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0 0 20 Apr 2015 1752199831PRE-FEASIBILITYREPORT PDF
0 0 20 Apr 2015 1752199831PRE-FEASIBILITYREPORT PDF
By
BEC Fertilizer
(Unit of Bhilai Engineering Corporation Ltd)
At
Plot No. 96
Sector – A, Sirgitti, CSIDC Industrial Estate
Bilaspur (Chhattisgarh)
1
INDEX
Sr. No. Description Page
no.
1.0 EXECUTIVE SUMMARY 3
2.0 INTRODUCTION OF THE PROPOSED PROJECT 4
2.1 Project Proponent 4
2.2 Need for Project 5
2.3 Employment Generation 5
3.0 Project description 6
3.1 Product and Raw Material 7
3.2 Manufacturing Process 8
3.2.1 Sulphufic Acid (SAP) 8
3.2.2 Single Super Phophate (SSP) 9
3.2.2(A) Boronated Single Super Phosphate (BSSP) 11
3.2.3 Triple Super Phosphate (TSP) 12
3.2.4 Granulated Single / Triple Super Phosphate 13
3.2.5 Sodium Silico Fluoride (By-product) 13
3.3 Resource – Utilize and Recycling 14
3.4 Waste Water Generation 15
3.5 Air Emission 16
3.6 Solid Waste Generation 16
3.7 Purpose of EIA study 17
4.0 Site Analysis 17
4.1 Connectivity 17
4.2 Land use / Topography 17
4.3 Infrastructure 18
5.0 Planning brief 18
6.0 Existing / Proposed infrastructure 18
7.0 Rehabilitation and Resettlement (R&R) Plan 19
8.0 Project Schedule and Cost estimates 19
9.0 Analysis of project 19
2
LIST OF FIGURES
Since 1985 BECF is in the field of Manufacturing fertilizers and other Agro-inputs.
We already have two units to manufacture Single Super Phosphate (SSP) at Bilaspur
(CG) and Pulgaon (Dist. – Wardha, Maharastra) of production capacity 140000 TPA
and 66000 TPA respectively.
The existing capacity of Bilaspur unit is to produce following:
01. Sulphuric Acid - 40,000 TPA
02. Single Super Phosphate - 1,40,000 TPA
03. Granulated NPK Fertilizer - 45,000 TPA
BECF proposes to expand the capacity of Bilaspur unit by installing new plants in
the existing premises. Proposed capacity shall be:
01. Sulphuric Acid - 1,40,000 TPA
02. Single/ Triple/ Boronated Super Phosphate - 4,40,000 TPA
03. Granulated Fertilizer - 4,40,000 TPA
(SSP/TSP / NPK /CustomizedFertilizer)
M/s. BEC Fertilizers (BECF) – a unit of Bhilai Engineering Corporation Ltd. BEC Ltd.
has five units located in Raipur and Bhilai cities of the Chhattisgarh State, India.
There are 5 Regional offices in New Delhi, Mumbai, Kolkata, Chennai and Bangalore
to facilitate and support various projects and develop corporate relations. BEC is the
most successful Engineering, Procurement and Construction (EPC) Company
including Heavy Equipment supplier in India. It undertakes complete project
implementation including Mechanical, Structural, Electrical and Civil jobs. BEC Ltd.
has group companies namely Vishva Vishal Engineering Limited, BEC Food and BEC
Fertilizers.
Fertilizers and Agro Chemicals Industry in India is keys to the Agriculture sector.
BEC Fertilizers include a modern technology Fertilizers manufacturing complex at
Bilaspur C.G., and the second fertilizer unit at Pulgaon, Maharashtra State to
manufacture "ANAND" Single Super Phosphate and NPK Fertilizers.
The proposed project will be started after receiving statutory clearances from
authority. Production Capacity, raw material and proposed product is discussed in
para 3.0 of the report.
5
1 Chhatisgarh 158850 MT
2 Maharashtra 587520 MT
3 Madhya Pradesh 513580 MT
Total 1259950 MT
Total plot area is 47.66 Acres. Existing plant is located in about 12 Acres area so
sufficient land is available for expansion of the unit. Environmental settings and
infrastructures available surrounding the proposed project is as under,
Manufacturing Process
Sulphur used as raw material is in solid form, which is first converted into
liquid form using steam. It is purified in the settling pit before sending to
furnace for combustion. In the Furnace,Sulphur burns with air to form
Sulphur Dioxide. As the process is Exothermic so temperature of the gases
in the furnace rises to above 1000ºC.
