PRODUCTION OF SINGLE SUPERPHOSPHATE

UNDER GUIDANCE OF: PRESENTED BY: Dr. G.K AGARWAL ADARSH PRABHAKARASST. PROFESSOR (091402)

ANKUR AGGARWAL (091439)

INTRODUCTION

• Fertilizers are chemical compounds spread on or worked into soil to increase its capacity to support plant growth. Fertilizers are food that plants need. It is one of the three components plants need to grow the others being water and soil. Just as human beings need different nutritional elements such as proteins, vitamins and carbohydrates, plants need different nutrients and minerals for healthy growth. Fertilizers supply these to the plant.

INDUSTRIAL APPLICATIONS

• SSP is an excellent source of three plant nutrients. The P component reacts in soil similarly to other soluble fertilizers. The presence of both P and sulfur (S) in SSP can be an agronomic advantage where both of these nutrients are deficient. In agronomic studies where SSP is demonstrated to be superior to other P fertilizers, it is usually due to the S and/or Ca that it contains.• Powdered SSP is useful in short duration crops such as Oil Seeds, Pulses and

Vegetables.• Granulated SSP is effective and useful in long duration crops like Sugarcane,

Wheat & Rice.

PRODUCT SPECIFICATIONSS.NO PARAMETERS REQUIREMENTS,PERCENTAGE BYMASS

1 Available phosphates, min 16.02 Water soluble phosphate

P2O5,min 13.5

3 Calcium by weight, min 16.04 Free phosphate acid,asP2O5,min 4.0

5 Moisture content,min 12.06. Sulphur,min 9.0

WORLD SCENARIO

INDIAN SCENARIO

TOP TEN SSP MANUFACTURERS IN INDIA

PHYSICAL PROPERTIESCAS NO 7758-23-8Molecular weight 252Melting point/Melting range Not determined (decomposes before melting).Boiling point/Boiling range Not determined (The substance decomposes

before boiling)

Appearance Form: Free flowing powder and GranulesColor Light brown, Grey,brownish whiteNature Acidic ,slight Hygroscopic / Caking at long

storage

Bulk density at 20°C 1000-1200 kg/m³Relative density at 20°C 2.41 g/cm³

Decomposition temperature >200°C (Thermal decomposition on losing wate)r

CHEMICAL PROPERTIES

Vapor pressure at 20°C 8,4x10-7 Pa

pH-value (10 g/l) at 20°C 3,7

HANDLING AND STORAGE

Store in cool, dry, well ventilated area, away from moisture, oxidizing agents, acids and foodstuffs. Ensure product is adequately labelled, protected from physical damage and sealed when not in use. Do not allow to come into contact with water, either from rain, condensation or the surface on which stored. Bagged fertilizer should be stored under cover and out of direct sunlight. If stored in the open do so for short periods only , and cover with a tarpaulin. Bulk bags should not be stacked more than two high. Store away from farm chemicals, eg insecticides, fungicides and herbicides.

SAFETY RELATED PROCEDURES

• General information: Do not leave affected persons unattended.• After inhalation: Supply fresh air; consult doctor in case of complaints.• After skin contact: Immediately wash with water and soap and rinse thoroughly.

If skin irritation continues, consult a doctor.• After eye contact: Rinse opened eye for several minutes under running water.

Seek medical treatment.• After swelling Rinse out mouth and then drink plenty of water.

CAPACITY SELECTION

• Total demand in India= 2.913 MMT/year• Total supply in India= 3.093 MMT/year

• Consumption increased by 8% over previous year • Production increased by 24% over previous year• To match the supply and the demand quantities we either have to design a

plant which can equalize the two things.• So, we will have to decide our plant capacity in between of these two extremes

• Therefore we have decided our plant capacity as = 500 tones/day.

PRODUCTION

• We have been producing the single superphosphate by acidulation of rock phosphate by sulfuric acid.

RAW MATERIALS AND THEIR RESOURCES

• ROCK PHOSPHATE: Rock phosphate is mined in many countries like India, China ,Israel Jordan, Syria, Morocco, Egypt, Malaysia, Indonesia and many African & American countries. The high(30-35% P2O5) grade of natural or beneficiated phosphate rock is ordinarily specified is suitable for the production. Since the demand is high for the P2O5 content product.

• SULPHURIC ACID: The technical grade Sulfuric acid that is 98.5% pure is suitable for the process. Dilute sulfuric acid (62-70%H2SO4) is the only other chemical involved. However spent sulfuric acid from other industries like textiles, Detergent and which is a waste, can also be used along with the technical grade sulfuric acid in the plants designed by us.

• FUEL: To dry GSSP any fuel like Furnace Oil, H.S. Diesel, LDO etc. may be used.

• FILLERS: Gypsum, Sand etc.

