Post on 26-Jul-2015
Biosilica for Manufacturing
and Applications
ChK Group, Inc. Plano, Texas
Rajan K. Vempati, Ph.D.
Subbaraman Viswanathan, Ph.D.
Biosilica a Premium Additive in High Performance Concrete (HPC)
Value Chain for Biosilica
Rice CultivationProcessing in RICE MILLS
ChK Process Biosilica ProductionPower 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
Zero Carbon – With Bio-Material Use(Produces Green Construction Material and 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 Silica Silica Fume
Actual Ton/Yr
Potential Ton/Yr
Actual Ton/Yr
USA 10,500,000 378,000 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 silica fume is imported
Biosilica Properties
• Silica content: > 90w%
• Type: Amorphous silica
• Carbon Wt%: < 0.1 W%
• Cristobalite Wt%: Not Detected 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
High Performance Concrete (HPC)Use to Mitigate Severe Erosion in Dams
Kinzua Dam in Pennsylvania HPC used to mitigate severe erosion due to abrasion with water flow
DOING WELL AFTER HPC INSTALLATION IN 1983
Bridges in FloridaCorrosion concerns – State Government Specifies Addition of 8 to 9%
Silica Fume in Concrete that Stands in Salt Water or Gets Splashed
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
The ChK ProcessFor Biosilica Production
ThermalOxidizer to Stack
Scr
ub
ber
an
d
Sta
ckSteam Boiler/ Turbine-Power
2 Energy Options 1
2
Partial OxidationPyrolysis and Gasification< 700 oC
Biosilica
Pyrolysis oilRefining to diesel..
Water/ Steam
Refinery Upgrading
Rice HullDrying150 oC
DriedRice Hull
Natural gas andRecycle fuel gas
Combustion 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
Future Plans• Biosilica and Energy Corporation (BsEC) formed to commercialize
the ChK Process
• Seeking investors to construct the first commercial plant
• Plant payback in less than 5 years
• Contacts:
Rajan K. Vempati, Ph.D.
President, ChK Group, Inc.
Phone: (214) 704-4128; e-Mail: chkgroup@att.net
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 molar ratio of reaction mixture: 20 to 100
– Temperature 190°C (could use 200 LB steam for heat up)
– Crystallization time 36 hours
– Seeding with up to 1% ZSM 5
– Product is filtered washed and dried at 120°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
Acknowledgements• Dr. Prasad Rangaraju - Clemson University, Clemson, SC
• Dr. Harish, K.V. - Clemson University, Clemson, SC
• Dr. Antonio Nanni - University of Miami, Coral Gables, FL
• Dr. Ferraro, R. M. - University of Miami, Coral Gables, FL
• Dr. Ramesh Borade
• Dr. Arun Bonapati - Harper International, Inc., Lancaster, NY
• NSF SBIR Phase II Award Number: 0724463