be packed using resealable polyethylene drums. Every drum would contain 25 kg of silica gel, and the remaining 20% of the production volume would be packed in sachet containing 1 kg. Products would be delivered upon purchase. Pharmaceutical companies would repack the silica gel into smaller sachet.

PLACE

Our company will capitalize itself on its strategic location, which affords proximity to its market. The SGEL Manufacturing Company plant site will be situated in Barangay Wakas, Bocaue, Bulacan.

DISTRIBUTION

Our product will be distributed by container vans carrying our product name, physical and chemical properties hazards and medications, and our company logo and address.

PROMOTION The SGEL Manufacturing Company will employ the following promotion strategies; ! The use of print media including trade magazines, brochures, yellow pages and the like. ! The utilization of contemporary communication facilities such as Internet, email, fax and others. Creation of website for the company will also be considered. ! Free distribution of product sample to the potential consumers. ! Invitation of potential buyers for seminars, plant visitation and inspection. ! Involvement in regional and international trade fairs and conferences. ! Establish trade partnership with the investor of Asian regions having large demand of silica gel for easier market penetration.


For customers to be more confident with our product, the SGEL Manufacturing Company shall obtain certificates from the following: ! International Organization for Standardization (ISO) ! British Pharmacopoeia ! United States Pharmacopoeia (USP) ! America Society Standards ! Australian Standards (AS)

To have a competitive advantage, the SGEL Manufacturing Company aims to secure hip in local and international association such as: ! Samahan sa Pilipinas ng mga Industriyang Kimikal (SPIK) or the Chemical Industries Association of the Philippines ! ASEAN Chemical Industry club (ACIC)

The SGEL Manufacturing Company shall also provide an active customer by: ! Just-in-time deliveries to clients will become the industry standard to match. Deliveries will be made directly to our customers or to strategically locate central depots in major markets. With distribution channels that are near to our customers, our Just-in-Time deliveries eliminate the need for expensive storage area at customer’s production site. ! SGEL Manufacturing Company will earn a reputation for efficient service and responsiveness to our customer’s individual needs. Working with our customers from product development ensures that the right material is selected for their application. We will implement our flexible capabilities that can accommodate special requests, such as tailor-made products, granulations, blends and mixes.


SALES PLAN

PRODUCT LAUNCHING

SGEL Manufacturing Company will be first to produce silica gel in the Philippines. The main raw material used in the manufacture of SGEL is rice husk. Originally, the only source of silica gel is through importation.

PROMOTIONS AND ADVERTISING ! Print Ads ! Creation of website for the company ! Brochures ! Free distribution of the product samples ! Yellow pages

PACKAGING AND DELIVERY 80% of SGEL Blue will be packed using resealable polyethylene drums. Every drum would contain 25 kg of silica gel, and the remaining 20% of the production volume would be packed in sachet containing 1 kg. Products would be delivered upon purchase. Pharmaceutical companies would repack the silica gel into smaller sachet.

PRICING The current selling price of silica gel ranges from Php225-255. SGEL Blue will be sold at Php230 per kilogram those who are packed in polyethylene drum while those in sachets will be sold Php250 per kilogram. The minimum order will be 450 kg.

The SGEL Manufacturing Company will produce a high quality and competitively priced silica gel so that companies that will use our products will continue to patronize us. Rational and

SGEL Manufacturing Company economic manufacture of high quality products on a large scale is not feasible without advance process and extensive process control technology. Through the application of the advanced manufacturing process and its first class management, SGEL Manufacturing Company will keep with its high production safety, continuously optimizing its production to upgrade the quality of its products. The quality system consists of advanced instruments in QC and QA, wellestablished mechanism, which is continuously modified and upgrade by quality management. The quality system facilitates the product quality management at high standard. The current selling price of silica gel ranges from Php225-255. SGEL Blue will be sold at Php230 per kilogram those who are packed in polyethylene drum while those in sachets will be sold Php250 per kilogram. The minimum order will be 450 kg.

MARKET SHARE

At present, the Philippines have no local manufacturer of silica gel. Traders in the domestic market are distributing silica gel, and their supply come from other countries. Because of this, traders had taken advantage of the current situation. Traders had sold the product at a higher price. Even though the price is relatively high than in other countries that can produce their own silica gel, customers still patronize the product being distributed by traders since they don’t have the option for the raw material of their product. And also, the demand for silica gel in the country is high because of its diversified uses. Silica gel is a versatile industrial chemical that is used as a part of the raw materials for further improvement of the quality of wide range of products. Thus, our company has a lot of potential target markets such as pharmaceutical, electronics, veterinary, and leather industries.

SGEL Manufacturing Company POTENTIAL MARKETS

1. Pharmaceutical, cosmetic and Toiletry Industries ! Pfizer ! Euromed ! BOIE ! UNILAB ! WARNER ! Wyeth ! Splash

2. Other Industries

! Republic Chemical Industries,Inc. ! Cord Chemicals, Inc ! Premiere Adhesives and Coatings, Inc ! Advance Paper Manufacturing Corp.



COMMERCIALLY PROVEN PROCESSES6 In other countries, silica gel is manufactured by hydrolysis of silicon tetrachloride with water and heating the hydroxide formed (Allen Miller TP-ANSEL KBONDD):

SiCl 4 + 4 H 2O → SiO2 ⋅ 2 H 2O + 4 HCl Silica gels can be prepared by several methods. Most commonly, a sodium silicate solution is acidified to a pH less than 10 or 11. The bulk-set process consists of the following steps: A silica hydrosol is prepared by mixing sodium silicate with a strong mineral acid. After it is allowed to set to a rigid mass, it is broken up mechanically. The silica concentration, temperature, and pH affect gelling time and final gel characteristics such as density, strength, hardness, surface area, and pore volume. The hydrogel particles are then washed free of electrolytes, and the washed gel is dried and activated. The rate of drying affects final gel properties. In the slurry process, sodium silicate solution and acid are mixed, either batch or semi continuously, to produce a gelatinous precipitate. This hydrogel is washed and dried often by spray drying. Sodium silicate is the cheapest source of silica although natural sources can also be used. Certain clays yield relatively pure silica when leached with acid. Gels made from soluble silicates usually have very small particle size and the salts must be washed away before use. Gels can be made directly from salt-free along with low salt content. Surface characteristics may also be different, such as lower specific surface area and larger pore diameter. Hydrolysis of pure silicon compounds, like ethyl silicate, silicon tetrachloride, and other volatile hydrolysable silica ether is another method of preparing gels. This method is more expensive, but produces very dense gels of high purity and very small pore size.

