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Summer Internship Report

A Study on the Production Department at

Auriga

Group of Companies.

By

Tahir saeed

DDP-FA12-BEC-073

Duration: 3rd

Aug to 31st Aug

Department of Chemical Engineering

Submitted To

Sir Tariq Mehmood Raza

Comsats Institute of Information Technology

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Acknowledgements

‘In the name of Allah, the most Gracious, the most merciful’

Internship remained a great experience for me as it added a lot to my knowledge.

It requires continuous hard work and zeal. I think that there are many people who

contributed a lot to this report and completion of this report would have not been

possible without the support of all these people, my respected teachers, my friends and

my well-wishers. I would like to mention that Mr. Rehan Paracha, who was

Production Manager at Auriga group of companies, has been very kind and supportive

throughout my stay at there. I would like to pay my gratitude to all my respected

teachers for their guidance and assistance in the completion of this report.

My gratitude will always remain due to the COMSATS Institute of Information

Technology and especially Auriga group of companies in increasing my

knowledge and experience by providing me such an opportunity. Both these

prestigious institutions will have a lasting impact on my life.

May Allah Bestow His Blessings on All of us.

Tahir saeed

COMSATS Institute of Information Technology, Lahore

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Table of contents

Executive Summary 4

Introduction/Background 5

Goals/Objectives 6

Granular Plant 7

Introduction 8

Raw Material 9

Explanations 10

List of Machinery 11

Emulsifier Concentrate 12

Introduction 13

Raw Material 14

Explanations 15

List of Machinery 16

Bio Organic Plant 17

Introduction 18

Raw Material 19

Explanations 20

List of Machinery 21

Wettable Powder 22

Introduction 23

Raw Material 24

Explanation and List of Machineries 25

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Executive Summary:

For almost half a century, the global agricultural system has relied heavily on the widespread

application of millions of tones and hundreds of types of synthetic chemical pesticides to

reduce crop losses. As most farmers are now treating their crops with a variety of pesticides

on a routine basis, rather than as a last resort in rare cases of heavy pest infestations, this

means that chemical inputs are applied multiple times to a crop throughout the whole

growing season. As a result of our dependence on chemical pesticides, and because of their

persistence and pervasiveness, almost every ecosystem on earth has already been negatively

impacted by these harmful chemical compounds.

How Industrial Agriculture Damages our Environment.” examines the use of synthetic

chemical pesticides in Pakistan, the widespread and severe environmental impacts they are

having - including how they are degrading some essential ecosystem services and, the

urgency of tightening the regulations that are supposed to control their use. The production,

sale and use of synthetic chemical pesticides has become a multi-billion euro industry

dominated by a small number of agro-chemical businesses. As well as Auriga group of

companies is taking part in producing pesticides, insecticides by means of planting different

types of Plants. Like Bio organic Phosphate, Wettable Powder Plant, Granulation Plant and

Emulsifying Plant.

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Introduction:

Auriga Group of companies is committed to make Pakistan self-sufficient in agriculture

because it is the largest productive sector and a bulk of our population depends upon it. With

population increasing to alarming levels, Pakistan’s agriculture needs to become more

productive and sustainable. Only agricultural innovations can help us cope with the situation.

Auriga Chemicals is the parent company. Auriga well built sales and marketing network with

a team of almost 400 dedicated agriculture graduates and 7 warehouses across Pakistan. The

company markets quality agricultural inputs at affordable prices backed by the on-farm

advisory service. This kind of marketing creates a win-win situation by guiding farmers to

manage weeds and increase yield potential. We are operating to make farming a

commercially sustainable and growing business.

Taking clue from the overwhelming success of Say-ban One Stop Shop, Auriga Group has

set up Auriga Solutions Centers on various locations to assist the farming community. From

providing agro products to free advisory services to the farmers and growers, Auriga

Solutions Centers support the agro community in growing more and reaping even more.

Auriga fertilizers is basically a research and production wing with a mandate to develop

novel combinations of micro and macro nutrients, together with growth regulators and

growth promoters, specific to different crops. We take pride in being the pioneers in this

industry and giving new trends to agribusiness industry. Our famous brands like Zarcon,

Zeneca, Galore, Grow up, Comus and Vital have become industry standards. The products

have unique combinations of micro and macro nutrients targeting different segments of the

market as per need of the specific soil and crops. Our next product from this wing is true

Potassium Humate. The test supply to the market has proven it to be a very good product and

we aim to take over 40% of the market in next couple of years

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Goals and Objectives:

The main objective of this summer internship is to gain experience in perspective chemical

Industry. Throughout the stay at industry I learn so many points.

I learned all about working in production department of a chemical industry.

I developed the communication skills needed to respond to the Managers and lay man

workers.

I analyze how to tackle industrial problems regarding any issue.

