Post on 14-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
Cultivation
Processing in
RICE MILLS
ChK Process
Biosilica
Production
Power
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 Plants
Generates Rice Hulls
Rice
Hulls
Biosilica
CO2
O2
Atmosphere
Steam & Power
BiosilicaRenewable Cementitious Material
Rice Field
(Upland Cultivation)
Rice Hull
From Rice Mills
Supply of Rice Hulls
Agricultural 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
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 Composition
SiO2 –W% 89 to 95%; Al2O3 0.41
Fe2O3 0.25; CaO 0.75%; MgO 0.43
K2O 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
BiosilicaHigh Performance Cement and In Architectural Cement
Unground Ground .
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
Addition of Biosilica in HPC Results in Slower
Curing and Higher Strengths (Increase by 35%)
Bridges in Florida
Corrosion 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
Biosilica Substantially Reduces
Chloride Permeability
The ChK ProcessFor Biosilica Production
Thermal
Oxidizer to Stack
Scr
ub
ber
a
nd
Sta
ckSteam Boiler/
Turbine-Power
2 Energy
Options1
2
Partial
Oxidation
Pyrolysis and
Gasification< 700 oC
Biosilica
Pyrolysis oil
Refining to diesel..
Water/
Steam
Refinery
Upgrading
Rice HullDrying150 oC
Dried
Rice Hull
Natural gas and
Recycle fuel gas
Combustion Air
2
Pilot Scale Rotary Calciner for BioSilicaManufacture
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