Production of Silica Gel From Rice HuskFULL

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
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 ENGR.DANIEL CHENG
Technical Adviser 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 ENGR. ELIZABETH ESPIRITU
Technical Adviser Faculty, School of ChE-Chm
_______________________ __________________________
ENGR.DANIEL CHENG ENGR. EDWIN OBRA
Financial Adviser Faculty, School of ChE-Chm
__________________________
ENGR. WINSTON B. FLORA
Course Adviser
APPROVAL
On the recommendation of the panel, 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 user 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.
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 countrys own resources.
Logo
SG MANUFACTURING
The name itself comes from the product we are producing, the silica gel. The
diamond is for the companys prosperity and the three lines represent steps that the company
would take before they would prosper.
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.
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 (70-90F) and high humidity (60-
90%). Its performance begins to drop off over 100F, but will continue to work until
approximately 220F. 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 non-
indicating 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.
Users 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 self-
indicating (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
! Cp @ 25C 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 @ 25C 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.
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 R Phrases
------------------------ -----------------
------------------ ------------------ ------------------
---- -
Silica Gel 63231-67-4 > 97% yes
Cobalt Chloride 7646-79-9 < 3% yes 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
Contact 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
No adverse effects expected.

Skin Contact:
May cause irritation with dryness and abrasion.
Eye Contact:
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 Contact:
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 Contact:
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 @ 21C (70F): 0
Boiling Point:
Melting Point:
Vapour Density (Air=1):
Vapour Pressure (mm Hg):
Evaporation Rate (BuAc=1):
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
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.
Contact 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) No
Cobalt (II) Chloride (7646-79-9) No
-----------\ Federal, State & International Regulations - Part 1 \-----------
--SARA 302-- -----SARA 313-----
Ingredient RQ TPQ List Chemical Catg.
Silica Gel (63231-67-4) No No No No
Cobalt (II) Chloride (7646-79-9) No No No Cobalt compound
-----------\ Federal, State & International Regulations - Part 2 \-----------
--RCRA-- --TSCA--
Ingredient CERCLA 261.33 8 (d)
Silica Gel (63231-67-4) No No No

Cobalt (II) Chloride (7646-79-9) 1 No No
Poison Schedule: No information found.
This MSDS has been prepared according to the hazard criteria of the Controlled
Products Regulations (CPR) and the MSDS contains all of the information required by
the CPR.
EC Classification: Carcinogenic
R Phrases R49 May cause cancer by inhalation R42/43 may cause sensitisation by
inhalation and skin contact.
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 contact 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 contact, 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 supported 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 user,
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 companys target market.
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 support 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 advertisements 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

membership 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 support 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 customers production site.
! SGEL Manufacturing Company will earn a reputation for efficient service and
responsiveness to our customers 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
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, well-
established 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
dont 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.
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
MACHINERY AND EQUIPMENT
EQUIPMENT SPECIFICATIONS
Rotary Kiln
Type : Direct Gas Fired
Material : Stainless Steel, 304
Area : 200 ft2
Feed Capacity : 2 tons
Temperature : 650-700C
Pressure Range : 1atm-25psi
Cost : P28,148,529.00
Dilution Tank
Material : Carbon Steel and API
Length : 4 meters
Diameter : 3 meters
Feed Capacity : 10,800 Liters
Temperature : 25C
Pressure : 1atm-25psi
Cost : P135,500.00
Dilution Tank
Material : Carbon Steel and API
Length : 4 meters
Diameter : 3 meters
Feed Capacity : 4000 Liters
Temperature : 25C
Pressure : 1atm-25psi
Cost : P47,450.00
Tray Dryer
Material : Carbon Steel
Area : 20 ft2
Temperature Range : 100-120C
Cost : P190,450.00
Batch Reactor
Type : Continuous Agitator
Area : 11 ft2
Cost : P9,570,586.00
Batch Reactor
Type : Continuous Agitator
Area : 6 ft2
Cost : P5,889,557.00
Centrifuge
Type : Screen Bowl
Material : Cast Iron and API 610
Feed Capacity : 100-200 tons
Cost : P37,255586.00
Screen
Type : Vibratory, Horizontal (2-Deck)
Deck Area : 32 ft2
Cloth : Polyurethane Screen
Cost : P900,900.00
Pulverizer
Type : Ball Mill
Material : Carbon Steel
Feed Capacity : 100-200 tons
Temperature Range : 25C
Cost : P407,550.00
Washer
Type : Sprinkler Type
Capacity : 1-100 tons
Length : 1-5 meters
Width : 0-3 meters
Cost : P128,050.00
Conveyor
Type : Close Conveyor Type :
Material : Carbon Steel Material : Carbon Steel
Feed Capacity : 0-100 tons Capacity : 100 tons
Length : 0-20 meters Cost : P8,320.00
Height : 3 meters
Cost : P14,517.00
Storage Vessel
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 650C 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 100C due to evaporation of adsorbed water from washing
process. At about 300C, 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 500C. The
temperature of the process should not exceed 650C. 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 55.6C 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 0C 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 0C. Increasing the temperature to above 3C 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.
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 75C 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.
SYNERISIS
After forty-five minutes of gel formation inside the oven at 65 to 75C,

