An Innovation by
M/s Saansera Farm2Fuel Solutions Pvt Ltd (Pioneers in sustainable energy solutions)
Empowering communities with clean, intelligent, and sustainable energy solutions
Introduction
- M/s Saansera Farm2Fuel Solutions Pvt Ltd pioneers sustainable innovations by utilizing biomass ash for high-value product generation.
- Successfully developed a method to manufacture waterglass (sodium silicate) from various biomass ashes, including fly ash, rice husk ash, bagasse ash, mustard husk ash, and groundnut shell ash.
- This process aligns with circular economy principles and provides economic & environmental benefits.
Disclaimer
- The images of the equipment and plant in this presentation are AI-generated visualizations.
- The actual design and specifications may vary based on the quantity of waterglass to be manufactured, availability of raw materials, space constraints, and compliance with statutory norms and regulations.
Suggested Plant Layout
Key Sections:
- Raw Material Handling Unit : Storage and pre-treatment of biomass ash.
- Ash Processing Unit : Screening, impurity removal, and chemical conditioning.
- High-Pressure Autoclave Reactor Section : Sodium Silicate extraction from ash.
- Filtration & Separation Unit : Purification of extracted solution.
- Evaporation & Drying System :Concentration and solidification of silica.
- Packaging & Storage – Final product storage and dispatch.
Additional Details:
- Proper storage ensures consistent feedstock quality.
- Advanced pre-treatment methods improve silica extraction efficiency.
Manufacturing Process Flow Chart
- Controlled alkaline reaction enhances silica yield.
- Digital monitoring ensures consistent processing conditions.
Biomass Ash Processing Unit
Equipment Used:
- Screening & sieving machines
- Magnetic separators for impurity removal
Function: Ensures purified ash with high silica content for processing.
Additional Details:
- Magnetic separation enhances impurity removal.
- Optimized screening methods ensure uniform particle size distribution.
Figure : image of a Biomass Ash Processing Unit, including screening, sieving machines, conveyor belts, and a magnetic separator for impurity removal.
Autoclave Reactor
Equipment Used:
- Stainless steel reactors
- Digital control panels for monitoring temperature and pressure (5-15 bar,
150-200°C)
Function: Extracts soluble silica from ash through controlled reaction
Additional Details:
- Controlled reaction enhances silica yield.
- Digital monitoring ensures consistent processing conditions.
Figure : image of a High-Pressure Autoclave Reactor, showcasing its industrial laboratory setup with stainless steel construction, multiple valves, and digital controls. .
Filtration & Separation Unit
Equipment Used:
- Industrial-grade filter presses
- Clarifiers for impurity removal
Function: Purifies extracted sodium silicate solution ensuring high-quality output.
Additional Details:
- Multi-stage filtration improves final product purity.
- Advanced clarifiers reduce processing time.
Figure : image of an Industrial-Grade Filtration & Separation Unit, featuring large filter presses and clarifiers for high-purity residue removal.
Evaporation & Drying System
Equipment Used:
- Steam-heated evaporators.
- High-efficiency spray dryers.
- Rotary kilns for solid product formation.
Function: Converts liquid sodium silicate into solid or powdered form.
Additional Details:
- Energy-efficient evaporators reduce operational costs.
- Controlled drying prevents product degradation.
Figure : image of the Evaporation & Drying System, showcasing steam-heated evaporators, a high-efficiency spray dryer, and a rotary kiln in an industrial setup.
Packaging & Storage
Equipment Used:
•Automated bagging machines
•Storage tanks for liquid waterglass
Function: Ensures efficient packaging and storage for distribution.
Figure : an image of an Industrial Packaging & Storage System, featuring automated bagging machines for powder sodium silicate and large storage tanks for liquid waterglass.
Figure : an image of an Integrated Industrial Plant for Waterglass Manufacturing, showcasing the entire large-scale process from biomass ash processing to packaging and storage.
Applications & Market Potential
•Adhesives & Binders: Used in paper, textiles, and cardboard. •Construction Industry: Enhances cement strength & waterproofing solutions.
•Detergents & Soaps: Stabilizer in cleaning agents.
•Water Treatment: Coagulant for industrial effluents.
•Foundry & Ceramics: Mould-making & coatings.
•Emerging Applications:
- Lithium battery coatings.
- Tyre Manufacture.
- Advanced geo-polymer composites.
- High-performance adhesives for industrial applications.
Economic & Environmental Benefits
•Revenue Generation: Adds value to biomass waste.
•Waste Management: Reduces biomass ash disposal challenges.
•Sustainability: Aligns with green initiatives and circular economy principles.
•Industrial Demand: Wide-ranging applications ensure market feasibility.
Way Forward
- Utilizing biomass ash to produce waterglass transforms a disposal problem into a profitable venture. M/s Saansera Farm2Fuel Solutions Pvt Ltd has successfully demonstrated this technology on a small scale and is now seeking business collaborations to expand and commercialize the process.
- With growing emphasis on sustainability, industries can leverage this expertise to enhance profitability while reducing their environmental footprint. Investing in waterglass production from biomass ash presents a lucrative opportunity for power plants, agro-industries, and entrepreneurs in the green economy.
- For collaborations and inquiries, reach out to us and be part of this revolutionary transformation in renewable energy byproducts.
Call for Academia and Industry Collaboration
- Seeking partnerships with academia, industries, and investors to scale up production.
- Opportunity for technology licensing and joint ventures.
- Collaborate with M/s Saansera Farm2Fuel Solutions Pvt Ltd to be part of this pioneering initiative.
For Collaborations & Inquiries:
Contact us at
📩 hello@saansera.com
📞 +917574982180
🌐 www.saansera.com
Together, let’s build a greener and more sustainable future!