I learn to develop appropriate solution to a problem in a short period of time.

I planned to study the methods of maintaining product quality by this firm.

I learned to apply the principles of chemical engineering to different plants which I

have learnt in my university.

I also learned the chemical, electrical, and mechanical part at my stay at Industry.

I also develop solutions to environmental problems, such as pollution control by

giving them my opinions.

I also learned the pesticides formulation by different processes at my stay at Industry.

The objective of internship will make it easier for me to find work and get off to a good

start in our career. Internships represent a cross-over point between university and career,

and will not only help us in my career, but also in planning our studies. The experience

we gain during an internship will indicate how we should structure our future studies,

particularly when it comes to deciding what aspects you should focus on. An internship

and our study focus will thus help you establish our individual career profile.

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Granular formulation and Packing Unit

What is meant by Granules?

A rock or mineral fragment larger than a sand grain and smaller than a pebble. Granules have

a diameter between 2 and 4 mm (0.08 and 0.16 in) and are often rounded.

Granular Formation:

Granular formulations are similar to dust formulations except that granular

particles are larger and heavier. The coarse particles are made from an absorptive

material such as clay, corn cobs, or walnut shells. The active ingredient either coats

the outside of the granules or is absorbed into them. The amount of active ingredient

is relatively low, usually ranging from 1% to 15%.

Granular pesticides are most often used to apply chemicals to the soil to control

weeds, nematodes, and insects living in the soil. Granular formulations are sometimes

used in airplane or helicopter applications to minimize drift or to penetrate dense

vegetation. Granular formulations also are used to control larval mosquitoes and other

aquatic pests. Granules are used in agricultural, structural, ornamental, turf, aquatic,

right-of-way, and public health (biting insect) pest control operations.

Advantages:

Ready to use, no mixing.

Drift hazard is low, and particles settle quickly.

Little hazard to applicator (no spray, little dust).

Weight carries the formulation through foliage to target.

Simple application equipment, such as seeders or fertilizer spreaders.

Disadvantages:

Do not stick to foliage or other no level surfaces.

May need to be incorporated into soil or planting medium.

May need moisture to start pesticide action.

May be hazardous to non-target species, especially waterfowl and other birds that

mistakenly feed on the grain like or seed like granules.

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Raw Material for the Formulation of Pesticides.

The raw material contains four products to reach formulation. These are as follow:

Silica

Slurry

Car tap

China Clay

Silica:

Silica is important in plant and animal life. Diatoms in both fresh and salt water extract silica

from the water to use as a component of their cell walls.

Many pesticide formulations are adversely affected by moisture, humidity, the presence of

viscous liquids, and static charge. Silica is the main ingredient in formulation, approximately

for 1 batch 1.774 tons of silica is used.

Slurry :

A thin mixture of a liquid, especially water, and any of several finely divided substances,

such as cement, plaster of Paris, or clay particles. But the slurry made for pesticides is quite

different from the above explanation. The slurry for pesticides includes Phosphoric Acid, Peg

6000 and Dye/Color. A total of 42 kg of slurry is used for 1 batch, which is a mixture of Peg

6000 car tap and color.

Phosphoric Acid :

Phosphoric acid is a colorless, odorless, relatively strong acid which is either a sparkling

liquid or transparent solid, depending on its concentration and temperature. Phosphoric acid

is soluble in water and alcohol and is corrosive to ferrous metals, alloys, porcelain, and

granite ware. It is manufactured by the treatment of phosphate rock. Phosphoric acid is

registered as a bactericide and disinfectant. It is used to disinfect dairy farm milk handling

facilities, equipment and dairy animals, and food processing water systems. Agriculturally,

phosphoric acid is registered as an adjuvant. In the formulation of pesticides 37 kg of

Phosphoric acid is used for 1 batch.

Peg 6000:

A compound used to modify therapeutic proteins and peptides to increase their solubility. It

is often used as a polar stationary phase for Gas Chromatography. Commonly also used in

mass spectrometry experiments. It is also used to preserve objects that have been retrieved

from the ocean. In pesticides it can be used because it can well dissolved in Phosphoric acid.

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Peg has low toxicity with systematic absorption less than .5 %. 25 kg is used for 1 batch

processing.

Technical Information

Physical State : Solid.

Solubility : Soluble in water (500 g/l) at 20 °C.

Storage : Store at room temperature

Melting point : 60-63 °C.

Dye/color: Dye or color is used to give color to the final product. The whole

batch consumes 1.25 kg of Dye/Color.