6

Encyclopedia of Chemical Technology, vol 20, pp.774-775

SGEL Manufacturing Company MACHINERY AND EQUIPMENT EQUIPMENT SPECIFICATIONS Rotary Kiln Type Material Area Feed Capacity Temperature Pressure Range Cost

: Direct Gas Fired : Stainless Steel, 304 : 200 ft2 : 2 tons : 650-700°C : 1atm-25psi : P28,148,529.00

Dilution Tank Material Length Diameter Feed Capacity Temperature Pressure Cost

: Carbon Steel and API : 4 meters : 3 meters : 10,800 Liters : 25°C : 1atm-25psi : P135,500.00

Dilution Tank Material Length Diameter Feed Capacity Temperature Pressure Cost

: Carbon Steel and API : 4 meters : 3 meters : 4000 Liters : 25°C : 1atm-25psi : P47,450.00

Tray Dryer Material Area Temperature Range Cost

: Carbon Steel : 20 ft2 : 100-120°C : P190,450.00

Batch Reactor Type Material Area Feed Capacity Temperature Range Pressure Range Cost

: Continuous Agitator : Stainless Steel, 304 : 11 ft2 : 252 tons : 55-60°C : 1atm-25psi : P9,570,586.00

SGEL Manufacturing Company Batch Reactor Type Material Area Feed Capacity Temperature Range Pressure Range Cost

: Continuous Agitator : Stainless Steel, 304 : 6 ft2 : 156 tons : 55-60°C : 1atm-25psi : P5,889,557.00

Centrifuge Type Material Feed Capacity Temperature Range Pressure Range Cost

: Screen Bowl : Cast Iron and API –610 : 100-200 tons : 55-60°C : 1atm-25psi : P37,255586.00

Screen Type Material Deck Area Cloth Cost

: Vibratory, Horizontal (2-Deck) : Stainless Steel, 304 : 32 ft2 : Polyurethane Screen : P900,900.00

Pulverizer Type Material Feed Capacity Temperature Range Pressure Range Cost

: Ball Mill : Carbon Steel : 100-200 tons : 25°C : 1atm-25psi : P407,550.00

Washer Type Capacity Length Width Cost

: Sprinkler Type : 1-100 tons : 1-5 meters : 0-3 meters : P128,050.00

Conveyor Type Material Feed Capacity Length Height Cost Storage Vessel

: Close Conveyor : Carbon Steel : 0-100 tons : 0-20 meters : 3 meters : P14,517.00

Type Material Capacity Cost

: : Carbon Steel : 100 tons : P8,320.00


SGEL MANUFACTURING PROCESS WASHING

Rice husks coming from the sources are first washed with water (recycled from the boiler) before feeding to the incinerator. This is done to remove soil, dirt, sand and other impurities acquired from harvesting and removal from grain.

INCINERATION

Incinerator used is the rotary kiln incinerator. Combustion is direct heating. Incinerator temperature is 600 to 650°C and pressure is atmospheric. The husks coming from the washing chamber is the fed to the incinerator. During the conversion of husk to ash, the combustion process removes the organic matter and leaves silica-rich residue. Weight loss occurs up to 100°C due to evaporation of adsorbed water from washing process. At about 300°C, volatile components ignite, causing the rice husks to start burning and to lose further the weight of the rice husk. The majority of the weight loss occurs when the residual carbon oxidizes at the temperature range 400 to 500°C. The temperature of the process should not exceed 650°C. Above this temperature, conversion from amorphous silica to quarts occurs, which is not the desired form. Silica desired is amorphous. Reaction time is one hour and forty-five minutes.

FORMATION OF SODIUM SILICATE

The ash from the incineration process is then fed to the reactor. 2.5M sodium hydroxide is added to the ash to produce liquid sodium silicate. Constant agitation of the mixture is done throughout the reaction process. The reaction occurs at ambient temperature and atmospheric pressure. The product stream leaves the reactor at temperature of 55.6°C due to heat produced by the exothermic reaction. Reaction time is forty-five minutes.


Reaction:

3.4SiO2 + 2NaOH

Na2O 3.4SiO2 + H2O

CENTRIFUGATION

Sodium silicate solution from the reactor is fed to the screen bowl centrifuge. During centrifugation, insoluble matters are separated from the sodium silicate solution. Unreacted silica and other oxides (K2O, MgO, CaO, etc.) in the ash are removed during centrifugation period. Unburned rice husk are also removed. The residence time of the sodium silicate solution inside the centrifuge is 20 minutes.

FORMATION OF SILICA SOL

A silica sol is stable dispersion of discreet, colloid-size particle of amorphous silica in aqueous solution. The higher the silica content of a sol, the more likely it is to gel. To obtain the hardest and the strongest gels, the gel is usually formed at low pH and at ordinary or even lower temperatures. The sodium silicate solution free of impurities or insoluble matters is reacted with sulfuric acid to form silica sol. The inlet temperature of sulfuric acid is 0°C and the concentration is 3M. It is added gradually to sodium silicate solution to prevent formation of low pH regions where gelation might occur. The temperature of the reaction is maintained at 0°C. Increasing the temperature to above 3°C will initiate reaction or gelling. Lowering pH value produces regions wherein sols are metastable, and gelling and aggregation are catalyzed. It is important to assure a homogenous mixture before the actual reaction takes place to reduce losses. Constant agitation is done throughout the reaction. The colloidal suspension produced is the silica sol. It is produced by exothermic reaction. Reaction time is forty-five minutes.

SGEL Manufacturing Company Reaction:

Na2O ⋅ 3.4SiO2 + H2SO4 → 3.4SiO2 + Na2SO4 + H2O GEL FORMATION

The colloidal dispersion or silica sol from the reactor is fed to the dryer heated by the stem from the boiler. The temperature is set at 65 to 75°C and pressure is atmospheric. To be able to produce a gel with good characteristics, drying time is set to forty-five minutes. Three stages are needed in the formation of silica gel. First is the polymerization of monomer or particles of silica to form small particles. In this stage, the particles collide and aggregate into chains and form small particles. Second stage is the growth of particles. Small particles formed during polymerization leads to the formation of sol to a more viscous solution. Third stage is the linking of particles together into branches chains, then networks, finally extending throughout the medium. In this stage the viscous solo becomes rigid by a coherent network of particles. The aggregates formed associated with other aggregates, thus bonding all aggregates to form rigid gel. Several factors affect the gelling time of silica sol. One is the rate of polymerization or gel formation. It is assumed to be inversely proportional with time. This means that at a lower value of the rate of polymerization, the gel formation is slower, thus requiring a longer gelling time. Another factor is the concentration. When the concentration of silica or sodium silicate is increased, the gelling time decreases. If the e concentration of SiO2 is more than 1%, aggregation may occur as soon as the first small particles are formed. Another controlling factor is the pH. At low pH, silica particles bear very little ionic charge and thus can collide and aggregate into chains and then networks. While the sol is being converted into gel, the growing aggregates contain the same concentration of silica and water as in the surrounding sol regions, by capillary action.

