NPK Fertiliser (Capacity: 400 Tons/Day)

NPK FERTILISER

[EIRI/EDPR/4430] J.C.: 2633XL

INTRODUCTION

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%.

Grades with no P2O5 or no K2O are also included in the “NPK” product range but they are normally named NP and NK fertilizers. These types of fertilizers can normally be produced in NPK plants and emission levels will typically be within the limits valid for NPK grades.

COST ESTIMATION

Plant Capacity                                    400 Ton/Day  

Land & Building (8185 sq.mt.)    Rs. 7.82  Cr    

Plant & Machinery                            Rs. 17.29 Cr 

Working Capital for 1.5 Months    Rs. 38.56 Cr 

Total Capital Investment                  Rs. 64.86 Cr 

Rate of Return                                  63%

Break Even Point                              30%

CONTENTS

INTRODUCTION

NPK FERTILIZERS CAN BE PRODUCED IN FOUR, BASICALLY DIFFERENT, WAYS:-

TECHNOLOGIES FOR NPK FERTILIZER

PROCESSING OF RAW MATERIALS

GRANULATION TECHNIQUES

DRUM GRANULATION WITH AMMONIZATION

MIXED ACID PROCESS WITH PHOSPHATE ROCK DIGESTION

PRODUCTION PROCESSES

THREE DIFFERENT PROCESSES ARE DESCRIBED:-

REQUIREMENTS OF DIFFERENT FERTILISERS FOR DIFFERENT CROPS

HOW MUCH FERTILIZER TO APPLY:

CONVERSION FACTORS

CONVERSION FACTORS DETERMINING QUANTITIES OF FERTILIZERS

NPK FERTILIZER AND THEIR GRADE

BIS  SPECIFICATIONS

PROPERTIES & STORAGE OF NPK FERTILIZER

HANDLING, STORAGE AND PACKING

PARTICLE SIZE

RAW MATERIALS

MARKET OVERVIEW

INCREASING PRODUCTION COUPLED WITH NEED FOR HIGHER YIELD OF CROPS

GROWING AGRICULTURAL SECTOR IN DEVELOPING COUNTRIES

INCREASING R&D ACTIVITIES BY NPK FERTILIZER MANUFACTURERS

RISING DEMAND FOR HIGH-QUALITY PLANT-BASED FOODS

RISING COST OF FERTILIZER RAW MATERIALS

MANUFACTURING PROCESS STEPS

SLURRY GRANULATION PROCESS

MANUFACTURING PROCESS

NPK GRANULATION PLANT CONSISTS OF

GRANULATION

DRYING

SIEVING

PRODUCT COOLING

CYCLONES AND SCRUBBING

FUMES SCRUBBING SYSTEM

DRYER SCRUBBING SYSTEM

DEDUSTING SCRUBBER SYSTEM

PROCESS FLOW

BLOCK DIAGRAM OF NPK MIXED GRANULATED FERTILIZER

NPK FERTILIZER GRANULATING PROCESS

PROCESS FLOW

EMISSION & POLLUTION CONTROL IN NPK FERTILIZER PLANT

THERE ARE TWO PROCESSES WHICH MAY CREATE POLLUTION

PROCESS OF NPK FERTILIZER

HANDLING, STORAGE AND PACKING

GUIDE FOR MIXING

RAW MATERIAL EVALUATION

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT/MACHINERY (BROADLY)

RAW MATERIAL PROJECTION

UREA

PRICE TRENDS

AMMONIUM SULFATE

SINGLE SUPER PHOSPHATE

MURIATE OF POTASH

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:

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF DI-AMMONIUM PHOSPHATE

SUPPLIERS OF  MONOPOTASSIUM PHOSPHATE

SUPPLIERS OF HDPE WOVEN BAGS

COMPLETE PLANT & MACHINERY SUPPLIERS - TURNKEY BASIS

SUPPLIERS OF PLANT & 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 EQUIPMENTS

SUPPLIERS OF DG SETS

SUPPLIERS OF BOILER

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF STORAGE TANKS

SUPPLIERS OF ETP PLANTS

UTILITIES PER MONTH (ESTIMATED)

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)

POTENTIAL RISKS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS

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)