SODIUM SILICATE

Rotary Furnace Process:

The State-Of-The-Art Technology is used to manufacture sodium silicate by fusing pure silica
sand with soda ash in rotary furnace at 1300oC, various SiO2 /Na2O ratios are produced.
When the molt is cooled down a clear glass of sodium silicate is obtained, which varies from
colorless to greenish blue in color is obtained. A premium product with exceptionally pure
quality (maximum of 0.3% metal oxides) is produced.
Mean Weight Ratio SiO2 : Na2O
2.1:1.0
3.3:1.0

SiO2 %
66.7
76.7

Na2O%
33.3
23.3

Main Use
Detergents
Paints

By using a steam pressure dissolver with in-line filtration, glass dissolves in exothermic
reaction and gives an exceptionally clear solution with a long shelf life. Various grades of
solution with ratio ranging from 2.0 to 3.3 combined with density ranging from 1.36 to 1.6
gm/cm3 and a viscosity ranging from 150 to 7500 CP are being currently manufactured.
Uses
Detergent
Detergent
Foundry
Titanium Dioxide
Recycle Paper
Oil Well
Construction
Chemcials
Adhesive

SiO2 : Na2O
Wt. Ratio
%
2.0
2.0
2.0
3.23
3.23
3.23
3.20

Na2O %
Wt. Ratio

SiO2 %
Wt. Ratio
30
34.20
30
27.50
27.50
27.50
30.25

Density
gm/cm3
@20oC
1.54
1.60
1.54
1.36
1.36
1.36
1.40

Total Solids
Wt. Ratio
%
45
51
45
36
36
36
40

Viscosity
CP
@20oC
600
7500
600
150
150
150
850

15
16.8
15
8.50
8.50
8.50
9.45

3.20

9.45

30.25

1.40

40

850

Hydrothermal Process:
Known as the "Wet Process" for the manufacture of silicates directly in solution form, where
the silica from san leached out under pressure by concentrated caustic soda solution. This
process lends itself to the production of crystalline silicates solution.

VARIOUS APPLICATONS OF SOLUBLE SILICATES

Soluble silicates have properties not shared by other alkaline salts which, together with their
relatively low cost, have resulted in wide spread use in many industries. Sodium silicate is
used in far greater quantities than silicates based on other alkali metals. Potassium silicate is,
however, sometimes preferred in applications where its specific advantages outweigh the
extra cost.
Detergency
One of the earliest uses of sodium silicate was to improve the properties of soap and even
today household detergents are one of the biggest single applications. Fabric washing
powders actually contain 6% - 15% sodium silicate by weight, within the ratio range 2.0 to
2.4. The role of silicates is multi-functional. They act as corrosion inhibitors for metals and
ceramics, assist in dispersion of defloculation of soil to prevent its re-desposition, and play an
important part in structuring the finished products.

Chemical Industry
Precipitated Silica and silica gels are used widely as reinforcing fillers in rubber, as matting
agents for surfaces coating and as polishing and structuring agents in toothpastes. They are
made using acid salts to neutralize the sodium silicate under carefully controlled conditions.
Zeolites, which are crystalline aluminosilicates, are synthesized from sodium silicate and
sodium aluminates. They have as their basic structural unit the SiO4 tetrahedral network, with
partial replacement of silicon by aluminum. These materials, sometimes referred to as
molecular sieves, are used for ion exchange, and as highly selective catalyst absorbents.
Apart from its use as a source of silica, sodium silicate often assists in production, or end-use
enhancement, of a number of other important industrial chemicals. Titanium dioxide is
widely used as the primary specifying pigment in the paint, plastic and paper industries. Its
performance is enhanced by silicate treatment to modify its surface characteristics.

Foundry
Iron, steel and non-ferrous castings are formed in patented sand moulds and cores which are
set to shape using a number of binder materials. Sodium silicate is widely used as a binder in
the principal setting systems-the silicate-carbon dioxide and self-setting sodium silicate
processes.

Adhesive
Sodium and potassium silicates are practically the only inorganic materials used as adhesives.
They are particularly suitable for adhesive application by reason of their low cost, reasonably
rapid set and high strength. The production of paper products, particularly tubes and drums
where strength is at a premium, provides and extensive field of application and there are
many other industries where silicates are employed. Silicate bonded insulation materials such
as vermiculite and perlite are completely non-flammable, the refractory nature of the bond
being a major advantage. Potassium silicate is sometimes preferred for applications where
heat insulation and fire resistance are chief aims, as it has a slightly higher softening/flow
point that its sodium counterpart.

Water Treatment
Alkaline silicate, usually are used in various ways to treat potable or industrial water, partial
neutralization of silicate with acids or acid salts produces an anionic sol which is an
extremely efficient coagulation aide, for use with aluminum sulphate during normal
purification process. Many bore hole water sources contain high source of iron and
manganese. Upon aeration or chlorination these will precipitate as red/brown colored
hydroxide, either in main pipelines or during use, giving rise to a high level of consumer
complaints. The problem can be overcome by adding a few parts per million of a sodium
silicate solution during the treatment process prior to aeration or chlorination.
Refractory Cement
The properties of Alkaline silicates are suitable for production of high temperature cements.
The bond is completely inorganic and compatible with the range of refractory fillers normally
used. Two types of refractory silicates cements may be produced. One, the so called plastic
cement, is prepared by mixing sodium silicate with a filler, which may be clay or a refractory
mineral, until the mix has a putty-like consistency. The other type is dry-blended using a
powered grade of silicate and then mixed with the appropriate amount of water when required
for use. Applications for refractory cement range from bonding or lining industrial furnace
walls and chimneys to cement for household fire-back and stove. Choice of silicate is largely
dictated by the degree of fluxing required. This increases with the amount of alkali present
and is greater for sodium rather than potassium silicate.