SGEL Manufacturing Company SYNERISIS

After forty-five minutes of gel formation inside the oven at 65 to 75°C, temperature is raised to 9°C. The time is set to twelve hours subjecting the gel to the temperature for shrinking. Condensation then occurs between the primary particles of the gel, which causes the gel to shrink. The entrained solution, water and Na2SO4 is separated from the gel, producing a firm, almost rigid gel. After sometime, the hydro gel becomes compact and eventually collapses to produce firm, almost rigid gel pellets.

SCREENING

The pellets from the synerisis oven are fed to the mechanically vibrating horizontal screen to separate oversized and undersized from the desired size. Screening is also done to remove most of the Na2SO4 left in the product. The pellet undergoes screening on the four-mesh top screen, which removes pellets greater then 7mm in diameter. The undersize will undergo another screening this time with seven-mesh bottom screen, which allows pellets of 4mm diameter and below to through. The undersize from the bottom screen and the oversize from the top screen are dumped into a pulverizer, and then back to synerisis oven. The desired product has diameter ranging between 7 to 5mm.

WASHING

The desired product is conveyed to a washing chamber wherein the water used is condensed steam from the boiler. Inside the washing chamber, water is sprayed on the hydrogel to eliminate the last of the electrolytes from the gel. The gel is washed until such time that the pH the washing becomes 4 to 6. Washing time is 30 minutes. Water fed is set to 500kg per batch. Since silica gel can adsorb moisture up to 40% its weight.

SGEL Manufacturing Company DRYING

From the washing chamber, the washed pellets containing adsorbed and adhered water are loaded to trays inside the dryer. The temperature is set at a range between 105 and 110°C. in this process, free or unbound water is vaporized including almost 90% of bound water of the pellets. Drying time is forty-five minutes. MIXING After drying the pellets are mixed with moisture sensitive cobalt chloride 10% by weight silica gel.

ACTIVATION

Because the pellets still contain 10% bound water, the product needs to be treated by thermal means to ensure purity. The silica gel from the dryer is loaded to activation oven set at 180 to 210°C and atmospheric pressure. During the process, hydroxyl ions are detached from the gel surface. Drying time is forty-five minutes.

STORAGE

After drying and achieving silica gel pellets, the product is put in temporary storage ready for packaging.

PACKAGING

Packing is automatically done. The gel is loaded in polyethylene storage drums that could hold 25kg of the product and others are packed in sachets that can hold 1 kg. The drum and sachets are then sealed and brought to the product storage area by forklift ready for dispatching.

SGEL Manufacturing Company MATERIAL BALANCE

F2 + Recycled Water F2 = 366.32 kg Recycled water = 133.68 kg

P1 = 978.61 kg WASHER 1 F1 Rice Husk = 478.61 kg Rice husk = 464.25 kg Impurities = 14.36

Rice husk = 464.25 kg Impurities = 14.36 kg Water = 500 kg

Assumptions: Rice Husk with 3% impurities

OMB at Washer 1: F1 + F2 + Recycled water = P1 478.61 + 366.32 + 133.68 = P1 P1 = 978.61 kg

45


P3 = 514.32 kg

P1 = 978.61 kg CENTRIFUGE 1

Rice husk = 464.25 kg Impurities = 0.0718 kg Water = 50 kg

Rice husk = 464.25 Impurities = 14.36 kg Water = 500 kg

P2 = 464.2882 kg Impurities = 14.2882 kg Water = 450 kg

Assumptions: 0.5 % impurities adheres to wet rice husk 10 % water adheres to rice husk

OMB at Centrifuge 1: P1 = P2 + P3 978.61 = 464.2882 + P3 P3 = 514.32 kg

46

SGEL Manufacturing Company P4 = 2200.52 kg Flue gas = 2150.52 kg Water = 50 kg

P5 = 86.42 kg

P3 = 514.32 kg INCINERATOR

Ash = 83.40 kg Solids = 2.95 kg Impurities = 0.0718 kg

Rice husk = 464.25 Impurities = 0.0718 kg Water = 50 kg

F3 (Air) = 1772.62 kg Assumptions: 100% water evaporated Flue gas completely removed Composition of Rice Husk Content

%Composition

Weight (kg)

Carbon Hydrogen Nitrogen Oxygen Sulfur Ash

39.9 5.05 0.5 35.85 0.1 18.6

185.24 23.44 2.32 166.43 0.47 86.35

Composition of Ash Content

% Composition

Weight (kg)

Silica Calcium Chlorine Iron Magnesium Manganese Phosphorus Potassium Sodium Sulfur

96.58 0.3 0.6 0.07 0.25 0.2 0.25 1.05 0.35 0.35

83.40 0.26 0.52 0.06 0.22 0.17 0.22 0.90 0.30 0.30

OMB at Incinerator: P3 + F3 = P4 + P5 514.32 + 1772.62 = 2200.52 + P5 P5 = 86.42 kg 47


F4 = 495.74 kg Water = 463.04 kg Sodium hydroxide = 32.70 kg

P6 = 582.16 kg

P5 = 86.42 kg REACTOR 1

Sodium silicate = 108.82 kg Water = 470.32 kg Solids = 2.95 kg Impurities = 0.0718 kg

Ash = 83.40 kg Impurities = 0.0718 kg Solids = 2.95 kg

Reaction:

3.4SiO2 + 2NaOH

Na2O3.4SiO2 + H2O

From the reaction:

SiO2 NaOH Na2O3.4SiO2 H2O

MW 60 40 266.19 18

kmol 1.39 0.82 0.41 0.41

Weight (kg) 83.40 32.70 108.82 7.36


48

P8 = 155.85 kg


Sodium silicate = 108.82 kg Water = 47.03 kg

Sodium silicate = 108.82 kg Water = 470.32 kg Solids = 2.95 kg Impurities = 0.0718 kg

P7 = 426.31 kg Water = 423.29 kg Solids = 2.95 kg Impurities = 0.0718 kg

Assumption: 10% water in P6 adheres


49


F5 = 248.18 kg Water = 208.11 kg Sulfuric acid = 40.06 kg

P9 = 420.71 kg

P8 = 155.85 kg REACTOR 2

Silica = 100.08 kg Sodium sulfate = 58.05 kg Water = 262.58 kg

Sodium silicate = 108.82 kg Water = 47.03 kg

Undersize (from screen)

