Detailed Project Report (DPR) on npk fertilizer in granule form

NPK FERTILIZER IN GRANULE FORM
[CODE NO.3911]  


Straight fertilizers such as Calcium Ammonium Nitrate (CAN), Ammonium Nitrate (AN), Ammonium Sulphate (AS), Urea, Single Superphosphate (SSP), Triple Superphosphate (TSP), Potash (Potassium Chloride) (MOP) and combined types such as Mono-Ammonium Phosphate (MAP), Di-Ammonium Phosphate (DAP) are well-defined products made using well-defined processes.

Compound or complex fertilisers such as NPK, are more difficult to define as there is an infinite number of N/P/K-ratios and the processes applied in their production are numerous.

The product name “NPK” is normally followed by three numbers to indicate the percent of N, P2O5 and K2O which the product contains, e.g. 24–6–12 indicates that this particular grade contains 24% N (nitrogen compounds), 6% P2O5 (phosphorus compounds) and 12% K2O (potassium compounds). In addition, the fertilizer may contain magnesium, boron, sulphur, micro-nutrients, etc. The typical content of nutrients (N + P2O5 + K2O) will normally be in the range of 40-60%.



COST ESTIMATION


Plant Capacity                    100.00 MT./day         
Land & Building (12000 sq.ft.)  Rs. 6.85 Cr                          
Plant & Machinery               Rs. 2.47 Cr                            
Working Capital for 2 Month     Rs. 19.46 Cr       
Total Capital Investment        Rs. 29.58 Cr
Rate of Return                    15%                   
Break Even Point             56%            


INTRODUCTION    
THESE TECHNOLOGIES FOR NPK FERTILIZER    
1. PROCESSING OF RAW MATERIALS    
2. GRANULATION TECHNIQUES    
3. DRUM GRANULATION WITH AMMONIATION    
4. MIXED ACID PROCESS WITH PHOSPHATE ROCK DIGESTION    
DESCRIPTION OF PRODUCTION PROCESSES    
REQUIREMENTS OF DIFFERENT FERTILISERS FOR DIFFERENT CROPS    
HOW MUCH FERTILIZER TO APPLY:    
CONVERSION FACTORS DETERMINING QUANTITIES OF FERTILIZERS    
NPK MIXED FERTILIZER AND THEIR GRADE    
B.I.S. SPECIFICATION    
PROPERTIES AND STORAGE OF NPK FERTILIZER    
HANDLING, STORAGE AND PACKING:    
PARTICLE SIZE:    
RAW MATERIALS AND THEIR SOURCES    
MARKET OVERVIEW OF NPK FERTILIZER    
ASIA PACIFIC IS EXPECTED TO ACCOUNT FOR THE LARGEST MARKET
    SIZE DURING THE FORECAST PERIOD    
METHOD OF NPK AND PK PRODUCTION    25
EXAMPLE I:    
EXAMPLE II:    
EXAMPLE III.    
MANUFACTURING PROCESS OF NPK MIXED FERTILIZER (GRANULATED
   MIXED FERTILIZER)    
SLURRY GRANULATION PROCESS    
MANUFACTURING PROCESS    
GRANULATION    
DRYING    
SIEVING    
PRODUCT COOLING    
CYCLONES AND SCRUBBING    
FUMES SCRUBBING SYSTEM    
DRYER SCRUBBING SYSTEM    
DEDUSTING SCRUBBER SYSTEM    
ADVANTAGE TO USE BULK BLENDING ARE AS FOLLOWS:-    
PROCESS FLOW DIAGRAM    
BLOCK DIAGRAM OF NPK MIXED GRANULATED FERTILIZER    
PRODUCTION OF NPK FERTILIZER    
NPK FERTILIZER GRANULATING PROCESS    
PROCESS FLOW DIAGRAM    
RAW MATERIALS    
EMISSION AND POLLUTION CONTROL IN NPK FERTILIZER PLANT    
THERE ARE TWO PROCESSES WHICH MAY CREATE POLLUTION:    
PROCESS/TECHNOLOGY OF NPKS FERTILIZER    
HANDLING, STORAGE AND PACKING    
ENVIRONMENTAL ASPECT IN NPKS FERTILIZER PLANT    
POLLUTION CONTROL    
GUIDE FOR MIXING    
RAW MATERIAL REQUIREMENTS    
NPKS GRADE: 12 : 15 : 20 : 6    
NPKS GRADE: 10 : 24 : 17 : 6    
NPKS GRADE: 12 : 16 : 22 : 6 : 5    
RAW MATERIAL PROJECTION    
UREA    
PRICE TRENDS    
AMMONIUM SULFATE    
SINGLE SUPER PHOSPHATE    
MURIATE OF POTASH    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    67
1. RAW-MATERIAL SUPPLY:    
2. MARKETS:    
3. POWER AND FUEL SUPPLY:    
4. WATER SUPPLY:    
5. CLIMATE:    
6. TRANSPORTATION:    
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES    
7. WASTE DISPOSAL:    
8. LABOR:    
9. REGULATORY LAWS:    
10. TAXES:    
11. SITE CHARACTERISTICS:    
12. COMMUNITY FACTORS:    
13. VULNERABILITY TO WARTIME ATTACK:    
14. FLOOD AND FIRE CONTROL:    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
1. DEPRECIATION:    
2. FIXED ASSETS:    
3. WORKING CAPITAL:    
4. BREAK-EVEN POINT:    
5. OTHER FIXED EXPENSES:    
6. MARGIN MONEY:    
8. TOTAL LOAD:    
9. LAND AREA/MAN POWER RATIO:    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF DI-AMMONIUM PHOSPHATE    
SUPPLIERS OF MONOPOTASSIUM PHOSPHATE    
SUPPLIERS OF HDPE WOVEN BAGS    
COMPLETE PLANT AND MACHINERY SUPPLIERS ON TURNKEY BASIS    83
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF VIBRATING SCREENS    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF TRANSFORMER    
SUPPLIERS OF HOT AIR GENERATING UNIT    
SUPPLIERS OF PACKAGING MACHINERY    
SUPPLIERS OF ROTARY DRYERS    
SUPPLIERS OF LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT    
SUPPLIERS OF D.G. SETS    
SUPPLIERS OF BOILER    


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)