Hot gases from the furnace are cooled in the waste heat boiler (01) to
produce steam. Gases after cooling are filtered and sent to convertor. In the
convertor SO2 gets converted into SO3 in presence of catalyst (Vanadium
Pentoxide).SO3 gasesafter third pass, are further sent to intermediate
absorption tower where SO3 gases are absorbed in directly with water to
form Sulphuric Acid. Unconverted gases are again sent to fourth pass of
the convertor to convert remaining gases to SO3. SO3 is again absorption
in the final absorption tower to form Sulphuric Acid. Finally gases from
absorption tower are let-out to atmosphere through stack.
Sulphuric acid produced is further cooled in the cooler before being sent to
Acid storage tanks.
9
Alkali Scrubber
SO2 in the stack gases are maintained as per the norms prescribed.
During plant start-up SO2 in the exit gases may rise above norms, so it is
treated in the Alkali scrubber with caustic solution to form Sodium
Sulphide. And clean gases are let-out to atmosphere through Chimney.
Reaction
2NaOH + SO2 = Na2SO3 + H2O
Process flow diagram for manufacturing of Sulphuric Acid is attached as
Fig.3
All the power requirement of the Acid Plant shall be fully met through captive power
generation. Surplus power available shall be utilized to meet the part requirement of
Fertilizer Plant.
Manufacturing process
Rock Phosphate is ground to fine powder (90% of 100mesh) in a Milling section and it
is conveyed through Screw Conveyor and Bucket Elevator to the Mixer where
reactions take place. ParallelySulphuric. Acid, water and recycledFlouro Silicic Acid
liquer are also added in the mixer in a pre-determined ratio. The Rock Phosphate,
Acid and dilution liquor react together in the Mixer (Reactor) to produce single Super
Phosphate.
Reaction - II
4HF + 3SiO2 + H2O SiO2.H2O + 2H2SiF6
Silica Sod.Silico-fluoride
Boron is a micronutrient, which is also necessary for the growth of plants to increase
the yield. As per FCO (Fertilizer Control Order), the Boron contained in the BSSP
should be 0.15% to 0.20%. Above 10 Kg/MT of Sodium Borate is added to get desired
Boron in the product. BECF shall manufacture Boronated SSP also in the existing
SSP plant.
Reaction - I
CaF2.3[Ca3{Po4}3] + 14H3PO4 + 3H2O
Rock Phosphate Phosphoric Acid Acid
10CaH4(PO4)2 + 2HF
Triple Supher Phosphate
Reaction - II
4HF + 3SiO2 + H2O SiO2.H2O + 2H2SiF6
Silica Sod.Silico-fluoride
Air emission
Rock Phosphate contains Silica and Fluorine as impurities, which contributes to the
gas emission in the process. Rock Phosphate consumption for manufacturing TSP is
only 460 Kgs PMT compared to 560 Kgs PMT for SSP, which is lower by 18%.
Consequently gas emission in this TSP manufacturing will get reduced by 18%
compared to SSP production. The flow diagram of scrubbing system is as per Fig. 7.
The granulation plant is a multi product unit where one or many of the individual
fertilizers viz, Urea, TSP DAP, SSP, MOP, Boron, Zinc, Copper, Molibadenum,
Sulphur, Iron, etc are mixed together in a predetermined ratio and they are broken
down and blended to make homogeneous mass. This mass is fed into granulator
where required quantity of water is added to moist the mass and rotated in a drum
called „Granulator‟. As a result of this the powdered mass is converted into granules
of various sizes. The wet granules are passed through a rotating dryer drum where
hot air generated from a furnace is passed through the mass. At the end of the dryer
drum dried granules are received and it is fed into a cooler drum where atmospheric
air is passed from the opposite direction to cool the material. The cooled granules are
screened in vibrating screens to segregate product size, oversize & undersize
particles. The oversize granules are crushed and along with undersize material it is
fed back to granulator for onward granulation. In the whole process no chemical
reaction takes place as it is a simple physical crushing and mixing and granulating
process using suitable machineries.
13
To produce granulated SSP, only SSP Powder will be the raw material. For NPK
Mixture manufacture Urea, DAP, SSP, MOP, etc are the raw materials. For
Customized Fertilizers, in addition to the above, micro nutrients viz, Boron, Zinc &
the other cation minerals in very small quantities will be added in the granulation
process.
Process flow diagram of SSP/TSP/NPK/Customized Fert.is attached as Figure– 5.
Specification of GSSP:
FluoroSilicio Acid is received in a rubber lined Mild Steel reactor. This reactor is
calibrated one and fitted with an agitator. In a row two such reactors are installed.
While one is under reaction process the other is made ready for next batch.