Reaction: Na2O3.4SiO2 + H2SO4

3.4SiO2 + Na2SO4 + H2O

From the reaction: Sodium silicate Sulfuric acid Silica Sodium sulfate Water

MW 266.19 98 60 142 18

kmol 0.41 0.41 1.39 0.41 0.41

Weight (kg) 108.82 40.06 83.40 58.05 7.36

OMB at Reactor 2: P8 + F5 + U = P9 155.85 + 248.18 + 16.68 = P9 P9 = 420.71 kg

50


P10 = 236.32 kg water

P11 = 184.39 kg

P9 = 420.71 kg DRYER 1 Silica = 100.08 kg Sodium sulfate = 58.05 kg Water = 262.58 kg

Silica = 100.08 kg Sodium sulfate = 58.05 kg Water = 26.26 kg

Assumption: 10% water in P9 adheres to P11 OMB at Dryer 1: P9 = P10 + P11 420.71 = 236.32 + P11 P11 = 184.39 kg

51


Undersize = 16.68 kg

P12 = 84.31 kg

To reactor 2 Sodium sulfate = 58.05 kg Water = 26.26 kg

P13 = 116.76 kg

P11 = 184.39 kg

P14 = 83.4 kg

Silica gel

SYNERISIS OVEN Silica = 100.08 kg Sodium sulfate = 58.05 kg Water = 26.26 kg

SCREEN

Oversize = 16.68 kg Oversize = 16.68 kg

Silica gel

PULVERIZER

Assumptions: Oversize = 20%; Undersize = 20% of P13 100% water evaporated in synerisis oven OMB at Synerisis oven: P11 + O = P12 + P13 184.39 + 16.68 = 84.31 + P13 P13 = 116.76 kg OMB at Screen: P13 = O + U + P14 116.76 = 16.68 + 16.68 + P14 P14 = 83.4 kg

52


F6 = 167.04 kg Water

P15 = 250.44 kg

P14 = 83.4 kg WASHER 2 Silica gel

Silica gel = 83.4 kg Water = 167.04 kg

OMB at Washer 2: P14 + F6 = P15 83.4 + 167.04 = P15 P15 = 250.44 kg

53


P17 = 116.76 kg




P16 = 133.68 kg water Goes to washer 1

* Silica gel can absorb up to 40% of its own weight


54


P18 = 30.02 kg Water

P19 = 86.74 kg

P17 = 116.76 kg DRYER 2 Silica gel = 83.4 kg Water = 33.36 kg


Assumption: 90% water evaporated OMB at Dryer 2: P17 = P18 + P19 116.76 = 30.02 + P19 P19 = 86.74 kg

55


F7 = 0.83 kg Cobalt chloride

P20 = 87.57 kg

P19 = 86.74 kg MIXER Silica gel = 83.4 kg Water = 3.34kg

Silica gel = 83.4 kg Water = 3.34 kg Cobalt chloride = 0.83

Assumption: Cobalt chloride = 1% of silica gel OMB at Mixer: P19 + F7 = P20 86.74 + 0.83 = P20 P20 = 87.57 kg

56


P21 = 3.34 kg Water

P22 = 84.23 kg

P20 = 87.57 kg ACTIVATION OVEN

Silica gel = 83.4 kg Cobalt chloride = 0.83 kg

Silica gel = 83.4 kg Water = 3.34 kg Cobalt chloride = 0.83 kg

Assumption: 100% water evaporated OMB at Activation Oven: P20 = P21 + P22 87.57 = 3.34 + P22 P22 = 84.23 kg

P23 = 84.23kg

P22 = 84.23 kg PACKAGING Sgel blue

Sgel blue

57

SGEL Manufacturing Company SUMMARY OF MATERIAL BALANCE

*per batch basis

TABLE 6 IN WEIGHT (kg) Rice husk 464.25 Impurities 14.36 Water (fresh) 366.32 Air 1772.62 Water (NaOH soln) 463.04 NaOH 32.7 Sulfuric acid 40.06 Water (in soln) 208.11 Water 167.04 Cobalt chloride 0.83

Total In

3529.33

OUT WEIGHT (kg) Impurities 14.28 Water 450 Flue gas 2150.52 Water 50 Solids 2.95 Water 423.29 Impurities 0.0718 Water 236.32 Sodium sulfate 58.05 Water 26.26 Water 30.02 Water 3.34 Silica gel 84.23 Total Out 3529.33

58

SGEL Manufacturing Company ENERGY BALANCE

INCINERATOR Rice husk = 464.25 kg Heating value of rice husk Using Dulong Formula7 HV = 14,544C + 62,028 (H – O/8) + 4,050S •

C, H, S, O – are the weight fractions

HV = 14,544 (0.399) + 62,028 (0.0505 – 0.3585/8) + 4,050 (0.01) HV = 61,859.89 BTU/Lb * 2.326 KJ/kg = 14,327.9 KJ/kg BTU/Lb Qin = 14,327.9 KJ/kg * 464.25 kg = 6,651,727.575 KJ Air: Assume 20% excess air Theo O2 = for CO2 + for H2O – O2 in = 15.44 kmol + 11.72 kmol – 5.2 kmol = 21.96 (1.2) = 26.352 kmol Moles N2 = 21.96 kmol O2 * 79 kmol N2 / 21 kmol O2 = 82.61 kmol (1.2) = 99.13 kmol Gases: Basis: Rice husk = 464.25 kg

7

Components

% Weight

Weight

MW

Kmol

C

39.9

185.24

12

15.44

H2

5.05

23.44

2

11.72

O2

35.85

166.43

32

5.2

S

0.1

0.46

32

0.014375

N2

0.5

2.32

28

0.08

Industrial Stoichiometry by Lewis


Total H2O = H2O from incinerator + H2O evaporated = 11.72 kmol + 9.78 kmol = 21.5 kmol 59 Total N2 = N2 in + N2 air = 0.08 kmol + 99.13 kmol = 99.21 kmol

O2 out = O2 + O2 air – n CO2 – n SO2 = 5.2 kmol + 26.352 kmol – 15.44 kmol – 0.014375 kmol = 16.10 kmol

@ 600˚ C Flue Gases

Kmol

H, KJ/Kmol

Mol * H

CO2

15.44

126.53

1953.62

H2O

21.50

64.65

1389.975

O2

16.10

118.41

1906.401

SO2

0.014375

Negligible

----------

N2

99.21

57.39

5693.66

H2O = (2676 – 104.8) KJ/kg(18 kg/kmol * 1 kmol/1000 mol) + (20.91 – 2.54) KJ/kmol = 64.65 KJ/kmol QFG = Σ (n * H) (TFG – Tref) = 11,943.656 KJ (600-25) = 6,867,602.20 KJ

Qash = mdT = 83.4/60 (17.09 + 0.00454 (600) – 897200/6502)(600-60) = 13001.73 cal * 4.1868 J/cal = 54.436 KJ


