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)