Cartap :

A highly effective, broad-spectrum, low toxic and low residual insecticide, Car tap is a

systemic insecticide with stomach and contact action. Insects discontinue feeding, and die of

starvation. Car tap hydrochloride is used, at 0.4 - 1.0kg /ha for controlling chewing and

sucking insects (particularly Lepidoptera and Coleopteran), at almost all stages of

development, on many crops; including rice, tea, cotton, potatoes, cabbages. A total of 75 kg

is used for the process

China Clay :

China clay is being used very effectively as a carrier in pesticide industries. In pesticides

formulation 37.5 kg is used for 1 batch. It can be used as a carrier for beneficial micro-

organisms such as strains of trichoderma. It can also be used as an anti-caking agent in the

production of fertilizers.

Benefits:

It acts as excellent carrier.

Low moisture content.

It can be slurred in water for spray applications.

List of Machinery Which Is Utilized For the Formulation of Pesticides:

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Conveyor Belt :

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt

conveyor). A belt conveyor system is one of many types of conveyor systems. A belt

conveyor system consists of two or more pulleys (sometimes referred to as drums), with

an endless loop of carrying medium the conveyor belt that rotates about them. One or

both of the pulleys are powered, moving the belt and the material on the belt forward. The

powered pulley is called the drive pulley while the unpowered pulley is called the idler

pulley. Its Rpm is 45 to 50.

Induction Motor :

The of the most common electrical motor used in most applications which is known as

induction motor .This motor is also called as synchronous motor because it runs at a

speed less than synchronous speed. In this, we need to define what synchronous speed is.

Synchronous speed is the speed of rotation of the magnetic field in a rotary machine and

it depends upon the frequency and number poles of the machine. An induction motor

always runs at a speed less than synchronous speed because the rotating magnetic field

which is produced in the stator will generate flux in the rotor which will make the rotor to

rotate, but due to the lagging of flux current in the rotor with flux current in the stator, the

rotor will never reach to its rotating magnetic field speed i.e. the synchronous speed. It

has different Rpms which includes 1400, 900, 2800 and 750 Rpm

Rotary Dryer :

Rotary dryers are known as the workhorse of industrial dryers. They are able to process a

wide variety of materials, and can lend a hand in nearly any industry requiring industrial

drying solutions. Its Rpm is 6-8.

Rotary Seive Drum :

The Rotary sieve is ok with dry compost and handles typical loads/sizes. However it

tends to clog up when used with moist compost. Some large pieces can jam and you’ll

need to stop and clear them before carrying on. Its Rpm is 11-13.

Elevator :

An elevator is a type of vertical transport equipment that moves people or goods between

floors (levels, decks) of a building, vessel, or other structure. Elevators are generally

powered by electric motors that either drive traction cables or counterweight systems like

a hoist, or pump hydraulic fluid to raise a cylindrical piston like a jack. Its Rpm is 55-60.

Slurry Tank:

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Where slurry is made.

Agitator :

An agitator is device or mechanism to put something

into motion by shaking or stirring. There are three main types of agitation

machine. The washing machine agitator, which rotates back and forth; the magnetic

agitator, which contains a magnetic bar which rotates about a magnetic field; manual

agitation, such as with a stirring rod. Its Rpm is 25 to 30.

Cyclone:

Cyclonic separation is a method of removing particulates from an air, gas or liquid

stream, without the use of filters, through vortex separation. Rotational effects

and gravity are used to separate mixtures of solids and fluids. The method can also be

used to separate fine droplets of liquid from a gaseous stream.

Mixer :

The terms "mixing" and "blending" are often used interchangeably, but in general

blending is a much gentler process. All mixing and blending can be categorized as either

a batch or continuous process. Batch mixers are typically used when production quantities

are small, strict quality control is needed, or the blend formula changes frequently.

Continuous mixers are typically used for high production rates, combinations of multiple

process streams, or to eliminate batch to batch variations.

Vibrator Seive Tray:

This is used to separate the final product from big particles. So that there should b no

inconvenience in packing unit.

Hopper

Burner

Lists of improvements in Granular formation and Packing unit:

Environment of the surrounding area should be get better, if we install more than 5

exhausts fans in vicinity of the process area.

After every three months, there should be kept an eye on maintenance factor of each

machine installed in the process. If not it should effect on the production and

economy of the product, and also it is dangerous for the plant operators to deal with

excess corrode machinery.

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Conveyor belts should be moving on proper channel or they create difficulty in

transporting material.

Cyclone should be check after it exhausts all the unnecessary fumes or dust to prevent

chocking in the lower section of the cyclone.

The gears and chain should be greased after 1 hour, because heavy machinery cause

or eradicate friction while the gears are moving.

Wet material should not be used in rotary sieve drum because it will choke the

different mesh no sieves, which creates resistance to flow of sand particles

To save time and labor work, electrical buckets should be used for the transportation

of material drum sieve drum to elevator.

Heavy load in elevators should not be used because the material starts choking in the

base of elevator, which creates difficulty for the elevator to work.

Pressure valves should be used carefully, because not to face any inconvenience.

Blower should be mounted on each mixer to extract the fumes and dusts for the safe

environments.