Process Flow Diagram

Material Balance around DEN

Component I/P(ton/day) O/P(ton/day)

Rock Phosphate 264 -

H2SO4 137.3 -

Water 109.2 -

SSP - 500

HF - 10.5

Total 510.5 510.5

Material balance around Scrubber

Component I/P O/P

SIF4 13.52 -

H2O 4.6 -

H2SIF6 - 12.4

SIO2 - 2.6

TOTAL 18.12 15

Material balance around Rotary Granulator

Component I/P O/P

SSP (Granular) 500 -

SSP (Fines) 50 -

Under size(Recycle) 50  

Water 7.5 -

Total 607.5 607.5

Material balance around Rotary Dryer

Component I/P O/P

SSP (Granular) 607.5 -

Water(evaporation) - 57.5

Total - 550

Material balance around Screen

Component I/P O/P

SSP 550 500

Over size (SSP) - 25

Under size (SSP) - 25

Total 550 550

ENERGY BALANCE

EQUIPMENT HEAT OF REACTION

CONTINIOUS BLENDER 3662997.46 KJ

SCRUBBER 1884149.86 KJ

DEN -111218754.6 KJ

CONTROL STRATEGY FOR FEEDER

PROCESS DESIGN

EQUIPMENT L/D RATIO PRESSURE DROP VOLUME

FEEDER - - 416.2 m sq

DEN 7.84 - 464 m sq

SCRUBBER - 820 mm WC -

ROTARY DRYER 6.34 - -

ROTARY COOLER 6.88 - -

MECHANICAL DESIGN

EQUIPMENT SHELL THICKNESS OUTER DIA

ROTARY COOLER 1.98 m 2.77 m

ROTARY HEATER 4.4 mm 6.16 m

Economic EvaluationList Of Equipments No. Of Equipments

Crusher 1

Ring roll mill 1

Feeder 1

Continious blender 1

Den 1

Venturi Scrubber 1

Cyclone Separator 2

Rotary Dryer 1

Rotary Cooler 1

1Capital cost Evaluation

Estimation of Capital Investment Cost

• Fixed Capital Investment = Plant Direct cost + Plant Indirect costA. Total Plant Direct cost (TPDC)

• Equipment Purchase Cost (PC) = Rs 89758788.89• Delivered Cost (110% of PC) = Rs 98734667.78• Installation Cost (39% of DC) = Rs 38506520.44• Processing Piping (10% of DC) = Rs 9873466.7• Instrumentation (26% of DC) = Rs 25671013.62• Electrical Facilities (10% of DC) = Rs 9873466.7• Building Cost (29% of DC) = Rs 28633053• Yard Improvement (12% of DC) = Rs 11848160.13• Total Plant Direct Cost = Rs 312,899,137.3

B. Total Plant Indirect cost (TPIC)• Engineering and Supervision Cost (32% of DC) = Rs 31595093.69• Construction Expenses (34% of DC) = Rs 33569787.05• Contractor fee (19% of DC) = Rs 18759586.88• Legal Expenses (4% of DC) = Rs 3949386.711• Contingency (37% of DC) = Rs 36531827.08• Total Plant Indirect cost = Rs 124,405,681.4

• Fixed Capital Investment = Plant Direct cost + Plant Indirect cost = Rs 437,304,818.9• Fixed Capital Investment(FCI) = Working Capital (20% of Total

Capital Investment) = 0.2 * (TCI)• Total Capital Investment (TCI) = Fixed Capital Investment + Working

Capital• TCI = Rs 546,631,023.6

Estimation Of Total Production Cost

• The Total Production Cost (Y)• TPC = Manufacturing Cost + General Expenses• Manufacturing Cost• Raw Material Cost

• Rock Phosphate = Rs 799,365.6• Sulphuric Acid = Rs 1,055,762.1

• Total Raw Material Cost = Rs 1,855,127.7• Operating Labour (22% of Y) = Rs 49,673,158.73• Direct Supervision and Clerical Labour (10% of Y) = Rs 22578708.51• Maintenance and Repair Cost (7% of FCI) = Rs 30,611,337.32• Operating Supplies (15% of Maintenance Cost) = Rs 4,591,700.598• Utilities (10% of Y) = Rs 22,578,708.51 • Patents and Royalties (4% of Y) = Rs 9,031,483.404 • Laboratory Charges (12% of Operating labour) = Rs 5,960,779.048

• Total Direct Production Cost = Rs 146,881,003.3• Fixed Charges • Depreciation (10 % of Equipment Cost) = Rs 8,975,878.889• Building Cost (assuming 15 yrs life) = Rs 85,540• Local Taxes (2% of FCI) = Rs 8,746,096.378• Property Insurance (1% TCI) =Rs546,631.026• Financing (10% of TCI/2 ) =Rs27,331,551.18• Total Fixed Charges = Rs 45,685,697.47