Qout = QFG + Qash = 6,867,602.20 KJ + 54.436 KJ

60

= 6,867,656.56 KJ

Q = Qout - Qin = 6,867,656.56 KJ - 6,651,727.575 KJ = 215,928.985 KJ

Using Fig. 27.53 (Perry’s Chemical Engineering Handbook) HV Bunker fuel = 153,000 BTU/gal (278.3 KJ/m3 / BTU/gal) = 42,579,500 KJ/m3 Bunker fuel needed = 215,928.985 KJ / 42,579,500 KJ/m3 = 5.071 x 10-3 m3

BATCH REACTOR 1 Reaction: 3.4SiO2 + 2NaOH

Na2O3.4 SiO2 + H2O

∆Hr° = ∆Hf° H2O + ∆Hf° Na2O3.4 SiO2 - ∆Hf° SiO2 - ∆Hf° NaOH

∆Hf° H2O = -285.84 kj/mole ∆Hf° Na2O3.4 SiO2 = -1606.25 kj/mole ∆Hf° SiO2 = -851.0 kj/mole ∆Hf° NaOH = -469.4 kj/mole ∆Hr°= -285.84 - 1606.25 + (851*3.4) + (469.4*2) ∆Hr°= 1940.11 kj/mole

H2O Na2O3.4 SiO2

Moles in 25720 0

Hin 0.3367 0

Moles in*Hin 8659.92 0

Moles out 26130 410

Hout 1.0327 1606.25

Moles out*Hout 26984.45 658562.5

SGEL Manufacturing Company SiO2

1390

NaOH

820

845.40 463.55

-1175106

0

380111

0

809.644 465.953

0 0

Q = ∆H = nAR∆Hr/VA + Σ(nHin – nHout)

61

= 1390 moles SiO2 * 1940.11 KJ + (-786335.08 + 685546.95) 3.4SiO2 Q= 692374.49 KJ P = 692374.49 KJ* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 192.33 Kwh BATCH REACTOR 2 Reaction: Na2O3.4SiO2 + H2SO4

3.4SiO2 + Na2SO4 + H2O

∆Hf° H2O = -285.84 kj/mole ∆Hf° Na2O3.4SiO2 = -1606.25 kj/mole ∆Hf° SiO2 = -851.0 kj/mole ∆Hf° H2SO4 = -907.51 kj/mole ∆Hf° Na2SO4 = -1384.5 kj/mole ∆Hr° = ∆Hf° H2O + ∆Hf° Na2SO4 + ∆Hf° SiO2 -∆Hf° H2SO4 - ∆Hf° Na2O3.4SiO2 ∆Hr° = -285.84 –1384.5 – (851*3.4) + 907.51 + 1606.25 ∆Hr° = -2049.98 kj/mole

SiO2 H2 O

Moles in 0 14170

Na2O3.4SiO2 410 H2SO4 Na2SO4

410 0

Hin+ -841.83 0.3367 1606.25 907.11 0.81012

Moles in*Hin 0 4771.04

Moles out 1390 14590

-658562.5

0

371915.1 0

0 410

Q = ∆H = nAR∆Hr/VA + Σ(nHin – nHout)

Hout -877.14 0.83875 0 -907.11 4.81012

Moles out*Hout -1219224.6 -12237.36 0 0 -1972.15


Q = 410 moles Na2O3.4SiO2 * -2049.98 KJ + (-281876.36 + 1233434.11) mole Q = 111065.95 KJ P = 111065.95 KJ* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 30.85 Kwh

DRYER 1 62

Assumptions: Latent heat + Sensible heat = Q Qgained soln = Qlost flue gas

Silica Sodium sulfate Water

Moles dT (KJ/mole) Q = ndT 1670 813.88398 1359186.247 410 10.29756 4221.996 14590 1.74108

25402.3572 1388810.604 KJ

Q = 1388810.604 KJ P =1388810.604 KJ* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 385.78 Kwh

SYNERISIS OVEN Assumptions: Latent heat + Sensible heat = Q Qgained soln = Qlost flue gas Moles Sodium sulfate 410 11460 Water 1668 Silica

dT 2.746016 0.03735 723.7044

Q = n dT 1125.86656 428.031 1207138.939


Q = 1208692.837 KJ P = 1208692.837* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 335.75 Kwh

63

SGEL Manufacturing Company DRYER 2 Assumptions: Latent heat + Sensible heat = Q Qgained soln = Qlost flue gas moles Silica 1390 Water 185.33 1390 185.56

dT 13.564733 0.39276 0.0332787 40.82

Q = ndT 18854.97887 72.79 46.257393 7574.56

Q = 26548.58626 KJ P = 26548.5826 KJ* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 7.37 Kwh

ACTIVATION OVEN Assumptions: Latent heat + Sensible heat = Q Qgained soln = Qlost flue gas

Moles dT Q = ndT 616.7384496 857266.4449 Silica 1390 16.7338 Water 185.56 0.09018

Q = 857283.1787 KJ P = 857283.1787 KJ* 1000 J* 1 Watt* 1 hr * 1 KW KJ J/s 3600 s 1000 W P = 238.134 Kwh


Qfg = 6867602 KJ 64

Assuming 10% losses in Q: Qavailable = 6180841.8 KJ Mass Flue Gas = 4360.36 kg Cflue gas = 6867602.0 KJ = 45103.15 KJ/kmol 152.26 kmol Average MWfg = [15.44*44 + 21.5*18 +16.1*32 + 0.014375*64 + 99.21*28] 152.26kmol Average MWfg = 28.63 kg/kmol Total mass flue gas = 4359.20 kg

DRYER 1 Mass flue gas = 1388810.604 KJ * 1 kmol * 28.63 kg 45103.15 KJ kmol Mass flue gas = 881.57 kg

SYNERISIS OVEN Mass flue gas = 1208692.837 KJ * 1 kmol * 28.63 kg 45103.15 KJ kmol Mass flue gas = 767.24 kg

DRYER 2 Mass flue gas = 26548.58626 KJ * 1 kmol 45103.15 KJ

* 28.63 kg kmol

Mass flue gas = 16.85 kg

65


ACTIVATION OVEN Mass flue gas = 857283.1787 KJ * 1 kmol * 28.63 kg 45103.15 KJ kmol Mass flue gas = 544.18 kg

Total mass flue gas recycled: 881.57 + 767.24 + 16.85 + 544.18 = 2209.84 kg Mass waste flue gas = 4360.36 – 2209.84 =2150.52 kg

66

SGEL Manufacturing Company SAFETY AND ENVIRONMENTAL PROTECTION MEASURES

EMPLOYMENT PROTECTION CONTROL MEASURES: Use local ventilation capable of minimizing dust emissions.