Proper amount and time should be given to slurry for the better results.

For mixer cleaning there should be use of some effective liquid, which saves time and

labor work.

Motor speed should be driven at optimum speed.

Pipes should be clean to prevent resistance to flow.

More than two sieves required after the final dryer process, to save time and better

product.

EMULSIFYING CONCENTRATE

Emulsifier Concentrate:

These formulations usually contain a liquid active ingredient, one or more

petroleum-based solvents, and an agent that allows the formulation to be mixed with water

to form an emulsion. Each gallon of EC usually contains 25% to 75% (2 to 8 pounds) active

ingredient. EC’s are among the most versatile formulations. They are used against

agricultural, ornamental, turf, forestry, structural, food processing, livestock, and public

health pests. They are adaptable to many types of application equipment, including small

portable sprayers, hydraulic sprayers, low-volume ground sprayers, and mist blowers.

Advantages:

Relatively easy to handle, transport, and store.

Little agitation required and will not settle out or separate when equipment is

running.

Will not plug screens or nozzles.

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Disadvantages:

Solvents may cause rubber or plastic hoses, gaskets, and pump parts and surfaces

to deteriorate.

May cause pitting or discoloration of painted finishes.

Flammable (should be used and stored away from heat or open flame

Raw Material:

Pyriproxyfen

Nansa

NE 5000

Xylene

Pyriproxyfen:

Pyriproxyfen is a pyrine based pesticide which is found to be an effective

against a variety of artopoda. Its formula is C20H19NO3. One batch contains 1400 kg of it.

Mode of Regulator: Insect growth regulator; Suppressor of embryogenesis, inhibitor

of metamorphosis, and inhibitor of reproduction.

Nansa:

Nansa is non ionic surfactant which is a white to light yellow flakes, granules or

powder. It is soluble in water. The primary hazard is the threat to the environment. Immediate

steps should be taken to limit its spread to the environment. It is used as a synthetic detergent.

One batch contains 348 kg of it.

Xylene:

Xylene, xylol or dimethylbenzene is an aromatic hydrocarbon mixture consisting of

a benzene ring with two methyl groups at various substituted positions. The three isomers of

Xylene have the molecular formula C8H10, also represented by the semi-structural

formula C6H4 (CH3)2. Xylene is a major petrochemical produced by catalytic reforming and

also by coal carbonization in the manufacture of coke fuel. It represents about 0.5–1% of

crude oil (depending on the source), and is found in small quantities in gasoline and aircraft

fuels. Xylene is mainly produced as part of the BTX aromatics (benzene, toluene and

xylenes) extracted from the product of catalytic reforming known as "reformate". The

mixture is a slightly greasy, colorless liquid commonly encountered as a solvent. One batch

contains 10255.2 liters of it.

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List of Machinery:

Mixer:

Mixing is a unit operation that involves manipulation of a heterogeneous physical system

with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass

transfer to occur between one or more steams, components or phases. Modern industrial

processing almost always involves some form of mixing. Some classes of chemical

reactors are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas

into another solid, liquid or gas.

Ball Valve:

A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball

(called a "floating ball") to control flow through it. It is open when the ball's hole is in line

with the flow and closed when it is pivoted 90-degrees by the valve handle. The handle lies

flat in alignment with the flow when open, and is perpendicular to it when closed, making for

easy visual confirmation of the valve's status.

Filters:

The filter which is used in Ec plant is cartage filter. Cartridge filters have large surface areas

enabling them to operate for long periods. Cartridge filter systems also permit better water

flow thus, placing less strain on the filter pump. These types of filters are also easiest to clean

by using a flow of high-pressure water from a hose. The filters are made of polyester or other

material that can provide a superfine filtering surface. The pleats are the key to the filter's

operation. The tight pleats, or folds, allow for a large amount of material to be used in a small

container. The more material used, the larger the surface area available to capture dirt or

debris from the water. The fabric catches and holds the impurities until the filter can be

cleaned or replaced. There 3 parts to a cartridge filter construction, end caps (made of plastic)

core structure to provide strength (most often PVC) and the pleated media (most often

polyester with a continuously graded fixed pore structure, these cartridges provide pre- and

final filtration within the same cartridge resulting in lower overall filtration and disposal cost.

Motor:

An induction or asynchronous motor is an AC electric motor in which the electric current in

the rotor needed to produce torque is obtained by electromagnetic induction from the

magnetic field of the stator winding. An induction motor therefore does not require

mechanical commutation, separate-excitation or self-excitation for all or part of the energy

transferred from stator to rotor, as in universal, DC and large synchronous motors. An

induction motor's rotor can be either wound type or squirrel-cage type. The motors in Ec

Plant are of 20 Hp. They are made up of mild steel.