• Plant Overhead Cost (10% of TPC)= Rs 22,578,708.51 • Manufacturing Cost = Fixed Charges + Plant Overhead cost + Direct Production Cost Manufacturing Cost = Rs 215,145,409.3

• General Expenses• Administration Rate (3% of TPC) = Rs 773,612.553• Distribution and Marketing Cost (10% of TPC) = Rs 22,578,708.51

• R & D Cost (5% of TPC) = Rs 11,289,354.26• Total General Expenses = Rs 10,641,675.8• TPC = Manufacturing Cost + General Expenses = Rs 225787085.1• Single Super Phosphate Price per Ton = Rs 3400• Total Sales = Rs 510,000,000• Gross Earning = Total Sales – Total Production Cost = Rs 284212914.9

Profitability analysis

• Profit before Tax = Revenue – Total Production Cost = Rs 284212914.9

• Profit after Tax = (1 - 0.35) * Profit before Tax = Rs 127895811.7• Rate of Return = (Profit after tax/FCI) * 100 = 29 %• Payback Period = Total Investment / Annual Cash Flow = 2 years 3 months

HAZOP For Feeder• The HAZOP process is based on the principle that a team approach to hazard analysis will

identify more problems than when individuals working separately combine results. • Here in feeder we are using Rock phosphate and suphuric acid and only thing that • we have to care about is the acid.Specific Parameters• Flow – Flow rate is mentioned and If flow rate is not that much it will affect the • quality of the product.• Temperature – Here the permissible temperature is 200 degrees and reaction does • does not reach at this temperature.• Pressure - Pressure has no role in this process.• Level –Level is controlled by level controller, if level is increased• Corrosion - It is noted down and change is done when it is needed.• Contamination-If a contamination occurs, we have to restart the process again.

REFERENCES• WEBSITES• Anonymous,SSP (Single Super phosphate Plant),At http://fertilizerplants.in/single-super-phosphate-plant.htmlon 17/08/2012• • Fertilizer Pricing (Govt. of India),Advantages of SSP Fertilizer, At http://www.fert.gov.in/fertilizersubsidy/ssp_ucs.aspon 14/09/2012• • DMCC Ltd. ,Specifications of SSP At http://www.dmcc.com/ssp.htmlon 08/10/2011• • Mega Tech International Private Limited,Venturi for SSP,Den for SSP,Athttp://www.cement-plant.com/single-super-phosphate-tsp-plants.html on 13/03/2011• • Economic scenario,Production and consumption of different states,Major companies producing SSP , Major countries producing all over the world ,At

http://www.jubilantindustries.com/ramban-ssp.html on 7/10/2010• • Anonymous,Physicalandchemicalproperties,Atwww.chemyq.com/En/xz/xz13/124636bbkaj.htm on 12/10/2009• • Anonymous,Process description of SSP,At fertilizerplants.in/single-super-phosphate-plant.html on 23/12/2010• • Anonymous,Specific heat value and heat of formation for SiF4,At encyclopedia.airliquide.com/Encyclopedia.asp?GasID=62 on 21/05/2005• • Anonymous,Specific heat value and heat of formation for H2SiF6 , At www.nist.gov/data/PDFfiles/jpcrd597.pdf on 12/3/2007• • Anonymous,Specific heat value and heat of formation for SIO2,At mmc.org/ftp/material/silicon-dioxide.html on 15/04/2003• • Anonymous,Specific heat value and heat of formation for SiO2,At inmmc.org/ftp/material/silicon-dioxide.html on 16/6/2011• • 12 .http://www.matche.com/EquipCost/Index.htm as on 12/7/2007,anonymous• 13.http://www.thehindubusinessline.in/bline/2008/04/12/stories/200804125054110 0.htm as on 11/4/2013 ,anonymous• 14 http://www.sulphuric-acid.com/sulphuric-acid-on-the-web/Market-Info.htm, as on 12/3/2013, anonymous• 15. http://www.mongabay.com/commodities/prices/phosphate_rock.php, as on 13/2/2013, anonymous

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www.nist.gov/data/PDFfiles/jpcrd597.pdf on 12/3/2007 • Anonymous,Specific heat value and heat of formation for SIO2,At mmc.org/ftp/material/silicon-

dioxide.html on 15/04/2003 • Anonymous,Specific heat value and heat of formation for SiO2,At inmmc.org/ftp/material/silicon-

dioxide.html on 16/6/2011

. .http://www.matche.com/EquipCost/Index.htm as on 12/7/2007,anonymous• .http

://www.thehindubusinessline.in/bline/2008/04/12/stories/200804125054110 0.htm as on 11/4/2013 ,anonymous

• http://www.sulphuric-acid.com/sulphuric-acid-on-the-web/Market-Info.htm, as on 12/3/2013, anonymous

• . http://www.mongabay.com/commodities/prices/phosphate_rock.php, as on 13/2/2013, anonymous

THANK YOU