RESPIRATORY PROTECTION: Not normally required if ventilation is used, otherwise, use dust mask.

PROTECTIVE CLOTHING: Chemical resistant gloves, long sleeved shirt, and tros should be worn.

EYE PROTECTION: Wear tight fitting safety goggles. An eyewash and shower should be available.

ENVIRONMENTAL PROTECTION ENVIRONMENTAL PRECAUTIONS: Use in a well ventilated area.

SPILL OR LEAK PRECAUTIONS: Wear plastic aprons, boots, chemicalresistant gloves and safety goggles. Sweep up spill, transferring residue to a salvage container. Hold for disposal.

WASTE DISPOSAL: Follow applicable municipal, provincial and federal regulations. Seek the advice of a professional disposal service.

REGULATORY CONTROLS DEPARTMENT OF TRANSPORTATION: Not regulatd under the Transport of dangerous Goods Act. OTHER REGULATORY REQUIREMENT: None

SGEL Manufacturing Company PRECAUTIONS: HANDLING, STORAGE AND USAGE: Store in a cool, wellventilated place away from incompatible materials. Keep bags dry at all times. RAW MATERIAL STUDY 67 Rice Husk Rice is one of the major crops grown throughout the world. After separation from the rice paddy, one-third of the mass remains as a waste material. Many workers have tried to use this agricultural waste to produce useful materials such as silica, silicon carbide and activated carbon. This agricultural waste is called “rice husk”. Rice husk is the outermost coat of rice grain, which is removed in two halves in the hauling8 process. When rice husk was allowed to burn under controlled temperature, higher pozzolanic properties are observed. Silica is the main mineral of rice husk ash.

TABLE 7 Palay Production9 Year Quantity (‘000 metric ton) Value (in million pesos) 1995

10,540.6

77,684.7

1996

11,283.6

91,284.1

1997

11,269.0

88,010.6

1998

8,554.8

105,557.9

1999

11,786.6

92,171.4

2000

12,389.4

69,123.0

These amount of palay when hauled would produce a large amount of rice husk that is needed by the company to produce silica gel. The table shows that the production of palay is sufficient enough for the company’s whole year production of silica gel.

8 9

Haul- pull, drag National Statistics Office and Department of Agriculture


SILICA CONTENT AND ELEMENTARY COMPOSITION OF ASH FROM RICE HULL10 68 TABLE 8

10

Constituent

Composition

Silica, % db

94.5-94.6; 91.1-97.0

Calcium, %

0.2-0.4; 1.4

Chlorine, %

Trace-0.5

Iron, %

0.03-0.1; 0.5

Magnesium, %

0.1-0.4; 1.2

Manganese, %

0.2

Phosphorus, %

0.1-0.4; 1.3

Potassium, %

0.4-1.7; 2.5

Sodium, %

0.1-0.6; 1.5

Sulfur, %

0.3-0.4; 0.1-0.6

Aluminum, µg/g

200

Boron, µg/g

10-15

Cium, µg/g

0.4

Chromium, µg/g

1.3

Copper, µg/g

10

Nickel, µg/g

2.4

Rice: Chemistry and Technology pp. 738 by Bienvenido Juliano

SGEL Manufacturing Company Zinc,

76

The table is used as a basis for computation for the incinerator in the material balance wherein the % silica of the ash is needed to be studied.

REPORTED ELEMENTAL COMPOSITION AND ASH CONTENT OF RICE HUSK11 69

TABLE 9 Constituent

Composition (%dry basis)

Carbon

37.7-42.1

Hydrogen

4.8-5.3

Nitrogen

0.5

Oxygen

31.7-40.0

Sulfur

0.07-0.12

Ash (silica 94%)

15-20.3

In the SGEL manufacturing process we need amorphous silica for our gel. The xray diffraction studies showed that highly amorphous silica was released by ashing rice husk at 700°C and an increase in ashing temperature up to 900°C led to increase in crystalline nature of silica. So in our process an increase in temperature would endanger the form of our silica in ash so we maintain it until the allowable temperature that it wouldn’t crystallize. The test mortar cubes using a mixture of hydrated lime, standard sand and rice husk ash silica obtained by ashing at different temperatures showed that, for both, 7 and 28 days curing, the comprehensive strength of the cubes increased as the ashing temperature is gradually increased from 500 to 700°C. However, a further increase in ashing temperature up to 900°C led to a decrease in the compressive strength, which is in conformity of the results obtained by x-ray studies. The SEM micrographs show rice 11

Chemistry and Technology pp.731 by Bienvenido Juliano

SGEL Manufacturing Company husk silica ashed at 500 and 600°C still contains significant quantity of carbonaceous matter and ashing at 700°C leads to carbon free silica. The regular structure of silica skeleton in rice husk does not crumble even on heating at 900°C .

Caustic Soda12 Fused solid with crystalline fracture. Rapidly absorbs carbon dioxide and water from air. Very corrosive (caustic) to animal and vegetable tissue and to aluminum metal in the presence of moisture. Sold as lumps, sticks, pellets, chips, etc. When kept in tight containers, the usual grades contain 97.98% NaOH. One gram dissolves in 0.9 ml water, 0.3 ml boiling water, 7.2 ml abs alcohol, 4.2 ml methanol, also soluble in glycerol. Generates considerable heat while dissolving, or when the solution is mixed with an acid. Volumetric NaOH solutions used in the laboratory must be protected from air to avoid formation of carbonate. Concentrated NaOH solutions dissolve practically no sodim carbonate. Human Toxicity: Corrosive to all tissues. Ingestion: vomiting, prostation, collapse. Constrictive scarring may result. Inhalation of the dust or concentrated mist may cause damage to respiratory tract. Caution: evacuation of stomach should not be attempted. USE: NaOH solutions are used to neutralize acids and make sodium salts, e.g., in petroleum refining to remove sulfuric and organic acids; to treat cellulose in making viscose rayon and cellophane; in reclaiming rubber to dissolve casein. NaOH solutions hydrolyze fats and foam soaps; they precipitate alkaloids (bases) and most metals (as hydroxides) from water solutions of their salts. Pharmaceutic aid (alkalizer). Caustic Soda is commercially available at 48-50% NaOH.

12 http://www.magspecialties.com/caustic_soda.htm

70

SGEL Manufacturing Company TABLE 10 Price of Commercially Available Caustic Soda Supplier

Concentration Cost (PhP)/kg Minimum Order

At Chemical Exponents

48-50%

18

30 kg

Atkimson

99%

30

100 kg

Sytengco Enterprises

48 –50%

19

25 kg

Sulfuric Acid13 Clear, colorless, odorless, oily liquid. Very corrosive! Has a very great affinity for water, abstracting it from the air and also from many organic substances; hence it chars sugar, wood, etc. Miscible with water and alcohol with the generation of much heat and with contraction in vol. When diluting, the acid should be added to the diluent.