Centrifugal Pump:

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Centrifugal pumps are a sub-class of dynamic ax symmetric work-absorbing turbo

machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational

kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically

comes from an engine or electric motor. The fluid enters the pump impeller along or near to

the rotating axis and is accelerated by the impeller, flowing radically outward into a diffuser

or volute chamber (casing), from where it exits. The centrifugal pumps in Ec plant Hp is 30.

The pump rpm is 2900.

Agitators:

Agitator is a device to put something into motion by shaking or stirring. There are three main

types of agitation machines like the washing machine agitator, which rotates back and forth;

the magnetic agitator, which contains a magnetic bar which rotates about a magnetic field;

manual agitation, such as with a stirring rod. The mixer agitator’s rpm is 50. They are made

up of stainless steel.

Gate Valve:

A gate valve also known as a sluice valve, is a valve that opens by lifting a round or

rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the

sealing surfaces between the gate and seats are planar, so gate valves are often used when a

straight-line flow of fluid and minimum restriction is desired. The gate faces can form a

wedge shape or they can be parallel. Gate valves are primarily used to permit or prevent the

flow of liquids, but typical gate valves shouldn't be used for regulating flow, unless they are

specifically designed for that purpose. Because of their ability to cut through liquids, gate

valves are often used in the petroleum industry.

List of Improvements:

Due to low voltage most of the equipments don’t work, if some work they don’t last for

a long period of time.

Valves should be operated well.

Motors should be operated at desired voltage otherwise due to uneven voltage they are

useless.

Filters should be prevented from choking otherwise they don’t work.

Washing of the equipment should be done prior to using any other material in the

mixers.

After every three months maintenance factor should be kept in mind.

There should be sensor on every motor so that it trips if the voltage is low.

The equipments used in the Industry should not across 40 dba noise.

Agitator speed should be optimum for better mixing.

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While taking work for pump, it is sure that it won’t cavitate.

Pump should be self priming.

Pump impeller width should be match with the desired fluid viscosity, to prevent pump

from choking.

There are no gauges on Pump; there should be pressure gauges and flow meter devices

on Pumps.

Pipes should be resistance flow.

BIO ORGANIC PHOSPHATE

What is Bio organic phosphate?

Phosphate rich organic manure is a type of fertilizer used as an alternative to

diammonium phosphate and single super phosphate. Phosphorus is required by

all plants but is limited in soil, creating a problem in agriculture. In many areas

phosphorus must be added to soil for the extensive plant growth that is desired

for crop production. Phosphorus was first added as a fertilizer in the form of

single super phosphate. SSP is non-nitrogen fertilizer containing Phosphate in

the form of mono calcium phosphate and Gypsum which is best suited for

Alkali soils to supplement Phosphate and reduce soil alkalinity.

An organophosphate (sometimes abbreviated OP) or phosphate ester is the

general name for esters of phosphoric acid. Many of the most important

biochemicals are organophosphates, including DNA and RNA as well as many

cofactors that are essential for life. Organophosphates are the basis of many insecticides,

herbicides, and nerve agents.

Advantages:

Ready to use without mixing and are easy to apply.

Granular product can penetrate foliage to reach the soil surface more easily than spray

droplets.

Disadvantages:

They may present a hazard to non target species especially birds.

They are more expensive as compared to other pest formulation products.

They may require soil incorporation or follow up rain before coming active.

Raw Material:

Rock Phosphate

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Pres mud

Molasses

Seed Mix

ROP

Rock Phosphate: Phosphorite, phosphate rock or rock phosphate is a sedimentary rock which contains high

amounts of phosphate bearing minerals. The phosphate content of phosphorite is at least 15 to

20%; if it is assumed that the phosphate minerals in phosphorite are hydroxyapatite and

fluoroapatite, phosphate minerals contain roughly 18 to 5 % phosphorus by weight and if

phosphorite contains around 20% of these minerals, phosphorite is roughly 3 to 7 %

phosphorus by weight, which is a considerable enrichment over the typical sedimentary rock

content of less than 0.2%. One batch contains 730 kg on 1000 kg basis.

Pres mud:

Sugarcane press mud is the residue of the filtration of sugarcane juice. The clarification

process separates the juice into a clear juice that rises to the top and goes for manufacture,

and a mud that collects at the bottom. The mud is then filtered to separate the suspended

matter, which includes insoluble salts and fine bagasse.

Large amounts of press mud are released by the sugarcane industry and the disposal of this

by-product is a major issue. In many cases press mud is burnt in brick kilns, resulting in the

loss and wastage of millions of tones of nutrients, which ultimately degrades the

environment. A common use is for fertilizer, in both the unprocessed or processed form.

Processes used to improve its fertilizer value include composting, treatment with

microorganisms and mixing with distillery effluents. One batch contains 180 kg on 1000 kg

basis.

