Di-Calcium Phosphate (Powder) (Production Capacity: 83 MT/Day)

DI-CALCIUM PHOSPHATE (POWDER)

[EIRI/EDPR/4737] J.C.: 2957XL

INTRODUCTION

Dicalcium phosphate is also known as the calcium hydrogen phosphate dehydrate or dibasic calcium phosphate with the molecular formula CaHPO4. The ‘di’ prefix indicates the formation of the HPO42– anion, which involves the removal of two protons from phosphoric acid (H3PO4). Dicalcium phosphate is mostly used as a dietary supplement. It is commonly found as a dehydrate; however, it can be converted into an anhydrous form by applying heat. It is insoluble in water and biomaterial in nature. Dicalcium phosphate contains a minimum 19% of phosphorus content and maximum 28% of calcium content; therefore, it is used as a source of phosphorus and calcium. 

Rock phosphates are natural sources of calcium phosphate in the form of tricalcium phosphate. Acidification of tricalcium phosphate with mineral acids yields phosphates and phosphoric acids. Acidification of rock salt with hydrochloric acid produces mono calcium phosphate which remains in solution which is treated to remove fluorides as precipitates. 

The supernatant liquid containing monocalcium phosphate is treated with lime to obtain dicalcium phosphate and calcium chloride which is considered as a by-product. Phosphoric acids which are obtained on acidification of natural phosphates are purified and then neutralized to produce dicalcium phosphate.

Animal-feed grade Di-Calcium Phosphate is made from wet process acid that has been treated to reduce fluorine content to an acceptable level.

It is intended to prepare a Feasibility Report to install 30000 MT/Year Di-Calcium Phosphate (Powder) production facilities as a New Project. 

COST ESTIMATION

Plant Capacity            83.334 MT/Day

Land & Building (22,645 sq.mt.)    Rs. 26.66 Cr

Plant & Machinery                    Rs. 61.27 Cr

Working Capital for 1 Month    Rs. 6.98 Cr

Total Capital Investment          Rs. 98.15 Cr

Rate of Return                          64%

Break Even Point                      34%

CONTENTS

INTRODUCTION

USES/APPLICATIONS

MARKET OVERVIEW

GLOBAL DICALCIUM PHOSPHATE MARKET: REGIONAL OUTLOOK

GLOBAL DICALCIUM PHOSPHATE MARKET: KEY PLAYERS

PRODUCT SPECIFICATIONS

DICALCIUM PHOSPHATE

CALCIUM CHLORIDE

HYDROFLUORIC ACID

BIS SPECIFICATION

FORMULATION

REACTION – (A)

REACTION – (B)

RAW MATERIALS

ROCK PHOSPHATE

HYDROCHLORIC ACID (>30%)

SPECIFICATIONS

PHYSICAL PROPERTIES

CALCIUM HYDROXIDE 

RAW MATERIAL/CHEMICALS SUPPLIERS

ROCK PHOSPHATE 

ACID

HYDRATED LIME

LABORATORY CHEMICALS

MANUFACTURING PROCESS STEPS/PROCESS FLOW/QUALITY CONTROL

THE STEPS INVOLVE IN THE MANUFACTURE OF DI-CALCIUM PHOSPHATE IS AS FOLLOWS.

PROCESS FLOW

QUALITY CONTROL 

USE OF MACHINERY (CRITICAL)

GRINDING

BALL MILL

FEEDING SYSTEM

FILTRATION

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

STP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT 

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT & MACHINERY

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

GRINDER

REACTORS

EVAPORATORS

MIXER

DRYER

STORAGE TANKS

CENTRIFUGE

PULVERIZERS

MATERIAL HANDLING EQUIPMENTS

LABORATORY EQUIPMENTS

BOILERS

INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

D.G. SETS

EOT CRANES

POWER TRANSFORMERS

COOLING TOWER

ETP PLANTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

PLATEFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE PROCESS 

POTENTIAL RISKS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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)