temperature is raised to 9C. 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 pass 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.
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 110C. 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 210C 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.
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 kg
Impurities = 14.36
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
P1 = 978.61 kg P3 = 514.32 kg
CENTRIFUGE 1
Rice husk = 464.25 Rice husk = 464.25 kg
Impurities = 14.36 kg Impurities = 0.0718 kg
Water = 500 kg Water = 50 kg
P2 = 464.2882 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
P4 = 2200.52 kg
Flue gas = 2150.52 kg

Water = 50 kg
P3 = 514.32 kg P5 = 86.42 kg
INCINERATOR
Rice husk = 464.25 Ash = 83.40 kg
Impurities = 0.0718 kg Solids = 2.95 kg
Water = 50 kg Impurities = 0.0718 kg
F3 (Air) = 1772.62 kg
Assumptions:
100% water evaporated
Flue gas completely removed
Composition of Rice Husk
Content %Composition Weight (kg)

Carbon 39.9 185.24
Hydrogen 5.05 23.44
Nitrogen 0.5 2.32
Oxygen 35.85 166.43
Sulfur 0.1 0.47
Ash 18.6 86.35
Composition of Ash
Content % Composition Weight (kg)

Silica 96.58 83.40
Calcium 0.3 0.26
Chlorine 0.6 0.52
Iron 0.07 0.06
Magnesium 0.25 0.22
Manganese 0.2 0.17
Phosphorus 0.25 0.22
Potassium 1.05 0.90
Sodium 0.35 0.30
Sulfur 0.35 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
P5 = 86.42 kg P6 = 582.16 kg
REACTOR 1
Ash = 83.40 kg Sodium silicate = 108.82 kg
Impurities = 0.0718 kg Water = 470.32 kg
Solids = 2.95 kg Solids = 2.95 kg
Reaction:
3.4SiO2 + 2NaOH Na2O3.4SiO2 + H2O
From the reaction:
MW kmol Weight (kg)

SiO2 60 1.39 83.40
NaOH 40 0.82 32.70
Na2O3.4SiO2 266.19 0.41 108.82
H2O 18 0.41 7.36
48
P6 = 582.16 kg P8 = 155.85 kg
CENTRIFUGE 2
Sodium silicate = 108.82 kg Sodium silicate = 108.82 kg
Water = 470.32 kg Water = 47.03 kg
Solids = 2.95 kg P7 = 426.31 kg
Water = 423.29 kg
Solids = 2.95 kg
Assumption:
10% water in P6 adheres
P6 = P7 + P8
582.16 = 426.31 + P8
P8 = 155.85 kg
49
F5 = 248.18 kg
Water = 208.11 kg
Sulfuric acid = 40.06 kg
P8 = 155.85 kg P9 = 420.71 kg
REACTOR 2
Sodium silicate = 108.82 kg Silica = 100.08 kg
Water = 47.03 kg Sodium sulfate = 58.05 kg
Water = 262.58 kg
Undersize
(from screen)
Reaction:
Na2O3.4SiO2 + H2SO4 3.4SiO2 + Na2SO4 + H2O
From the reaction:

MW kmol Weight (kg)
Sodium silicate 266.19 0.41 108.82
Sulfuric acid 98 0.41 40.06
Silica 60 1.39 83.40
Sodium sulfate 142 0.41 58.05
Water 18 0.41 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
P9 = 420.71 kg P11 = 184.39 kg