Keep tightly closed. Handle with caution,

avoiding with the skin as it produces severe burns. Caution: Corrosive to all body tissues. Inhalation of concentrated vapor may cause serious lung damage. with eyes may result in total loss of vision; skin may produce severe necrosis. Ingestion may cause severe injury and death. Frequent skin with diluted solution has caused dermatitis. USE: In manufacture of fertilizers, explosives, dyestuffs, other acids, parchment paper, glue, purification of petroleum, pickling of metal. Sulfuric acid is commercially available at 98-99% H2SO4. TABLE 11 Price Of Commercially Available Sulfuric Acid Supplier

Concentration

Cost (PhP)/5 gal

Minimum Order

(5 gal=1 Container) Atkimson

98-99%

Cobalt Chloride14 13

http://en.wikipedia.org/wiki/Sulfuric_acid

325

5 gal

71

SGEL Manufacturing Company Pale blue hygroscopic leaflets; colorless in very thin layers; turns pink on exposure to moist air.

Water It is the smallest utility material requirement for the plant.

72

14

www.brenntag.be/prd/product/ cobaltchlorurecobaltchlorideen.shtml

SGEL Manufacturing Company TABLE 12 LIST OF RICE MILLS15

Barangay Wakas Bocaue, Bulacan

1. Bocaue Rice mill

Rice mill

2. Estelita Librada

Rice mill

3. Catalino Samson

S Rice mill

4. Teodoro Jayma

Rice mill

5. Ana Maria Santos

Rice mill

6. Alexander Santos

Rice mill

7. Teresa Caisido

Rester Rice mill

8. Ramon Castillo

Cynthia Rice mill I

9. Ramon Castillo

Cynthia Rice mill II

10. Ramon Castillo

Cynthia Rice mill III

11. Teodoro Chan

T&I Rice mill I

12. Teodoro Chan

T&I Rice mill II

13. Vernicito Mapue

Lucky VC Rice mill

14. Imelda Roldan

Rice mill

15. Romeo Mendoza

Rice mill

16. Miguel Hipolito

Tambo Rice mill

17. Teodoro Chan

T&L Rice mill II

18. Teresita Galvez

Tita Rice mill

19. Ernesto Ira

Erning & Liway Rice mill I

20. Ernesto Ira

Erning & Liway Rice mill II

21. Rogelio dela Cruz

Fideliz Rice mill

22. Regina Pualenco

Jomarro Rice mill

23. Marianne Pualenco 24. Cecilia Libunao

15

Project Development Office of Bocaue,Bulacan

Deo-Joshua Rice mill Rice mill

SGEL Manufacturing Company 25. Monica Ballesteros 26. Dolores Santos

RMB Rice mill Angelu Rice mill

27. Laureano Bautista

Marvelous Rice mill

28. Victoria Santiago

Rice mill

29. Julia Dalisay

JLD Rice mill

30. Emma Sulit

Rice mill

31. Garcia-Tecson

Rice mill

32. Leonarda Angeles

Rice mill

33. Exequel Santiago Jr.

Rice mill

34. Elizabeth Pineda

Mutya Rice mill

35. Ruthgardo Manalad

Rice mill

36. Marilen Mariano

Rice mill

37. Simon Rodrigo Pascual

Tim’s Rice mill

38. Antonio Mariano

A S M Rice mill

39. Patrick Paul Ayroso

Edison Rice mill

40. Adelina Concepcion

AMC Areo Rice mill

41. Jeremias San Pedro

JSP Rice mill I

42. Jeremias San Pedro

JSP Rice mill II

43. Marcelino Mariano

Jem’s Rice mill

44. Eunice Mariano

Globe Rice mill

45. Danilo Dinong 46. Eduardo Mariano 47. Romeo Ignacio Mendoza 48. Marcelino Mariano

Gold Rush Husk Rice mill Vicar Jem Rice mill BKR Rice mill Jem Rice mill

49. Rodolfo Mendoza

San Pedro Rice mill I

50. Rodolfo Mendoza

San Pedro Rice mill II

51. Antonio Mariano

ASM Rice mill

52. Leticia Lazaro

LML Rice mill

53. Santiago Castillo

Rice mill

54. Nicanor Galamay

MJM Rice mill

73


The list of rice mills is important to the study, it states the supplier of the main raw material in the production of silica gel, which is rice husk.

74



Aside from profit generation, the SGEL Manufacturing Company is geared toward social and economic benefits arising from the employment and production of the company. Being the pioneer manufacturer of an extremely versatile industrial chemical that is used to make wide variety of products, the project is worthy of financing. It has the following socio-economic distributions. Community Development. The establishment of a silica gel plant in the area would mean additional income for Bocaue,Bulacan provincial government. The taxes that will be paid by the company to the Philippine Government will helped develop the community. This will financed the national and local projects of our country. Foreign Exchange Savings. The Philippines is totally dependent on importation of silica gel from other countries, and thousand of dollars are being paid to the suppliers. By establishing a silica gel plant in the country the importation will be alleviated. This will increase foreign exchange savings. Furthermore, the commercialization of silica gel as adsorber in cosmetics and pharmaceutical industries. Improved Standard of Living.

The company will generate income and

employment in the country. The project directly benefits individuals working in the company and their respective families. In addition to the salary, the company will also provide fringe benefits like health care, insurance, pension, and the like. More income in the hands of people would mean greater demand for other goods, thereby generating further employment and income. Because the company places high value to the upliftment of life in the country, the SGEL Manufacturing Company if grateful to also those who need help the most; the promising student, hard working farmer, calamity victim, and other less fortunate people in the community. Its community programs will benefit the societies where it operates, without any expectation of direct benefits. The company shall be involved in the community assistance programs from donation types to more meaningful livelihood projects and technology transfer.


Educational institutions, which are trustees of the company’s scholarship grants, may choose beneficiaries of the scholarships. Skills development programs shall be given also to selected students for them to acquire more relevant and practical skills. Then the company shall also the socio-civic and religious organization in the area. Furthermore, it shall also sponsor programs that will environmental care and foster sustainable development. Increased Foreign Exchange Reserves. Because of the strong demand of the product in Asia and in other parts of the world, SGEL Manufacturing Company will participate in exportation of the product after focusing on the local market. This will increase the dollar reserves of the country. Lowering of Prices by adopting the most efficient raw material, which is manufactured locally, the price of silica gel can be lowered in the domestic market without sacrificing its quality. This is possible because at present there is no local manufacturer of the product and the raw material is abundant. Lowering the price of silica gel will possibly cause a decrease in the price of the product derived from silica gel. Utilization of Local Market. Utilizing our agricultural crop like rice for the benefit of the Filipino people is highly commendable by the government. And taking advantage of our agricultural waste is one way to improve the economy. The products are derived from silica gel are very important nowadays in pharmaceutical industry as desiccants. It is also considered as adsorber in the food industry.