Separately in a Soda Ash solution preparation tank Soda Ash is dissolved in fresh
water and the concentration is analyzed. Metered quantity of soda ash solution is
slowly added into the reactor while the liquor is under agitation. The acid is
neutralized by the alkaline soda solution and sodium silico fluoride crystals separate
from the solution. The pH of the reaction mass is checked and when pH reach 7 soda
addition is stopped. After thorough agitation the solution is allowed to settle. The
14
clear top solution (water) is decanted and the settled mass is taken to a centrifuge to
separate water from the SSF crystal.
The wet mass is dried in a tray dryer and finally packed in 50 kg bag after quality
analysis and approval. The collected water from centrifuge and reactors is stored and
used in SSP plant for dilution of H2SO4.
Process flow diagram of Sodium Silico Fluoride is attached as Figure– 6.
Power / Energy `
Power requirement of proposed project will be made available through Chhattisgarh
State Electricity Board (CSEB). Total power requirement of proposed plant shall be
3200 KWH.
2 nos. of D. G. sets of capacity 1070 KVA are available to meet emergency power
requirement of the plant.
01 No. TG Set (Condensing Type) of 2500 KVA shall be installed to generate power
with available Surplus team from Sulphuric Acid plant.
01 No. 33KV Electrical Sub Station of capacity ( 4000 KVA) shall be installed.
15
Fuel
Coal – Existing 5.0MT/Day Proposed 30 MT/Day for Granulation plant.
To treat the sewage generated due to domestic activities will be disposed through
septic tank following by soak pit.
Floor washing, spillages and oil & grease etc from plants need to be treated. These
floor washing and spillages are collected and taken through an exclusive pipe line to
the final effluent treatment section for treatment. Similarly floor washing liquid
effluent from SSF plant is diverted to final effluent treatment plant for neutralization,
etc. Total effluent generated in the project is 120 M3/D. It shall be utilized for
irrigation purpose inside the factory premises.
All the effluent water from cooling towers bleed, boiler blowdown and RO plant of
Sulphuric Acid plant shall be recycled and utilized fully in the SSP / TSP Plants for
processing.
The granulation plant does not generate any effluent as it is a dry mixing process.
No water from factory premises shall be discharged outside factory premises hence it
will be a ZERO effluent discharge unit.
Schematic flow diagram of ETP is attached as Figure – 8.
3.5 Air Emission
Sr. Stack Attached Height from Diameter Air Pollution Expected
to ground (m) Control system pollutants
No. (m)
1 Flue Gas Stack
Granulation Plant 15 meter 600 mm Twin Cyclone SPM, SO2, NOx
2 Process Stack
(A) SSP Plant at Den 30 meter 1000 mm Cyclone separator SPM, Fluorine
Outlet Multi stage scrubber
system with venturi
and spraying towers
(B) Acid Plant at final 30 meter 1000 mm Alkali scrubber, SO2, Acid mist
absorption tower demister and mis-
eliminators
16
1 E.T.P. Sludge 1 MT/PM 34.3 Stored in haz. Waste storage area and shall
be utilized in SSP plant.
2 Used oil 3000 Liters 5.1 Sold to MoEF approved recyclers.
/PA
3 Empty 50Nos/PA 33.3 Sold to MoEF/CECB approved scrap dealer.
Containers
4 Sulphur sludge 40 MT/PM - Stored in hazardous waste area. It shall be
used in the SSP product, as modifier.
5 Catalyst (V2O5) 3000 Ltrs/PA - Packed in 200 Ltrs drums and stored in
specified area.Sold to MoEF/CECB approved
agency
1 Marine Sanctuary No
2 Stream / Rivers Yes (Arpa River)
3 Airports Yes (Raipur – 130 Km)
4 Railway station Yes (Bilaspur – 5 Km)
5 Bus Station Yes
6 National Highways Yes (NH – 200)
7 Bank Yes
9 Social Infrastructure
Primary / High School Yes
Religious Place Yes
Existing infrastructure
BEC Fertilizer, Bilaspur is a running unit since 1985. It has created all necessary
infrastructures for the operation of the unit. It is planning to carry out expansion of
the unit by installation of new plants in the existing premises.
The total plot area is 47.66 acres. Existing plant is installed in the area of about
12Acres. Additional area required for expansion is about 12 Acres. Remaining area
available shall be utilized for future expansion. Presently surplus land is being
utilized by plantation of various types of trees. Treated effluent of plant is being used
for irrigation.
All the existing facilities e.g. administrative building, raw material / finished goods
storage, raw water storage, roads / drains, weighbridge. Canteen, workshop, DG sets,
Laboratories etc. shall be utilized during installation and operation of the new plant.
During construction of plant, essential requirements of power, water, skilled &
unskilled manpower and other services will also be available. Apart from that,
communication and transportation will also be made available.
It will help in smooth and timely execution of the project.