DRYER 1
Silica = 100.08 kg Silica = 100.08 kg
Sodium sulfate = 58.05 kg Sodium sulfate = 58.05 kg
Water = 262.58 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
P12 = 84.31 kg Undersize = 16.68 kg

To reactor 2
Sodium sulfate = 58.05 kg

Water = 26.26 kg
P13 = 116.76 kg
P11 = 184.39 kg Silica gel P14 = 83.4 kg
SYNERISIS OVEN SCREEN
Silica = 100.08 kg
Sodium sulfate = 58.05 kg
Water = 26.26 kg
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
P14 = 83.4 kg P15 = 250.44 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
P15 = 250.44 kg P17 = 116.76 kg

CENTRIFUGE 3
Silica gel = 83.4 kg Water = 33.36 kg
Water = 167.04 kg
P16 = 133.68 kg water

Goes to washer 1
* Silica gel can absorb up to 40% of its own weight
P15 = P16 + P17
250.44 = 133.68 + P17
P17 = 116.76 kg
54
P18 = 30.02 kg
Water
P17 = 116.76 kg P19 = 86.74 kg

DRYER 2
Water = 33.36 kg
Assumption:
OMB at Dryer 2:
P17 = P18 + P19
116.76 = 30.02 + P19
P19 = 86.74 kg
55
F7 = 0.83 kg
Cobalt chloride
P19 = 86.74 kg P20 = 87.57 kg

MIXER
Water = 3.34kg 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
P20 = 87.57 kg P22 = 84.23 kg

ACTIVATION OVEN
Silica gel = 83.4 kg Silica gel = 83.4 kg
Water = 3.34 kg Cobalt chloride = 0.83 kg
Cobalt chloride = 0.83 kg
Assumption:
OMB at Activation Oven:

P20 = P21 + P22
87.57 = 3.34 + P22
P22 = 84.23 kg
P22 = 84.23 kg P23 = 84.23kg

PACKAGING
Sgel blue Sgel blue
57
SUMMARY OF MATERIAL BALANCE
*per batch basis
TABLE 6
IN WEIGHT (kg) OUT WEIGHT (kg)

Rice husk 464.25 Impurities 14.28
Impurities 14.36 Water 450
Water (fresh) 366.32 Flue gas 2150.52
Air 1772.62 Water 50
Water (NaOH soln) 463.04 Solids 2.95
NaOH 32.7 Water 423.29
Sulfuric acid 40.06 Impurities 0.0718
Water (in soln) 208.11 Water 236.32
Water 167.04 Sodium sulfate 58.05
Cobalt chloride 0.83 Water 26.26
Water 30.02
Water 3.34
Silica gel 84.23
Total In 3529.33 Total Out 3529.33
58
ENERGY BALANCE
INCINERATOR

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
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
7
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 = (n * H) (TFG Tref)

= 11,943.656 KJ (600-25)
= 6,867,602.20 KJ
Qash = mCpdT
= 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 (Perrys 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
Moles Hin Moles Moles Hout Moles

in in*Hin out out*Hout
H2O 25720 0.3367 8659.92 26130 1.0327 26984.45
Na2O3.4 0 0 0 410 - 658562.5
SiO2 1606.25
SiO2 1390 - -1175106 0 - 0

845.40 809.644
NaOH 820 - 380111 0 - 0
463.55 465.953
Q = H = nARHr/VA + (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
Moles Hin+ Moles Moles Hout Moles

in in*Hin out out*Hout
SiO2 0 -841.83 0 1390 -877.14 -1219224.6
H2 O 14170 0.3367 4771.04 14590 - -12237.36
0.83875
Na2O3.4SiO2 410 - -658562.5 0 0 0
1606.25
H2SO4 410 907.11 371915.1 0 -907.11 0
Na2SO4 0 0.81012 0 410 - -1972.15
4.81012
Q = H = nARHr/VA + (nHin nHout)

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
Assumptions: 62
Latent heat + Sensible heat = Q
Qgained soln = Qlost flue gas
Moles CpdT (KJ/mole) Q = nCpdT

Silica 1670 813.88398 1359186.247
Sodium 410 10.29756 4221.996
sulfate
Water 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:
Moles CpdT Q = n CpdT