Acid Resistant Cement

Acid resistant brickwork and tank linings are required in many industrial processes and, while
acid resistant bricks are readily available, choice of suitable cements is restricted. Potassium
silicate has proved an extremely useful binder for these cements as the action of an acid and
potassium silicate produces free silica which is resistant to all acids except hydrofluoric.
These cements are formulated in a similar manner to refractory cements, but fillers chosen
must also be acid resistant in this case.

Mineral Beneficiation
Sodium silicate is used in froth flotation to disperse slimes. It also acts as a depressant for
siliceous gangue minerals and non-metallic beneficiation processes. A number of minerals,
including copper, tin, tungsten, fluorspar and phosphate, utilize silicate in this way.
Corrosion Prevention
Corrosion is a well-known problem in industries where water systems are involved. Many
systems have been developed over the years to protect metal surfaces from the effects of
corrosion. One such method which has proved extremely successful is the addition of small
quantities of sodium silicate to the water in the system. Sodium silicate is effective in
controlling corrosion of many metals and will protect systems containing several different
metals where electrolytic corrosion is often a grave problem. The ferrous metals; lead brass,
copper, zinc and aluminum are all completely protected and problems caused by such
phenomena as plumb-solvency eliminated. Sodium silicate actually reacts with the corrosion
products of the metal to form almost insoluble protective film of metal silicate.
Soil Consolidation
Various techniques are employed to consolidate or seal the ground prior to further operations.
In a number of these techniques a siliceous gel is precipitated from a solution of sodium
silicate and a suitable reactant. The method by which the gel is prepared varies. One
technique is to inject the silicate and a reactant such calcium chloride in separate streams,
which react instantly, forming a gel at the point where consolidation is required. Co-reactants
suitable for this technique include sodium bicarbonate or aluminates and a range of organic
esters.
Silicate Paints & Coating
Coatings based on soluble silicates are used for various purposes including sealing porous
surfaces, heat insulation, binding loose fivers and formulation of certain paints. Although
sodium silicate can be used for these applications, it has a tendency to form a unsightly white
bloom by interacting with atmospheric carbon dioxide. Potassium silicate is less affected and
therefore often preferred. Surface suitable for coating or sealing with silicates include
vermiculite, perlite, asbestos and other fibrous or loose-grained minerals and the nonflammability of the silicate is often an important consideration. Alkaline silicates are
employed in anti-corrosion paints, particularly those based on zinc, and in situations where
heat resistance is vital and can be formulated with aqueous synthetic resin dispersions to
reduce cost.
Ceramic and Minerals
A clay slip, a suspension of clay in water is used to produce ceramic shapes for such
applications as the production of bathroom ware. It is important to keep the slip mobile while
minimizing water content, which is later removed in the process. To achieve this, a small
amount of sodium silicate, usually of silica: Alkali ration 2:1, is added to act as deflocculant
or "slip aid" as it is known in the industry. A similar use occurs in the wet process for
Portland cement where sodium silicate is used to deflocculate aqueous slurries of chalk and
clay, again with the objective of maximizing solids with minimum viscosity.

Roofing Tiles
Roofing granules are mineral particles, coated with a coloring pigment prior to incorporation
into tiles. The silicates served to bind the coloring pigment to the granule, prior to firing at a
high temperature. Sodium silicate is commonly employed but, under certain conditions,
potassium silicate may offer advantages by helping to lower the "fixing" temperature.

Concrete Treatment

New or old concrete surfaces can be improved by treatment with sodium silicate to
provide a harder surface, which is far less prone to dusting. The effect is not confined
to the surface, as the silicate penetrates into the concrete and reacts with residual free
lime to reduce porosity.

Welding Rods

A welding rod flux coating consists of a variety of mineral and metal powders, bound
together with sodium or potassium silicate, extruded onto a supporting wire. Apart
from aiding extraction and acting as a binder, the silicate provides a source of alkali
for the acr process itself.

Reclamation of Mineral Oils

During use, mineral oils collect many impurities. For example, carbon, grit, water
and various acidic components which impair their properties. The oil can, however,
be recovered using chemical processes which rely upon neutralization of acidity and
separation of solid impurities into an aqueous phase. Sodium silicate plays an
important role in both these mechanisms.

Agglomeration
Silicates find application as binders in granulating and briquetting fine articles. If the
silicate bond is to be water insensitive it is necessary either to heat the bonded
product, as when fabricating colored roofing granules, or use it in conjunction with a
chemical species which will insolubilise the bond. This happens spontaneously, to
some degree, if the material to be bonded contains reactive metal ions of, for example,
calcium, aluminum or magnesium. Alternatively, it can be induced by addition of a
heavy metal salt. Example of agglomeration applications range from soap and
detergent granules to fine pellets or briquettes of phosphate sponge iron and chrome
fines.