NPK FERTILIZER IN GRANULE FORM

[EIRI/EDPR/3911] J.C.: 2030INR, 2031US$

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%.

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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.

The most widespread NPK fertilizers in Europe contain nitrate and/or ammonium
salts.

NPK fertilizers can be produced in four, basically different, ways:-

 Ammonium phosphate/ammonium nitrate-based NPK fertilizers

 Nitrophosphate-based NPK fertilizers (mixed acid route)
 Nitrophosphate-based NPK fertilizers (ODDA-route)
 Mechanical blending of single or multi-nutrient components

These Technologies for NPK Fertilizer

1. Processing of raw materials

– Mixed acid slurry processes with digestion of rock phosphate

– Phosphoric acid slurry processes
– Mixing of solid raw materials

2. Granulation techniques

– Drum granulation
– Blunger/pugmill granulation
– Spherodiser granulation
– Prilling
– Low costs of labour and maintenance
– Low cost of investment

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3. Drum granulation with ammoniation

– Broad range of formulations

– Neutralisation of phosphoric and sulphuric acids in the granulation drum
– No phosphate rock digestion
– High costs of raw materials (P2O5)
– Simple gas scrubbing
– Low costs of labour and maintenance
– Low cost of investment

4. Mixed acid process with phosphate rock digestion

– Broad range of formulations

– Phosphate rock digestion enabling a considerable part of the phosphorus to
be supplied from the low cost raw material, phosphate rock
– Flexible control of the reactions of raw materials in the liquid phase
– High product quality
– Complex gas scrubbing
– Medium costs of labour and maintenance
– Medium cost of investment

DESCRIPTION OF PRODUCTION PROCESSES

Three different processes are described:-

– Granulation with a pipe reactor system
– Drum granulation with ammoniation
– Mixed acid process with phosphate rock digestion

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 CONTENTS

INTRODUCTION
THESE TECHNOLOGIES FOR NPK FERTILIZER
1. PROCESSING OF RAW MATERIALS
2. GRANULATION TECHNIQUES
3. DRUM GRANULATION WITH AMMONIATION
4. MIXED ACID PROCESS WITH PHOSPHATE ROCK DIGESTION
DESCRIPTION OF PRODUCTION PROCESSES
REQUIREMENTS OF DIFFERENT FERTILISERS FOR DIFFERENT CROPS
HOW MUCH FERTILIZER TO APPLY:
CONVERSION FACTORS DETERMINING QUANTITIES OF FERTILIZERS
NPK MIXED FERTILIZER AND THEIR GRADE
B.I.S. SPECIFICATION
PROPERTIES AND STORAGE OF NPK FERTILIZER
HANDLING, STORAGE AND PACKING:
PARTICLE SIZE:
RAW MATERIALS AND THEIR SOURCES
MARKET OVERVIEW OF NPK FERTILIZER
ASIA PACIFIC IS EXPECTED TO ACCOUNT FOR THE LARGEST MARKET
SIZE DURING THE FORECAST PERIOD
METHOD OF NPK AND PK PRODUCTION
EXAMPLE I:
EXAMPLE II:
EXAMPLE III.
MANUFACTURING PROCESS OF NPK MIXED FERTILIZER (GRANULATED
MIXED FERTILIZER)
SLURRY GRANULATION PROCESS
MANUFACTURING PROCESS
GRANULATION
DRYING
SIEVING
PRODUCT COOLING
CYCLONES AND SCRUBBING
FUMES SCRUBBING SYSTEM
DRYER SCRUBBING SYSTEM
DEDUSTING SCRUBBER SYSTEM
ADVANTAGE TO USE BULK BLENDING ARE AS FOLLOWS:-
PROCESS FLOW DIAGRAM
BLOCK DIAGRAM OF NPK MIXED GRANULATED FERTILIZER
PRODUCTION OF NPK FERTILIZER

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NPK FERTILIZER GRANULATING PROCESS
PROCESS FLOW DIAGRAM
RAW MATERIALS
EMISSION AND POLLUTION CONTROL IN NPK FERTILIZER PLANT
THERE ARE TWO PROCESSES WHICH MAY CREATE POLLUTION:
PROCESS/TECHNOLOGY OF NPKS FERTILIZER
HANDLING, STORAGE AND PACKING
ENVIRONMENTAL ASPECT IN NPKS FERTILIZER PLANT
POLLUTION CONTROL
GUIDE FOR MIXING
RAW MATERIAL REQUIREMENTS
NPKS GRADE: 12 : 15 : 20 : 6
NPKS GRADE: 10 : 24 : 17 : 6
NPKS GRADE: 12 : 16 : 22 : 6 : 5
RAW MATERIAL PROJECTION
UREA
PRICE TRENDS
AMMONIUM SULFATE
SINGLE SUPER PHOSPHATE
MURIATE OF POTASH
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
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:

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5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF DI-AMMONIUM PHOSPHATE
SUPPLIERS OF MONOPOTASSIUM PHOSPHATE
SUPPLIERS OF HDPE WOVEN BAGS
COMPLETE PLANT AND MACHINERY SUPPLIERS ON TURNKEY BASIS
SUPPLIERS OF PLANT AND 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 EQUIPMENT
SUPPLIERS OF D.G. SETS
SUPPLIERS OF BOILER

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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)

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 COST ESTIMATION

Plant Capacity 100 MT/Day

Land & Building (3 Acres) Rs. 6.85 Cr
Plant & Machinery Rs. 2.47 Cr
Working Capital for 2 Months Rs. 19.46 Cr
Total Capital Investment Rs. 29.59 Cr
Rate of Return 16%
Break Even Point 57%

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