Sodium sulfate 410 2.746016 1125.86656
Water 11460 0.03735 428.031
Silica 1668 723.7044 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
DRYER 2
Assumptions:
moles CpdT Q = nCpdT

Silica 1390 13.564733 18854.97887
Water 185.33 0.39276 72.79
1390 0.0332787 46.257393
185.56 40.82 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:
Moles CpdT Q = nCpdT

Silica 1390 616.7384496 857266.4449
Water 185.56 0.09018 16.7338
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

45103.15 KJ kmol
DRYER 2

45103.15 KJ kmol
65
ACTIVATION OVEN

45103.15 KJ kmol
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
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

trousers 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, chemical-

resistant 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
PRECAUTIONS: HANDLING, STORAGE AND USAGE: Store in a cool, well-

ventilated 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 companys whole year production of silica gel.
8
Haul- pull, drag
9
National Statistics Office and Department of Agriculture
SILICA CONTENT AND ELEMENTARY COMPOSITION OF ASH FROM RICE

HULL10
68
TABLE 8
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, g/g 200
Boron, g/g 10-15
Cadmium, g/g 0.4
Chromium, g/g 1.3
Copper, g/g 10
Nickel, g/g 2.4
10
Rice: Chemistry and Technology pp. 738 by Bienvenido Juliano
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 x-
ray diffraction studies showed that highly amorphous silica was released by ashing rice
husk at 700C and an increase in ashing temperature up to 900C 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
wouldnt 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 700C. However, a further increase
in ashing temperature up to 900C 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
husk silica ashed at 500 and 600C still contains significant quantity of carbonaceous
matter and ashing at 700C leads to carbon free silica. The regular structure of silica
skeleton in rice husk does not crumble even on heating at 900C .
Caustic Soda12
Fused solid with crystalline fracture. Rapidly absorbs carbon dioxide and 70
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
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 71
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 contact with the skin as it produces severe burns.
Caution: Corrosive to all body tissues. Inhalation of concentrated vapor
may cause serious lung damage. Contact with eyes may result in total loss of
vision; skin contact may produce severe necrosis. Ingestion may cause severe
injury and death. Frequent skin contact 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% 325 5 gal
Cobalt Chloride14
13 http://en.wikipedia.org/wiki/Sulfuric_acid
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
TABLE 12
LIST OF RICE MILLS15
Barangay Wakas Bocaue, Bulacan
1. Bocaue Rice mill Rice mill

2. Estelita Librada Rice mill
3. Catalino Samson CPS 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 Deo-Joshua Rice mill
24. Cecilia Libunao Rice mill
15
Project Development Office of Bocaue,Bulacan
25. Monica Ballesteros RMB Rice mill

26. Dolores Santos Angelu Rice mill
27. Laureano Bautista Marvelous Rice mill
28. Victoria Santiago Rice mill
29. Julia Dalisay JLD Rice mill
73
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 Tims 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 Jems Rice mill
44. Eunice Mariano Globe Rice mill
45. Danilo Dinong Gold Rush Husk Rice mill
46. Eduardo Mariano Vicar Jem Rice mill
47. Romeo Ignacio Mendoza BKR Rice mill
48. Marcelino Mariano 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
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 support 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 companys 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 support the socio-civic and religious organization in the area.
Furthermore, it shall also sponsor programs that will support 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 user, 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
APPENDIX 4: MATERIAL BALANCE COMPUTATIONS
Calculations for Cp values used in Batch Reactor 1 and 2
For H2O
From Felder
@ 25C
H = 33.63 joule * (35-25) * 1 KJ

Mole 1000 J
H = 0.3363 KJ/mole
Cp @ 55.6C
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
650CpdT = (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
55.6CpdT = (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
0CpdT = (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
35CpdT = (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
0CpdT = (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
Cp = 1 cal * 4.186 J * 1 KJ * 40 g
gmole cal 1000 J mole
Cp = 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 CpdT with Ti = 0C and Tf = 75 C
Data from Chemical Engineering Thermodynamics by Vaness, p. 639:
*[Cp/R = A + BT + CT2]dT
For H2O
CpdT = [1.25 x 10-3(75)2/2 0.18 x 10-6 (75)3/3] 8.314 J/gmol
CpdT = 29.018 J/gmol
Data from Perrys Chemical Engineering Handbook, 7th edition:
*[Cp = 10.87 + 0.008712T 241200/T2]dT
SiO2
CpdT = 0.008712(75)2/2 + 241200/75
CpdT = 3240.50 cal * 4.186 J * 1 KJ * 60 g = 813.88398 Kj/mole
gmole 1 cal 1000 J mole
Na2SO4
Cp @ cal = 32.8, 289-371 K range

