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FCI ARAVALI GYPSUM &MINERALS INDIA LTD.PRE-FEASIBILITY REPORT

Page 7

Prepared by : Mantec consultants Pvt. Ltd.

1. Executive Summary

1.1 Introduction

1.1.1 Project & Project Proponent

FCI Aravali Gypsum and Minerals India Limited (FAGMIL), is a public sector

undertaking under the Ministry of Fertilizers. It was previously known as Jodhpur

Mining Organization, and was a segment of the public sector undertaking, Fertilizer

Corporation of India Ltd. The main activity of FAGMIL was to supply mineral gypsum

to Sindri Fertilizer Plant. The gypsum produced was the basic raw material required

for Ammonium sulphate production.In 2003, the Jodhpur Mining Organization was

demerged from FCIL and formed into a new Company known as FCI Aravali Gypsum

and Minerals India Limited (FAGMIL).

There are nine mines under the Jodhpur Mining Organization producing gypsum.The

gypsum powder produced in the FAGMIL is used in reclamation of sodic lands as a

source of Sulphur, and as raw material in Cement Industries, in Plaster of Paris and

Gypsum Fibre Board industries.The company has been paying dividend to GOI

continually, and has reserves of more than Rs.100 crores. The company has plans to

expand the business by spending the available reserves to increase the company

turnover. Accordingly, the company has plan for setting up a Single Super

Phosphate (SSP) production facilities in Chittorgarh District of Rajasthan, based on

indigenous / imported Rock Phosphate.

1.1.2 Nature of the Project

The project will be located at Villages Pandoli in Chittorgarh district of Rajasthan,

adjacent to State Highway, SH-9, at a distance of 6 kms from Chittorgarh City. A plot

of Govt. land (reserved for industrial purpose) measuring 11.01hectares has been

allotted to the Company for establishment of SSP manufacturing facilities. The

project pertains to establishment of facilities for manufacturing of 800 TPD or

240,000 TPA of granulated single super phosphate. This is a grass root project and

will consist of the following main plants:

a) Single superphosphate plant : 800 TPD or 240,000 TPA capacity

b) SSP granulation plant : 800 TPD or 240,000 TPA capacity

Other facilities required for operation of the project, viz., boundary walls, internal

roads, truck parking, weigh bridge, storage facilities, work shop, administrative

building, canteen, community centre, first-aid post, green belt, electric sub-station,

DG Set, etc. are also included in the project proposal.

The main raw materials for manufacture of SSP are Sulphuric acid and rock

phosphate. The project will utilize imported rock phosphate and by-product

Sulphuric acid from Hindustan Zinc Limited, Chanderia. As Chittorgarh Block has

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been declared as dark zone, make-up water requirements of the project and facilities

will be met from surface/ground water from neighbouring areas brought to the site

in tankers.

1.1.3

Need of the project

Due to increasing population pressure, the demand for food, feed, fodder, fibre, fuel,

pulses, and oilseed products is rapidly increasing. The challenge of the coming

decades is to feed our burgeoning population. It is antipicated that in India in the

year 2025, total food grains demand will reach 291 million tonnes. The main course

open for achieving the goal of increased food grain production is by increasing

productivity per unit area.Higher crop yields mean greater removal of nutrients

from the soil. The soil is not an inexhaustible store of plant nutrients and we cannot

over-mine it. Thus fertilizer is the key to success in meeting the challenge of food

security in the future.Single super phosphate, due to its low price, is a poor farmersfertilizer. It also helps to improve the sulphur deficiency in soil and thus helps the

farmers in enhancing the yield at least cost for the crops especially for vegetables, oil

seed, sugar cane, tea etc.The role of fertilizer phosphorus in increasing crop

production in India is now increasingly being appreciated in the view of the low soil

phosphorus status and continued erosion in soil phosphorus during the past

hundreds of years. With the introduction of high yielding varieties and increase

cropping intensity the extent of phosphorus removal by crop has significantly

increased. Therefore, adequate fertilizer phosphorus is to be added to soils to

sustain high crop yields for years to come.