Molasses:

Molasses, or black treacle is a viscous by-product of the refining of sugarcane or sugar beets

into sugar. Molasses made from sugar beets differs from sugarcane molasses. Only the syrup

left from the final crystallization stage is called molasses; intermediate syrups are called high

green and low green, and these are recycled within the crystallization plant to maximize

extraction. Beet molasses is 50% sugar by dry weight, predominantly sucrose, but contains

significant amounts of glucose and fructose.

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Seed Mix:

Chemical fertilizers combine other byproducts of the petrochemical industry and other

chemicals to supply intense amounts of Nitrogen, Phosphorus, and Potassium to the soil.

They do not feed soil biology or build healthy soil. Organic fertilizers combine with seed mix

and naturally occurring materials and minerals to supply safe amounts of N, P, and K to your

crops so that they grow vigorously, but at a natural rate. Meanwhile, they feed microbial

action in the soil and contribute to a more healthy and diverse soil biology.

ROP:

Phosphate fertilizers are produced by adding acid to ground or pulverized phosphate rock. If

sulfuric acid is used, single or normal, phosphate (SSP) is produced, with a phosphorus

content of 16–21% as phosphorous pent oxide (P2O5). If phosphoric acid is used to acidulate

the phosphate rock, triple phosphate (TSP) is the result. TSP has a phosphorus content of 43–

48% as P2O5.

Two processes are used to produce TSP fertilizers: run-of-pile and granular. The run-of-pile

process is similar to the SSP process. Granular TSP uses lower-strength phosphoric acid

(40%, compared with 50% for run-of-pile). The reaction mixture, slurry, is sprayed onto

recycled fertilizer fines in a granulator. Granules grow and are then discharged to a dryer,

screened, and sent to storage.

List of Machinery

Mixer:

Mixing is a unit operation that involves manipulation of a heterogeneous physical system

with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass

transfer to occur between one or more steams, components or phases. Modern industrial

processing almost always involves some form of mixing. Some classes of chemical reactors

are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas into

another solid, liquid or gas. .

Conveyer belt:

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt

conveyor). A belt conveyor system is one of many types of conveyor systems. A belt

conveyor system consists of two or more pulleys (sometimes referred to as drums), with an

endless loop of carrying medium the conveyor belt that rotates about them. One or both of the

pulleys are powered, moving the belt and the material on the belt forward. The powered

pulley is called the drive pulley while the unpowered pulley is called the idler pulley. Its Rpm

is 45 to 50 Rpm

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Induction Motor:

The most common electrical motor used in most applications which is known as induction

motor .This motor is also called as synchronous motor because it runs at a speed less than

synchronous speed. An induction motor always runs at a speed less than synchronous speed

because the rotating magnetic field which is produced in the stator will generate flux in the

rotor which will make the rotor to rotate, but due to the lagging of flux current in the rotor

with flux current in the stator, the rotor will never reach to its rotating magnetic field speed

i.e. the synchronous speed. It has different Rpms which includes 1400, 900, 2800 and 750

Rpm.stator will generate flux in the rotor which will make the rotor to rotate, but due to the

lagging of flux current in the rotor with flux current in the stator, the rotor will never reach to

its rotating magnetic field speed i.e. the synchronous speed. It has different Rpms which

includes 1400, 900, 2800 and 750 Rpm.

Rotary Dryer:

Rotary dryers are known as the workhorse of industrial dryers. They are able to process a

wide variety of materials, and can lend a hand in nearly any industry requiring industrial

drying solutions. Its Rpm is 6-8.

Rotary Seive Drum:

The Rotary sieve is ok with dry compost and handles typical loads/sizes. However it tends to

clog up when used with moist compost. Some large pieces can jam and you’ll need to stop

and clear them before carrying on. Its Rpm is 11-13.

Elevator:

An elevator is a type of vertical transport equipment that moves people or goods between

floors (levels, decks) of a building, vessel, or other structure. Elevators are generally powered

by electric motors that either drive traction cables or counter weight systems like a hoist, or

pump hydraulic fluid to raise a cylindrical piston like a jack. Its Rpm is 55-60.

Agitator:

An agitator is a device or mechanism to put something into motion by shaking or stirring.

There are three main types of agitation machine. The washing machine agitator, which rotates

back and forth; the magnetic agitator, which contains a magnetic bar which rotates about a

magnetic field; manual agitation, such as with a stirring rod.

Vibrator Seive Tray:

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This is used to separate the final product from big particles. So that there should b

no inconvenience in packing unit.

Granulator:

In Bop plant granulator is machinery in which granules formulation takes place. Granulator is

a open type because aerobic process is taking place, in which bacteria needs oxygen to live, If

it is close bacteria will die.

It is suitable for hot and cold granulation and high, medium and low concentrations of mass

production of compound fertilizer. It contains further properties like;

High balling strength.

