Sodium Silicate Manufacturing Technology
Inside Rajaram Enterprise's state-of-the-art chemical manufacturing facility in Vapi, Gujarat. Discover how we transform high-purity silica sand into premium liquid silicates, glass cullets, and powders.
8-Stage Industrial Manufacturing Lifecycle
1. Raw Material Sourcing & Batching
High-purity silica sand (SiO₂ > 99.5%) and dense soda ash (Na₂CO₃) are weighed with automated load-cell batching systems to maintain exact stoichiometric ratios.
2. High-Temp Regenerative Furnace Fusion
The batch is fed into gas-fired regenerative furnaces at temperatures between 1100°C and 1250°C, producing molten sodium silicate glass with zero un-melted quartz residue.
3. Quenching & Glass Cullet Formation
Molten glass streams exit the furnace and undergo rapid thermal shock quenching, shattering into transparent bluish solid glass lumps (cullet).
4. High-Pressure Autoclave Dissolution
Solid glass cullet is fed into high-pressure steam autoclaves at 4-6 bar pressure, rapidly dissolving the silicate glass into concentrated liquid.
5. Baume Gravity & Molar Ratio Adjustment
The liquid silicate is adjusted with treated water and alkali to reach target Baume gravity (°Bé 38 to 62) and exact SiO₂:Na₂O weight ratios.
6. Multi-Stage Pressure Leaf Filtration
The viscous solution passes through pressure leaf filters removing microscopic suspended solids down to < 10 microns, producing crystal-clear liquid silicate.
7. Quality Control Lab & COA Issuance
Every batch is sampled by QA chemists for Baume density, total solids %, and ratio titration before signing off the Certificate of Analysis (COA).
8. Drumming, Tanker Loading & Export Shipping
Finished products are packaged into 50kg carboys, 250kg drums, 1000L IBC totes, or pumped directly into 25-ton stainless road tankers and export shipping containers.
Automated Process Control & Environmental Standards
Our Vapi plant features automated DCS temperature monitoring, zero effluent water recycling systems, and dedicated road tanker loading bays, guaranteeing environmental compliance and prompt delivery across India and global export markets.