1.1.4

Demand Supply Gap

Analysis of demand and supply scenario of SSP in India demonstrates that though

the indigenous production of SSP has increased significantly, its demand has also

increased proportionately. As a result, the demand supply gap remains, thereby

encouraging setting up of additional manufacturing units in the country.

1.1.5 Employment Generation

The project will generate direct employment opportunities to approximately 76

persons, comprising 36 persons on company roll and 40 semi-skilled and unskilledwork force on contract basis. The project will also provide indirect employment

opportunities to approx. 100 persons in service sectors.

1.2

Project Description

1.2.1 Location

The proposed project site, comprising 11.01 hectares land (Plot No. 2615), is located

in Village Pandoli, Tehsil & District Chittorgarh, Rajasthan. It is Government land,

reserved for industrial purpose, and was allotted to FAGMIL for establishing the SSP

project. The plot is located adjacent to State Highway No. 9, approximately 6 kmsaway from Chittorgarh City.

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1.2.2 Project description

SINGLE SUPER PHOSPHATE PLANT:

The process of manufacturing of SSP consists of reaction of Ground Rock Phosphateof required fineness and P2O5content with Sulphuric Acid in specified proportion.

The product of acidulation of Rock Phosphate is called Green Super Phosphate which

is allowed to cure for 2 to 3 weeks before the same is ready for packing or further

processing.

The main chemical reactions involved in the manufacturing of SSP from rock

phosphate, Sulphuric acid and recycled flouosilisic acid are as follows:

3Ca3(PO4)2+ 6H2SO4+ 3H2O 3Ca(H2PO4)2.H2O + 6CaSO4

CaF2+ H2SO4 CaSO4+ 2HF

4HF + SiO2 SiF4+ 2H2O

3SiF4+ 3H2O 2H2SiF6+ SiO2.H2O

Ca3(PO4)2+ 2H2SiF6+ 4H2O Ca(H2PO4)2+ CaSiF6.2H2O

GRANULATED SSPPLANT:

Cured Single super phosphate is fed to the granulation plant through a Cutter/ Lump

Breaker and fed to Granulator through Feed Belt Conveyor. In granulator Drum

Water is Sprinkled and granules are formed which are fed to the Dryer Drum where

the Granulated SSP is heated through hot air generated through a HSD fired Furnace.

Hot Granulated SSP is Fed to Cooler drum through Belt Conveyor and the Product is

cooled. The product Granulated SSP is passed through Vibrating Screens where

under size and oversize materials are separated, and the desired product is sent for

automatic packing and bagging. The under size material is recycled to the Granulator

and the oversize material is crushed through Twin Roller Hammer Mill and is

recycled to the Granulator.

RAW MATERIALS AND INPUTS:

Estimated requirements of the raw materials and inputs are as follows:

Table 1-1 : Annual Raw Material & Utility Requirement

Sl. No. Raw Material/Utilities Unit Annual Requirement

1.0 Rock Phosphate MT 139200

2.0 Sulphuric Acid MT 86400

3.0 Power MWh 6000

4.0 Fuel Oil MT 2640

5.0 Water 100 m3 696

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1.2.3 Resources optimization, recycle & reuse

The following schemes have been incorporated for optimization, recycle & reuse ofresources:

a) Recycle of blow down (waste water containing approx. 12% H 2SiF6) from the

scrubbing system in the SSP plant to the mixer in SSP plant, which would also

reduce consumption of Sulphuric acid in the acidulation process.

b) Precipitated silica from the scrubbing system will be used as filler to the product.

1.2.4 Generation and management of wastes

1.2.4.1Solid wastes:

The silica precipitated in the scrubber unit of SSP plant will be separated from

the dilute fluosilicic acid, and added to the granulation drum as filler in the

product.

Used oil, decanted from pumps, compressors and other equipment, will be

stored in metallic containers and disposed through CPCB/RSPCB authorized

recyclers.