The demand profile obtained was very encouraging. The study shows the consumption of silica gel in the Philippines is increasing with a growth rate of 6062% a year. This is due to the rapid expansion of pharmaceutical: soap and detergent industries, which are the major consumers of our product. This triggered the importation of this product. Furthermore, the major , the pharmaceutical industry is one of the most stable markets. The demand picture, from the point of view of new producers, is encouraging and tempting enough to be invested upon a profitable business area. Whenever the demand is great, the supply must be able to match the situation. So far, there is no local manufacturer. Therefore, the absence of any local producer of silica gel will give new manufacturer less problem in entering the local market. Based on local market segmentation, pharmaceutical

SGEL Manufacturing Company APPENDIX 4: MATERIAL BALANCE COMPUTATIONS

Calculations for values used in Batch Reactor 1 and 2

For H2O From Felder @ 25°C H = 33.63 joule * (35-25) * 1 KJ Mole 1000 J H = 0.3363 KJ/mole @ 55.6°C 55.6 – 25 = x – 33.63 100 – 25 33.92 – 33.63 x = 33.75 kj/mole H = 33.75 * (55.6 – 25) * 1KJ 1000 J H = 1.0327 Kj/mole

For SiO2 From Handbook ∫650dT = (0.00447)(615)2 + 302000 = 1336.3897 cal * 4.186 J * 1 KJ = 5.5995 Kj/mole 35 2 615 mole 1 cal 1000 J H = 5.5995 – 851 H = -845.4005 kj/mole ∫55.6dT = (0.00447)(20.6)2 + 302000 = 9870.17 cal * 4.186 J * 1 KJ = 41.35 Kj/mole 35 2 20.6 mole 1 cal 1000 J H = 43.35 – 851 H = -809.644 Kj/mole


∫0dT = (0.00447)(-35)2 + 302000 = -8625.833 cal * 4.186 J * 1 KJ = -36.14 Kj/mole 35 2 -35 mole 1 cal 1000 J H = -36.14 – 851 H = -887.14 Kj/mole ∫35dT = (0.00447)(35)2 + 302000 = 8634.0471 cal * 4.186 J * 1 KJ = 36.17 Kj/mole 0 2 35 mole 1 cal 1000 J H = 36.17 – 851 H = 814.83 Kj/mole

For H2SO4 From Handbook ∫0dT = (15.59 x 10-2)(-35)2 = 95.48875 cal * 4.186 J * 1 KJ = -907.11 Kj/mole 35 2 mole 1 cal 1000 J

For NaOH = 1 cal * 4.186 J * 1 KJ * 40 g gmole cal 1000 J mole = 0.1676 kj/mole H = 0.1676*35 = 5.8475 kj/mole – 469.4 = -463.5525 kj/mole H = 0.0676 (55.6 – 35 ) = 3.44741 kj/mole – 469.4 = -465.953 kj/mole For Na2SO4 From Handbook H = -32.8 cal * 4.186 J * 1 KJ = -4.81012 Kj/mole mole 1 cal 1000 J


DRYER 1 Solving dT with Ti = 0°C and Tf = 75 °C Data from Chemical Engineering Thermodynamics by Vaness, p. 639: *∫[/R = A + BT + CT2]dT For H2O dT = [1.25 x 10-3(75)2/2 – 0.18 x 10-6 (75)3/3] 8.314 J/gmol dT = 29.018 J/gmol Data from Perry’s Chemical Engineering Handbook, 7th edition: *∫[ = 10.87 + 0.008712T – 241200/T2]dT SiO2 dT = 0.008712(75)2/2 + 241200/75 dT = 3240.50 cal * 4.186 J * 1 KJ * 60 g = 813.88398 Kj/mole gmole 1 cal 1000 J mole Na2SO4 @ cal = 32.8, 289-371 K range K-n SYNERISIS OVEN *Refer formula to Dryer 1, Ti = 75°C and Tf = 95°C For H2O dT = [1.25 x 10-3(20)2/2 – 0.18 x 10-6(20)3/3]8.314 J/gmole dT = 2.075 J/gmole For SiO2


dT = 0.008712(20)2/2 + 241200/20 dT = 12061.74 J/gmol For Na2SO4 @ cal = 32.8, 289-371 K range K-n DRYER 2 Data from Perry’s Chemical engineering Handbook,7th ed: Consider H2O: 35°C→100°C→110°C 1. dT = [1.25 x 10-3(65)2/2 – 0.18 x 10-6(65)3/3]8.314 J/gmol = 21.82 J/gmol 2. ∆Hv = C1 x (1-Tr)C2 + C3 xTr + C4xTrxTr where Tr = T/Tc Tc = 647.1 k Tr = 373/647.1 = 0.576 ∆Hv = 5.2052 x 107(1.0.576)0.3199-0.21*0.576 + 0.25795*0.576*0.576 = 40818.08 Kj/kmol = 40.82 Kj/mol 3. dT = [0.00015(10)2/2 + 0.00000134(10)3/3] dT = 7.95 x 10-3 cal/mol

Consider SiO2: *Refer to Tray Dryer 1 for formula, Ti = 35°C and Tf = 110°C dT = 0.008712(75)2/2 + 241200/75 dT = 3240.50 cal/gmol Activation Oven Ti = 110°C and Tf = 210°C H2O *Refer to tray Dryer 2 for formula range 300 – 2500 K dT = [0.00015(100)2/2 + 0.00000314(100)3/3 ] = 1.20 cal/gmol = 1.20 x 4.1868 / 1000 = 5.01 x 10-3 Kj/gmol SiO2


* Refer to Tray Dryer 1 for formula data for SiO2 dT = 0.008712(100)2/2 + 241200/100 dT = 2455.56 cal/gmol

APPENDIX 3: METHOD OF PROJECTION USED

The method of projection used in forecasting the demand and price for the next ten (10) years is the Linear Regression Method. Using the formula y = a+ bx; where y is the projected quantity and x is the next ten years of commercial production. ! B is computed using the formula n∑xiyi - ∑xi∑yi ; where n is the total number of n∑xi2 –(∑xi)2 years taken to project, ∑xi is the sum of all the years, ∑yi is the sum of all the quantities falling under the respective year used in the projection.

! A is computed using the formula ∑yi - b∑xi n




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