K-n
SYNERISIS OVEN
*Refer Cp formula to Dryer 1, Ti = 75C and Tf = 95C
For H2O
CpdT = [1.25 x 10-3(20)2/2 0.18 x 10-6(20)3/3]8.314 J/gmole

CpdT = 2.075 J/gmole
For SiO2
CpdT = 0.008712(20)2/2 + 241200/20

CpdT = 12061.74 J/gmol
For Na2SO4
Cp @ cal = 32.8, 289-371 K range
K-n
DRYER 2
Data from Perrys Chemical engineering Handbook,7th ed:
Consider H2O:
35C100C110C
1. CpdT = [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. CpdT = [0.00015(10)2/2 + 0.00000134(10)3/3]

CpdT = 7.95 x 10-3 cal/mol
Consider SiO2:
*Refer to Tray Dryer 1 for Cp formula, Ti = 35C and Tf = 110C
CpdT = 0.008712(75)2/2 + 241200/75

CpdT = 3240.50 cal/gmol
Activation Oven
Ti = 110C and Tf = 210C
H2O
*Refer to tray Dryer 2 for Cp formula range 300 2500 K
CpdT = [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 Cp formula data for SiO2
CpdT = 0.008712(100)2/2 + 241200/100

CpdT = 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 nxiyi - xiyi ; where n is the total number of
nxi2 (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 - bxi

n

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SGEL Manufacturing Company

MAPUA INSTITUTE OF TECHNOLOGY

PRODUCTION OF SILICA GEL BLUE

In completion to the requirements of CHFK583

Engr. Winston Flora

Name of the Product

Name of the Enterprise

! Be aware of the concerns of the community regarding our products as well as

Advantages of Silica Gel as a Desiccant2

SELF-INDICATING (BLUE) SILICA GEL

Please note the following points:

There are three types of silica gel:3

1. Regular density gel

2. Intermediate density silica gel

3. Low density silica gel

PRODUCT USES AND APPLICATIONS

MATERIAL SAFETY DATA SHEET5

Synonyms: Silica, amorphous; Silica, precipitated and gel (CAS # 112926-00-8)

SAFETY DATA Ratings (Provided here for your convenience)

Potential Health Effects

No adverse effects expected.

Aggravation of Pre-existing Conditions:

First Aid Measures

Fire Fighting Measures

Accidental Release Measure

Ventilate area of leak or spill. Wear appropriate personal protective equipment as

Handling and Storage

Exposure Controls/Personal Protection

Airborne Exposure Limits:

WARNING: Air-purifying respirators do not protect workers in oxygen-deficient

Physical and Chemical Properties

Stability and Reactivity

Silica Gel (63231-67-4) No No No

Label Hazard Warning:

Label First Aid:

MARKETING MIX ANALYSIS

To have a competitive advantage, the SGEL Manufacturing Company aims to secure

PROMOTIONS AND ADVERTISING

PACKAGING AND DELIVERY

1. Pharmaceutical, cosmetic and Toiletry 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

SiCl 4 + 4 H 2O SiO2 2 H 2O + 4 HCl

MACHINERY AND EQUIPMENT

SGEL MANUFACTURING PROCESS

Incinerator used is the rotary kiln incinerator. Combustion is direct heating.

FORMATION OF SODIUM SILICATE

3.4SiO2 + 2NaOH Na2O 3.4SiO2 + H2O

FORMATION OF SILICA SOL

A silica sol is stable dispersion of discreet, colloid-size particle of amorphous

Na2O 3.4SiO2 + H2SO4 3.4SiO2 + Na2SO4 + H2O

After forty-five minutes of gel formation inside the oven at 65 to 75C,

Packing is automatically done. The gel is loaded in polyethylene storage drums

Flue gas = 2150.52 kg

Hr= -285.84 - 1606.25 + (8513.4) + (469.42)

Average MWfg = [15.4444 + 21.518 +16.132 + 0.01437564 + 99.21*28]