Good appearance.

Corrosion resistance.

Wear resistance.

Low energy consumption.

Long service life.

Easy operation and maintenance.

List of Improvements:

Due to low voltage most of the equipments don’t work, if some work they don’t last

for a long period of time.

Motors should be operated at desired voltage otherwise due to uneven voltage they

are useless.

Washing of the equipment should be done prior to using any other material in the

mixers.

After everyone month’s maintenance factor should be kept in mind.

There should be sensor on every motor so that it trips if the voltage is low.

The equipments used in the Industry should not across 40 dba noise.

Agitator speed should be optimum for better mixing.

While taking work for pump, it is sure that it won’t cavitate.

Pump should be self priming.

Pump impeller width should be match with the desired fluid viscosity, to prevent

pump from choking.

There are no gauges on Pump; there should be pressure gauges and flow meter

devices on Pumps.

Pipes should be resistance flow.

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Filtration of juice cane suspension should be done properly to prevent from low

quality production.

There should be optimum load on elevators while feeding in hoppers.

Showering of juice cane should be done timely.

Care should be taken while removing moisture from the product.

Burner temperature should be optimum by preventing from damaging the product.

Paddle mixer should be washed timely for better mixing.

Wettable Powder

A wettable powder is an insecticide or other pesticide formulation consisting of the active

ingredient in a finely ground state combined with wetting agents and sometimes bulking

agents. Wettable powders are designed to be applied as a dilute suspension through liquid

spraying equipment. Wettable powders do not dissolve. When mixed with water a wettable

powder forms a suspension. That is, the particles that make up the material float throughout

the solution. The main advantages of wettable powder insecticides: initial knock-down of

targeted pests.

Advantages:

Easy to store, transport and handle.

Easily measured and mixed.

Disadvantages:

Inhalation hazard to applicator while measuring and mixing the concentrated powder.

Often clog nozzles and screens.

Constant agitation is required to prevent from settlement of powder.

Raw Material:

Buprofezin

Niten

Surf crop df-hcd

Df-S Alpha

SiO2

CacO3

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Buprofezin:

Buprofezin belongs to the group of so-called insect growth regulators, in particular the chitin

synthesis inhibitors. It inhibits the biosynthesis of chitin in the target insects, and thereby

interferes with the growth of immature insects (larvae), so that they die after a few days. The

operation is mainly carried out by contact, but also through ingestion in the stomach.

Buprofezin is especially effective against Hemiptera, including (larvae), whiteflies, and

against cap-, shield and , these are difficult to control pests. It is not harmful to bees and

beneficial insects, such as wasps, which are used for biological or integrated pest

management. One batch contains 450 kg of it.

Nitenpyram:

Nitenpyram is an insecticide used in agriculture and veterinary medicine to kill external

parasites of pets. It is aneonicotinoid, a neurotoxin that blocks neural messages and binds

particularly tightly in the central nervous system of insects, causing rapid death. One batch

contains 75 kg of it.

Silicon Dioxide:

Silicon dioxide, also known as silica (from the Latin silex), is a chemical compound that is

an oxide of silicon with the chemical SiO2. It has been known since ancient times. Silica is

most commonly found in nature as quartz, as well as in various living organisms. In many

parts of the world, silica is the major constituent of sand. Silica is one of the most complex

and most abundant families of materials, existing both as several minerals and being

produced synthetically. One batch contains 20 kg of it.

Calcium Carbonate:

Calcium carbonate is a chemical compound with the formula CaCO3. It is formed by three

main elements: carbon, oxygen and calcium. It is a common substance found in rocks in all

parts of the world, and is the main component of shells of marine organisms, snails, coal

balls, pearls, and eggshells. Calcium carbonate is the active ingredient in agricultural lime,

and is commonly used medicinally as a calcium supplement or as an antacid, but excessive

consumption can be hazardous. One batch contains 106 kg of it.

List of Machinery:

Cone Mixer:

Cone mixers are used to mix or blend a wide range of materials used in different industries

including food, chemical, pharmaceutical, plastic and mineral industries. They are mainly

used to mix different materials using different types of blades to make a good quality

homogeneous mixture. Included are dry blending devices, paste mixing designs for

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high viscosity products and high shear models for emulsification, particle size reduction

and homogenization. Industrial mixers range from laboratory to production line scale.

Storage Cone:

It is used for the storage of discharge product.

Jet Mill :

Jet mill is dry ultrafine grinding equipment, integrated fluidized-bed airflow grinding and

self-diffluent classifying technology. During grinding process no temperature rise, no

pollution and low wear, especially used in the heat sensitive, low melting point and high

purity material for superfine grinding. Flammable and explosive materials can be ground with

inert gases, which can be cycle used.

