biogenic silica v1 acs presentation_v1 (2)
TRANSCRIPT
Biogenic Silica & Nanophase Mn Oxide
for Manufacturing & Applications
ChK Group, Plano, Texas
Subbaraman Viswanathan, Ph.D.
Richard Wagner, Ph.D.
Rajan Vempati, Ph.D.
BioSilica a premium additive in HPC{High Performance Concrete}
Value Chain for BioSilica
Rice CultivationProcessing in RICE MILLS
ChK Process BioSilicaProductionPower Generation
BioSilica to HPC use
Power to the grid
Currently Rice Hull is sent to landfills at a cost
Black ash is not suited for HPC due to high carbon content
ChK Process unique features:• BioSilica™ Carbon
content < 0.1% with NO graphitic carbon
• Zero crystallinity with no cristobalite
• Produces process heat and power based on site requirements
• No solid waste as inorganic matter in rice hull becomes BioSilica™
• Simple process easy to operate and control
• Zero CARBON emissions and future carbon CREDITS
Biogenic silicaRenewable cementitious material
Rice Field (Upland Cultivation)
BioSilica Unground & Ground
Rice HullFrom Rice Mills
ZERO Carbon – with Bio-Material useProduces Green Construction Material & Power
Rice Hull BioSilica Plant
O2CO2
Photosynthesis
Rice Fields
Rice Milling PlantsGenerates Rice Hulls
Rice Hulls
BioSilica
CO2
O2
Atmosphere
Steam & Power
Supply of Rice HullsAgricultural Waste Generated by the Rice Milling Industry
No Real Value: Most Uses never Cover the cost of transportation
Supply Potential
Rice Bio SilicaSilica Fume
Actual Ton/Yr
Potential Ton/Yr
Actual Ton/Yr
USA10,500,00
0378,000 60,000*
GLOBAL
550,000,000
19,800,000
5
Rice Hull Properties
HHV Dry Basis MJ/Kg
16.2[6,965 BTU/LB]
Moisture, W% 9.7%
Volatile, W% 66%
Carbon, W% MF 40.2%
Ash, W% 18.2%
Ash CompositionSiO2 –W% 89 to 95%; Al2O3 0.41Fe2O3 0.25; CaO 0.75%; MgO 0.43K2O 2.2%
Most of this silicafume is imported
BioSilica™ Properties
• Silica content: > 90w%
• Type: Amorphous silica
• Carbon W%: < 0.1 W%
• Cristobalite, W%: None (Not detected) No Crystalline silica
• Major uses:– Pozzolan additive to concrete; replaces 10 to 20% of cement
– Produces ZSM-5 zeolite by thermochemical methods WITHOUT an organic template
– Filler in paints and plastics
Comparison of Concrete Additives used as POZZOLANS
Origin $/Ton ColorParticle Size
Comments
Silica FumesFe-Si
Byproduct (limited)
$585 GreyUltra Fine
USA Supply Decreasing
Metakaoline Heated Kaolinite $400 White
1.5 Micron
Geological constraints on deposits
Black Rice Hull Ash
Gasifier byproduct <$50 Black
+10 Micron
3-40% Carbon Content, Crystalline Silica Present,Poor Freeze-Thaw
BioSilica™ Rice Hulls $300 Off White
5-10 Micron
Non-Toxic, very low Carbon, Architecturally pleasing
7
BioSilica™ is better performing as well as cost competitive
BioSilica could be used in High Performance Cement & in Architectural Cement
Unground Ground .
HPC (High Performance Concrete)use to mitigate severe erosion in dams
Kinzua Dam in Pennsylvania HPC (High Performance Concrete) used to mitigate severe erosion due to abrasion
with water flowDOING WELL AFTER HPC INSTALLATION IN 1983
Addition of BioSilica in HPC results in slower curing and higher strengths (increase by 35%)
Bridges in FloridaCorrosion concerns – State Government specifies addition of 8 to 9% silicafume in concrete that stands in salt water or gets splashed with it
Bridge in Florida in US – 1 highway
Other applications for BioSilica in HPC• Parking lots in cold climates – subjected to severe chloride corrosion from
salted roadways• High rise buildings that require HPC with high modulus of elasticity
BioSilica substantially reduces chloride permeability
The ChK ProcessFor BioSilica Production
ThermalOxidizer to Stack
Scr
ubber
&
Sta
ckSteam Boiler/ Turbine-Power
2 Energy Options 1
2
Partial OxidationPyrolysis& Gasification< 700 oC
Biosilica
Pyrolysis oilRefining to diesel..
Water/ Steam
Refinery Upgrading
Rice HullDrying150 oC
DriedRice Hull
Natural gas &Recycle fuel gasCombustion Air
2
Pilot Scale Rotary Calciner for BioSilica™ Manufacture
6 in diameter tube 20 FT long 3-Zone
temperature control
Large (Commercial Scale) Rotary Calciner (Illustrative)
6 FT diameter tube > 60 FT long
Heat input with a string of natural gas burners
Attractive return on Investment [IRR > 20%]Table 1: Process Economics SummaryPlant type Biosilica™ Plant
OnlyBiosilica™ Plant with power module
Capacity, TPY of Biosilica™ 18,400 18,400
Power generation 0 6 MW
CAPEX $ 9 Million $ 18 Million
Feed Rice Hull cost $8/T $8/T
Product Biosilica™ price (*) $300/T $300/T
Power sale price -- $60/MWH
IRR, % 24% 19%
NPV $13 million $ 16 Million
Future Plans
• BioSilica and Energy Corporation formed to commercialize the ChK Process
• Seeking investors to construct the first commercial plant
• Plant payback in less than5 years
• Contacts:
Subbaraman Viswanathan (VIS) Ph.D.
President, BsEC
Phone: 832-457-6486; e-Mail: [email protected]
Rajan Vempati, Ph.D.
Vice President, BsEC
Phone: 832-457-6486; e-Mail: [email protected]
BioSilica use in ZSM-5 production
• ChK Process; patented
– ChK has developed a process to minimize heating requirements without using any organic template
• Synthesis conditions
– Si/Al ratio of reaction mixture: 20 to infinity
– Temperature 210 Degrees C (could use 200 LB steam for heat up)
– Crystallization time 36 hrs 20 to 72 hours
– Seeding with up to 1% ZSM 5
– Product is filtered washed and dried at 120° degrees C.
– For special applications, ZSM-5 could be calcined, as needed
• Product ZSM-5 properties
– Si/Al Molar ratios of 80 and above are easily obtained.
– Carbon content of Rice Hull ash affects the type and quality of ZSM-5