MONO CALCIUM PHOSPHATE (ANIMAL FEED GRADE -IP GRADE)
[EIRI/EDPR/1702] J.C.528XL
INTRODUCTION
Inorganic feed phosphates (IFP) are inorganic salts of phosphoric acid. The use of inorganic feed phosphates is necessary to meet the phosphorus requirements for animal production: to ensure optimal growth, fertility and bone development.
Feed phosphates are of great importance among the feed materials produced for intensification of livestock farming. They are produced and applied in relatively large quantities, although for several years, both their production and use were often characterized by an unfavorable opinion resulting from the potentially adverse impact on the environment. Emergence of the “mad cow” disease BSE (bovine spongiform encephalopathy) and the Creutzfeldt-Jakob disease, which genesis was considered in the use of meat and bone meal - the main competitor of feed phosphates, have contributed to the change of this opinion.
The products obtained in the chemical processes appeared to be much safer, which resulted in restrictions, introduced into the European legislation, on the use of products based on the utilization of products derived from slaughter wastes. Feed phosphates are one of the most important factors in the intensification of livestock farming . They enable compensation of phosphorus and calcium deficiency in the feeds. The estimated overall production capacity of worldwide industrial plants is about 4.5 mln Mg/year. The national prospective, differentiated by various experts, indicate the minimum demand of 90 thousand Mg/year, and in the next few years up to 130-150 thousand Mg. Another important problem of the production of feed phosphates is introduction into their composition other chemical components which are essential for intensive methods of livestock farming. The most important are preparations containing calcium, sodium and selenium. Feed additives such as micronutrients or ultra-trace elements are applied in much smaller amounts. In this respect, products containing copper, zinc, iron, magnesium, cobalt and iodine can be distinguished among the feed materials.
The essence of the trends in development of the technology of feed phosphates production observed in recent years is aimed at reduction of manufacturing costs while preserving the basic operating parameters and better adjustability to the physicochemical properties of their operational applications. For this purpose, such issues like power consumption of manufacturing process, source of phosphorus compounds, water consumption balance, optimization of operations and unit processes used in technology, development of new apparatus and equipment used in the manufacturing process, are considered. These endeavors resulted in significant long-term manufacturing costs reduction, achieved by the leading world producers which cause price stabilization or even reduction for these products on global markets. In consequence ongoing elementary and development research of the process and the implementation of innovative alterations in techniques of feed additives manufacturing is required. Manufacturers that have-not changed their technologies in recent years are exposed to significant difficulties in range of relatively increasing production costs what makes their endurance, among the producers in a free market economy in Europe, limited and sometimes even impossible. The same situation can be found also in domestic industry. This paper focuses on several different technological options that allow determining conditions under which the production of feed phosphates at reduced water amount in the process is possible. This is directly related to the possibility of reducing the energy demand of the process and therefore unit costs.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (10,000 sq.mt.) Rs. 8.96 Cr
Plant & Machinery Rs. 4.56 Cr
Working Capital for 2 Months Rs. 5.76 Cr
Total Capital Investment Rs. 20.39 Cr
Rate of Return 27%
Break Even Point 49%
CONTENTS
INTRODUCTION
DEVELOPMENT IN TECHNOLOGIES OF FEED PHOSPHATES PRODUCTION
TABLE 1 RESULTS OF LABORATORY TESTS OF FEED CALCIUM HYDROGEN PHOSPHATE PRODUCTION USING CONCENTRATED PHOSPHORIC ACID
TABLE 2 CHARACTERISTICS OF PHOSPHORIC ACID FROM AB LIFOSA USED FOR THE PRE- PARATION OF FEED PHOSPHATES UNDER INDUSTRIAL CONDITIONS
TABLE 3 CHARACTERISTICS OF CALCIUM OXIDE AND CALCIUM CARBONATE FROM ZW KUJAWY USED FOR THE PREPARATION OF FEED PHOSPHATES UNDER INDUSTRIAL CONDITIONS
TABLE 4 CHEMICAL COMPOSITION OF FEED DICALCIUM PHOSPHATE OBTAINED UNDER INDUSTRIAL CONDITIONS
CONCLUSIONS
IMPORTANCE
PRODUCTION OF INORGANIC FEED PHOSPHATES
EXAMPLE OF PHOSPHORIC ACID PRODUCTION
DIFFERENT TYPES OF INORGANIC FEED PHOSPHATES
EXAMPLE OF A CALCIUM FEED PHOSPHATE PRODUCTION
QUALITY
PHOSPHORUS REQUIREMENTS
PREVENTING DEFICIENCIES
PHOSPHORUS METABOLISM
MONOCALCIUM PHOSPHATE FOR ANIMAL AND POULTRY FEED GRADE
MONOCALCIUM PHOSPHATE MCP IP GRADE
MCP IP GRADE MONOCALCIUM PHOSPHATE SPECIFICATIONS: FCC
PACKING: 25 KGS NET PAPER BAGS OR 25 KGS NET PLASTIC WOVEN BAGS.
GENERAL SIDE EFFECTS
MARKET POTENTIAL
COMPOSITION OF BLANCED CATTLE FEED
DIALY DICALCIUM PHOSPHTE REQUIREMENT FOR CATTLE & BUFFALOES
PERCENTAGE MILK PRODUCT (NUTRIENTS REQUIRED PER KG FAR OF MILK)
POPULATION BY 2015
FEED PHOSPHATE MARKET BY TYPE (DICALCIUM PHOSPHATE, MONOCALCIUM PHOSPHATE, TRICALCIUM PHOSPHATE, DEFLUORINATED PHOSPHATE & OTHERS), BY LIVESTOCK (SWINE, CATTLE, POULTRY, AQUATIC ANIMALS & OTHERS), BY GEOGRAPHY - GLOBAL TRENDS & FORECASTS TO 2018
FEED PHOSPHATE MARKET VALUE, BY LIVESTOCK, 2013 VS. 2018 ($MILLION)
SCOPE OF THE REPORT
BY TYPE
BY LIVESTOCK
BY GEOGRAPHY
CUSTOMIZATION OPTIONS:
INDUSTRY ANALYSIS
COMPETITIVE INTELLIGENCE
GLOBALIZATION & TRADE
MANUFACTURING PROCESS (ANIMAL FEED GRADE)
FLOW SHEET
MANUFACTURING PROCESS (IP GRADE)
OTHER COMMERCIAL METHODS
MANUFACTURERS/EXPORTERS/SUPPLIERS OF MONOCALCIUM PHOSPHATE
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
CURED SINGLE SUPER PHOSPHATE
COMPLETE PLANT SUPPLIERS OF MCP
SUPPLIERS OF PLANT AND EQUIPMENTS
REACTION KETTLES
FILTER PRESS
CONVEYOR BELT
BOILER
D.G. SETS
AUTOMATIC FILLING MACHINE
STORAGE TANK
LABORATORY TESTING EQUIPMENT
MATERIAL HANDLING EQUIPMENTS
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
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:
7. TERM LOANS:
8. TOTAL LOAD:
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)