Working Principle:

The pressed air via dryer raps into the grinding chamber through Laval jet, the material at the

intersection of airflow is crashed, the powdered material enters into the classifying section

together with uprising airflow, under the action of centrifugal force from classifying wheel

and draft fan, the oversized powder is repulverized and the qualified powder is collected by

the cyclone and bag filter.

Motor:

An induction or asynchronous motor is an AC electric motor in which the electric current in

the rotor needed to produce torque is obtained by electromagnetic induction from

the magnetic field of the stator winding. An induction motor therefore does not

require mechanical commutation, separate-excitation or self-excitation for all or part of the

energy transferred from stator to rotor, as in universal, DC and large synchronous motors. An

induction motor's rotor can be either wound type or squirrel-cage type.

Air Compressor:

An air compressor is a device that converts power (using an electric motor, diesel or gasoline

engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of

several methods, an air compressor forces more and more air into a storage tank, increasing

the pressure. When tank pressure reaches its upper limit the air compressor shuts off. The

compressed air, then, is held in the tank until called into use. The energy contained in the

compressed air can be used for a variety of applications, utilizing the kinetic energy of the air

as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air

compressor turns on again and re-pressurizes the tank.

Blower:

A Blower is a mechanical device for moving air or other gases. The terms "blower" and

"squirrel cage fan” are frequently used as synonyms. These fans increase the speed of air

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stream with the rotating impellers. They use the kinetic energy of the impellers or the rotating

blade to increase the pressure of the air/gas stream which in turn moves them against the

resistance caused by ducts, dampers and other components. Centrifugal fans accelerate air

radially, changing the direction (typically by 90°) of the airflow. They are sturdy, quiet,

reliable, and capable of operating over a wide range of conditions.

Screw Agitators:

A screw agitator is a device to put something into motion by shaking or stirring. There are

three main types of agitation machines like the washing machine agitator, which rotates back

and forth; the magnetic agitator, which contains a magnetic bar which rotates about a

magnetic field; manual agitation, such as with a stirring rod.

Butterfly Valve:

A butterfly valve is a valve which can be used for isolating or regulating flow. The closing

mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows

for quick shut off. Butterfly valves are generally favored because they are lower in cost to

other valve designs as well as being lighter in weight, meaning less support is required. The

disc is positioned in the center of the pipe, passing through the disc is a rod connected to an

actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or

perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow

therefore pressure drop is always induced in the flow, regardless of valve position.

Actuator:

An actuator is a type of motor that is responsible for moving or controlling a mechanism.

It is operated by a source of energy, typically electric current, hydraulic fluid pressure or

pneumatic pressure, and converts that energy into motion.

Dust Collector:

A dust collector is a system used to enhance the quality of air released from industrial and

commercial processes by collecting dust and other impurities from air or gas. Designed to

handle high-volume dust loads, a dust collector system consists of a blower, dust filter, a

filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished

from air cleaners, which use disposable filters to remove dust.

Air Filters:

A particulate air filter is a device composed of fibrous materials which removes

solid particulates such as dust, pollen, mould, and bacteria from the air. A chemical air filter

consists of an absorbent or catalyst for the removal of airborne molecular contaminants such

as volatile organic compounds or ozone. Air filters are used in applications where air quality

is important, notably in building ventilation systems and in engines.

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PLC:

A programmable logic controller, PLC, or programmable controller is a digital computer used

for automation of typically industrial electrochemical processes, such as control of machinery

on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many

machines, in many industries.

Rotary Feeders:

Rotary feeders, also known as rotary airlocks or rotary valves, are commonly used in

industrial and agricultural applications as a component in a bulk or specialty material

handling system. Rotary feeders are primarily used for discharge of bulk solid material

from hoppers/bins, receivers, and cyclones into a pressure or vacuum-driven pneumatic

conveying system. Components of a rotary feeder include a rotor shaft, housing, head plates,

and packing seals and bearings. Rotors have large vanes cast or welded on and are typically

driven electric motors.

List of Improvements:

Due to low voltage most of the equipments don’t work, if some work they don’t last for

a long period of time.

Actuators and pneumatic valves should be operated and care taken well otherwise dust

collectors won’t work.

Motors should be operated at desired voltage otherwise due to uneven voltage they are

useless.

Dust filters should be covered by their bags otherwise they don’t work properly.

Washing of the equipment should be done prior to using any other material in the cone

blenders.

After every three months maintenance factor should be kept in mind.

Compressor filters should be washed at least once every 3 months.

There should be sensor on every motor so that it trips if the voltage is low.

Sticky material/powder should not b used because it jams the machine.

Desired material should be introduced into the screw agitator, to prevent from choking.

Plc should be work properly. It’s his duty to show all connections on the touch screen.

Compressors should not b operated at low voltage.

Desired material should be introduced into grinding section of jet mill, otherwise it will

choke.