Used containers will be stored and disposed through CPCB/RSPCB authorized

recyclers

1.2.4.2Liquid wastes:

The plants will be operated on zero effluent basis. The only process waste water, i.e.,

blow-down from the scrubber unit in SSP plant (approx. 30 KLD, containing approx.

15% H2SiF6) will be recycled to the Mixer in SSP plant, where it will reduce

consumption of fresh water and Sulphuric acid.

Wastewater from toilets and washrooms, approx. 8 KLD, will be treated in septic

tanks, and disposed in soak pits.

1.2.4.3Gaseous emission:

In the rock grinding unit, air containing residual rock phosphate dust will be

passed through pulse jet bag filters, and the effluent air containing less than 125

mg/Nm3 particulate matter will be discharged through a stack of 30 m height.

Fluorine laden gases from the mixer and den (products of acidulation) will be

passed through the scrubbing system comprising a venture scrubber followed

by a 3-stage cross-flow scrubber. The effluent air stream, containing less than 25

mg/Nm3 fluoride and less than 50 mg/Nm3 particulate, will be discharged into

atmosphere through a stack of 40 m height.

Heating air from Dryer and cooling air from cooler in granulation plant will be

passed through cyclones to bring down particulate matter concentration below

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125 mg/Nm3. Air exiting the cycloneswill be discharged through a stack of 30 m

height.

Flue gases from the DG set will be discharged through a stack of 11 m height,

1.3

Site analysis

1.3.1 Connectivity

The site is adjacent to State Highway (SH-9) from Chittorgarh to Kapasn, at a

distance of 3 kms from its junction with NH-79. Chittorgarh and Chanderia Railway

Stations, both with loading and unloading facilities, are located within 9 km distance

from the project site. The project site is at a distance of 560Kms from Dahej Port,

which is the port proposed for import of rock phosphate.

1.3.2 Land form, Land use and Land ownership

The plot of land identified for locating the project lies in Pandoli Village of

Chittorgarh District of Rajasthan. The land is waste and barren, is rocky, uneven and

sloping from central ridge on the two sides.The plot of land was under Government

ownership, reserved for industrial purpose. It has been allotted to the project

proponent for establishment of SSP plant.

1.3.3 Topography & Soil

The topography of the plot is extremely rugged. Elevation of the plot varies from

approx. 423 m to 427 m above MSL. The maximum height is observed along thecentral ridge, sloping all along towards the two sides. There is, practically, no soil

cover over the rocky face of the plot.

1.3.4 Climate of the area

The climate of area is quite dry and parched. The summer season extends from April

to June and is quite hot. The average temperature in summers falls between 43.8 C

to 23.8 C. The winter season lasts from October to February. Chittorgarh weather in

the winters is pretty cool. The temperature averages around 28.4 C to 11.6 C. The

monsoon season falls during the months of June to August. As far as climatic

conditions of Chittorgarh, Rajasthan in monsoon are concerned, there is only slightrainfall that averages around 800mm.

1.3.5 Social infrastructure

Ground water is the main source of water for domestic and irrigational

requirements, supported by a number of ponds. All the villages are well connected

to NH 60 by roads. Chittorgarh, which is an old city, is the major market place in the

area, and is easily accessible from the site.

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1.5.2 Residential area

Development of residential area is not proposed, as most of the work force will be

drawn from neighboring villages.

1.5.3 Green belt

Approximately one third of the available project area has been identified for

development of green belt, where species prospering in the area will be planted and

developed. Additional areas have been identified for development of lawns and

gardens.

1.5.4 Social infrastructure

The project proponents propose to invest approximately 5% of the total project cost

under corporate social responsibility scheme.

1.5.5 Drinking water and sewerage system

As ground water extraction in the area is prohibited, drinking water will be brought

to the site in Tankers. Wastewater from toilets and wash rooms shall be treated in

septic tanks and disposed in soak pits.

1.5.6 Industrial waste management

The plants will be operated with zero liquid effluent discharge. Blow down from SSP

plant scrubber unit (dilute fluosilicic acid) will be recycled to the mixer. This willresult in saving of make-up water and Sulphuric acid.

