Fluxara Advanced
Renewables & Applications
20 TPD PS · 30 TPD PCC

Fluxara converts rice husk — agricultural waste available at ₹5,500/MT — into high-value specialty silica and nano-calcium carbonate through a fully closed-loop chemical process. The circular chemistry means NaOH (the costliest input) is recovered at 82% and CO₂ (from furnace combustion) replaces purchased acid at ₹0 cost.

12 acres at Kothakota, Wanaparthy district, Telangana. ₹30L/acre. Within 50 km of multiple rice mills (FCI procurement zone). ~150 km from Piduguralla CaO quarry. 300–380 km to Chennai/Krishnapatnam export ports.

Furnace + THU20 MT/day RH · ≤700°C
Therminol 55 · atmospheric

Process Hall~60 × 24 m RCC
400 kWp solar rooftop

Storage TanksNaOH 48% · CaO silo
Na₂SiO₃ buffer

WarehousePS + PCC despatch
8–9 FCL/month export

ETP + ZLD80% water recovery
130 KLD fresh makeup

Admin + 750 kVA HTTSSPDCL HT-I(A) tariff
750 kW DISCOM connection

AI render (qwen-image-3.0-pro) · Annotated · Kothakota Phase 1 layout

Aerial · 200m altitude

12-acre campus. Solar roof visible from above. Rice fields north. Phase 2 expansion land south.

Site Parameter	Value
Area — Phase 1	6 acres (operational)
Area — Total acquired	12 acres
Land cost	₹3.60 Cr (₹30L/acre)
District	Wanaparthy, Telangana
DISCOM office	TSSPDCL Wanaparthy
Power required	750 kW HT connection
Solar PV	400 kWp on process roof
Water source	Borewell + ZLD 80% recycle
Fresh water makeup	130 KLD/day
Rice husk radius	<50 km · FCI mills
CaO source	Piduguralla, AP (~150 km)
Export port	Krishnapatnam / Chennai (~350 km)
TSPCB category target	Orange (PI 41–59)

Rice husk → combust at ≤700°C → leach RHA in NaOH → filter → precipitate with CO₂ → spray-dry → causticise (recovers NaOH + makes PCC). The NaOH loop closes at 82% recovery; CO₂ is 100% internal. MVR is mandatory from Day 1.

Process Flow · Six Stages

All 6 stages + NaOH recovery arc + CO₂ internal loop. Generated with qwen-image-3.0-pro.

Process Hall Interior · SS316L Reactors

Leach reactors · Filter presses · Spray dryer bank · Siemens S7-1200 PLC + SCADA

Mass Balance — Daily @ 20 TPD PS

Stream	MT/day	MT/yr
Rice husk (fuel)	20.00	6,600
Purchased RHA	19.40	6,402
Bonus RHA (combustion)	3.60	1,188
Total RHA to leach	23.00	7,590
SiO₂ available (92%)	21.16	6,983
SiO₂ extracted (88%)	18.62	6,145
✦ Precipitated Silica (PS)	20.00	6,600
✦ Nano-PCC (co-product)	30.00	9,900
Desilicated residue	4.40	1,452
CO₂ generated (combustion)	25.05	8,267
CO₂ used (precipitation)	14.20	4,686
CO₂ surplus (BCR upside)	10.85	3,581
NaOH gross circuit	~37.0	—
NaOH fresh makeup (100%)	6.70	2,211
NaOH as 48% lye	14.00	4,620
CaO consumed (≥85% purity)	20.50	6,765
Fresh water makeup	130 KLD	—

Critical path: SiO₂ extraction efficiency (88%) and NaOH recovery (82%) are lab-validated estimates. Lab trials (extraction + causticisation Na-balance) are the highest-priority pre-commissioning activity — Month 2–4 per timeline.

