Solvay SA is investing in a new unit at its site in Livorno, Italy, that will produce circular highly dispersible silica (HDS), made with bio-based sodium silicate derived from rice husk ash.
The new silicate process will considerably reduce the carbon footprint of the company's HDS. The process uses rice husks, the outer coverings of rice grains that remain as the waste materials after the rice grains have been removed - and which are mainly composed of silica. Rice husks are in ample supply wherever rice is produced, including Italy.
Coupled with renewable energy integration at the plant, this process will allow Solvay to achieve a 50% reduction in CO2 per ton of silica, making the Livorno site Europe’s best-in-class silica production site in terms of CO2 footprint. The company will be gradually replacing its existing Zeosil portfolio with circular HDS, it said. Production is expected to start by the end of 2024.
HDS is used to reinforce tires by replacing carbon black in tire treads, reducing rolling resistance and improving traction on wet surfaces. With the investment in the new unit, Solvay is the first to commit to circular HDS production at a European site within a specified timeframe and is now focused on building the necessary ecosystem to bring it to market. To that end, the company is working closely with Continental on the project.
“Silica is essential for the high performance of our tires. And with Solvay’s bio-circular silica, our tires will at the same time become more sustainable,” said Claus Petschick, Head of Sustainability at Continental Tires.
Solvay also plans to build a new plant in the U.S. over the coming years to expand its circular highly dispersible silica capacity, and is looking into applying the manufacturing process at existing plants in Asia and South America.
“The launch of our circular HDS in Europe is just the first step in a longer-term project that will enable us to offer a circular solution to tire manufacturers,” said Ilham Kadri, CEO of Solvay.