Silica precipitated in the scrubbing unit will be separated and added to the

granulation drum as filler to the product. Spent oil and used containers will be

disposed through CPCB/RSPCB registered recyclers/ agencies.

Pulse jet bag filters will be provided in the rock grinding section for control of dust

emission. Fluorine bearing gases from Mixer and Den in SSP plant will be passed

through ventury scrubber, followed by 3-stage scrubbing system. In granulation

plant, control of dust will be achieved through cyclones for dryer and coolerexhausts.

1.5.7 Power requirement and source

Total power requirement of the plants and associated facilities has been estimated

as approx. 900 KW. To meet power requirement of the plants and facilities,

connection from State electric grid AVVNL) will be taken. To meet emergency

requirement (for lighting and scrubber operation), a DG Set of 125 KVA capacity is

also proposed.

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1.6

Rehabilitation and resettlement

No dwelling unit exists on the proposed project area, and displacement of

population is not involved. Prior to its acquisition, the plot was government land,

reserved for industrial use. Therefore, rehabilitation or resettlement ofland oustees

or land losers is not required.

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1.7

Project schedule & cost estimates

Construction activities will start after all statutory clearances, including

environmental clearance to the project. These clearances should be completed

before the zero date of the project i.e. before the commencement of the active phase

of the project.The physical activities will start with provision of boundary wall to the

plot.

All the project execution related activities, as mentioned earlier, are interlinked and

have impact on the final outcome. The execution of the relevant project activities has

to be planned and controlled in such a way that the goals of the project are achieved

in the set time frame. The basic design and detailed engineering shall be completed

by 3 to 4 months from zero date. Mostly all the fabricated items and vendor items

shall be procured locally within 10-12 months. The critical items shall be procured

from the reputed vendors. The plant can be erected and commissioned within 18months from zero date. It is assumed that before commissioning, FAGMIL shall

ensure the availability of required utilities at the battery limit of proposed plant.

The Project Capital Cost of proposed Granulated SSP project at Chittorgarh

(Rajasthan) has been estimated at about Rs. 70.95 Crores.The project capita cost

includes cost of:

Land & Land Development

Civil Works

Plant and Machinery incl. Spares Incidental Expenses

Engineering Fees & Services

Project Management Charges

Erection Charges

Margin on Working Capital

Financing Charges

Startup Expenses

Contingency

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2.

Introduction

2.1

Identification of project and project proponent2.1.1 Project and project proponent

FCI Aravali Gypsum and Minerals India Limited (FAGMIL), previously known as

Jodhpur Mining Organization, was a segment of the public sector undertaking,

Fertilizer Corporation of India Ltd.

The main activity of FAGMIL was to supply mineral gypsum to Sindri Fertilizer Plant.

The gypsum produced was the basic raw material required for Ammonium sulphate

production. In 2003, the Jodhpur Mining Organization was demerged from FCIL and

formed into a new Company known as FCI Aravali Gypsum and Minerals IndiaLimited (FAGMIL).

There are nine mines under the Jodhpur Mining Organization producing gypsum. It

has credit for the exploration of 265 gypsum deposits with a reserve of more than

100 million tonnes all across the state of Rajasthan. The gypsum mines are situated

in different parts of Rajasthan like at Mohangarh, Kavas, Bikaner, Suratgarh, and

Ramsinghpur. In Asia the best quality gypsum is supplied by the Mohangarh mines,

situated in the district of Jaisalmer, Rajasthan. Apart from these mines, few new

mines also are acquired by FAGMIL like Thethar, Padampura, Khal, Randhisar, and

Mohangarh.

The gypsum powder produced in the FAGMIL is used in reclamation of sodic lands

as a source of Sulphur, and as raw material in Cement Industries, in Plaster of Paris

and Gypsum Fibre Board industries.