Circular Chemistry — The NaOH Loop

The causticisation step simultaneously recovers NaOH AND produces PCC — these cannot be separated. This is why PCC is an obligatory co-product: deferring it would collapse the NaOH recovery economics.

Reaction	Stoichiometry
1 · NaOH Leaching	SiO₂ + 2NaOH → Na₂SiO₃ + H₂O
2 · PS Precipitation	Na₂SiO₃ + CO₂ + H₂O → SiO₂↓ + Na₂CO₃
3 · NaOH Recovery + PCC	Na₂CO₃ + Ca(OH)₂ → 2NaOH + CaCO₃↓
4 · CaO Slaking (on-site)	CaO + H₂O → Ca(OH)₂ · exothermic

Ratio	Value
NaOH/kg SiO₂	1.331 kg
CO₂/kg Na₂SiO₃	0.361 kg
CaCO₃ (PCC) / kg Na₂CO₃	0.944 kg
NaOH recovered / kg Na₂CO₃	0.755 kg
Ca(OH)₂ / kg CaO (at 85%)	1.122 kg

Circular Chemistry · 82% NaOH Loop

Gross thermal from 20 MT/day rice husk combustion: 243 GJ/day. After 82% boiler efficiency: 199.3 GJ/day available. At 20 TPD PS scale, process heat demand is 178.1 GJ/day — leaving only 21 GJ/day surplus. Without MVR the plant cannot operate.

₹24 Cr (range ₹23–26 Cr pending RFQs). Indian-market BOM throughout. Six priority RFQs must be executed before engineering freeze to lock ±10% accuracy.

NaOH 48% lye is the dominant cost at 30.8% of total. Every 1% improvement in NaOH recovery = ~₹0.72 Cr/yr saved. CTAB (HDS surface treatment) is the highest supply-chain risk — imported, 4-week buffer mandatory.

Year 1: moratorium (interest-only ₹1.64 Cr). Year 2: first P+I (₹3.87 Cr — tightest year, DSCR 2.8×). Year 4+: full grade mix, blended PS ₹77/kg, PCC ₹23/kg. DSCR covenant: 1.25× minimum.

Sensitivity Analysis — Y4+ Base (₹75 Cr Rev · ₹48.2 Cr EBITDA · DS ₹3.47 Cr)

PS revenue trajectory: export standard (Y1) → HDS qualification (Y2) → dental/FSSAI (Y3+). PCC four grades from bulk coatings to high-value plastics compounding.

Photorealistic renders of the Kothakota biorefinery generated with Alibaba Model Studio (qwen-image-3.0-pro · 2752×1536). Two variants per scene.

Isometric Layout · Variant A

SE aerial · Golden hour · Furnace · Solar roof · Chemical tanks · Blue warehouse · Security gate

Isometric Layout · Variant B

Alternative perspective · Emphasises ETP clarifier · Transformer yard · Admin building

Aerial Drone · 200m · Variant A

True-colour aerial · Solar roof visible · Rice fields north · Phase 2 land south

Aerial Drone · 200m · Variant B

Alternative lighting · Trucks at loading bays · Internal roads visible

Process Hall · Variant A

SS316L leach reactors · Color-coded piping · Spray dryer bank · SCADA HMI

Process Hall · Variant B

Alternative angle · Precipitation vessels · Filter press staging area

Circular Chemistry · Variant A

82% NaOH loop · CO₂ zero cost arc · PS 20 MT/day · PCC 30 MT/day

Circular Chemistry · Variant B

Alternative layout · Glowing node diagram · Process chemistry closed loop

Process Flow Diagram · Variant A

Six stages · NaOH recovery arc · CO₂ internal loop · Stage capacities

Process Flow Diagram · Variant B

Alternative visual · Equipment icons · Color-coded streams

Financial close → Day 1 commercial production in 12 months. DISCOM 750 kW application filed Month 0. FSSAI E551 applied Month 10 (12–18M cycle). Customer engagement Month 1 — not after commissioning.