Till date, FAGMIL has the only activity as mentioned above and earning profit. It is

also paying dividend to GOI continually. The company has reserves of more than

Rs.100 crores. The company has plans to expand the business by spending the

available reserves to increase the company turnover. Accordingly, the company has

plan for setting up a Single Super Phosphate (SSP) production facilities in

Chittorgarh District of Rajasthan, based on indigenous / imported Rock Phosphate.

2.1.2 Pre-Feasibility Report (PFR)

FAGMIL entrusted Projects & Development India Limited (PDIL), an Engineering &

Consultancy Organization, to prepare a Feasibility Report (PFR) for the project

considering SSP manufacturing of viable capacity at suitable location.Projects &

Development India Ltd. (PDIL), a Government of India Undertaking, having

extensive experience in the field of preparation of a number of PFRs, DFRs and

TEFRs for various projects, has prepared this report.The details of raw material and

utility requirement, man-power, project capital cost, cost of production and financial

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analysis wereworked out and included in the report for project appraisal and

investment decision.

This Pre-feasibility report has been prepared to comply with the requirements of

Guidelines for Preparation of pre-feasibility report for obtaining priorenvironmental clearance in terms of the provisions of EIA notification, 2006, issued

by the Ministry of Environment and Forests (J-11013/41/2006-1A.II(I) dated 30-12-

2010. It has been prepared on the basis of, and utilizes the data presented in the

Feasibility Report prepared by PDIL.

2.2

Brief description of nature of project

2.2.1 Nature of the project

The project will be located in a plot of land measuring 11.01hectares,at Village

Pandoli in Chittorgarh District of RajasthannearSH-9. The plot is Government land

reserved for industrial purpose, andhas been allotted by the State Government for

the proposed SSP project. The project pertains to establishment of facilities for

manufacturing of 800 TPD or 240,000 TPA of granulated single super phosphate.

This is a grass root project and will consist of the following main plants:

a) Single superphosphate plant : 800 TPD or 240,000 TPA capacity

b) SSP granulation plant : 800 TPD or 240,000 TPA capacity

Other facilities required for operation of the project, viz., boundary walls, internalroads, truck parking, weigh bridge, storage facilities, work shop, administrative

building, canteen, community centre, first-aid post, green belt, electric sub-station,

DG Set, etc. are also included in the project proposal.

The main raw materials for manufacture of SSP are Sulphuric acid and rock

phosphate. The project will utilize imported rock phosphate, which will be brought

up to Dahej Port by sea route, and from there by rail route up to Chittorgarh or

Chanderia. By-product Sulphuric acid will be brought from Hindustan Zinc Limited,

Chanderia. As Chittorgarh Block has been declared as dark zone, make-up water

requirements of the project and facilities will be met from surface/ground waterfrom neighbouringareas, brought to the site in tankers.

The plants have in-built facilities for pollution control. Waste water from the plants

shall be recycled quantitatively as dilution water for acidulation of rock phosphate.

Air pollution control measures are in-built in the plants, and effluent gases will be

discharged through stacks of adequate heights.

2.2.2 Single Super phosphate plant

The SSP plant will have the rated capacity to produce 800 TPD powder SSP (running

for 300 days per year). Thus, the plant will produce 240,000 TPA powder SSP. Theproduct specification, meeting the FCO requirements, are as follows:

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a) Water soluble P2O5(min) : 14.5%

b) Citrate soluble P2O5(min) : 16%

c) Free phosphoric acid as P2O5(max) : 4 %

d) Moisture content (max) : 5 %

2.2.3 Granulation plant

The granulation plant will have the rated capacity to produce 800 TPD granulated

SSP (running for 300 days per year). Thus, the plant will produce 240,000 TPA

granulated SSP. The product specification, meeting the FCO requirements, are as

follows:

a) Water soluble P2O5(min) : 14.5%

b) Citrate soluble P2O5(min) : 16%

c) Free phosphoric acid as P2O5(max) : 4 %

d) Moisture content (max) : 5 %

e) Particle size (1 to 4 mm IS sieve) : 90%

f) Particle size below 1 mm : less than 5%

2.3

Need of the project and its importance to the country

2.3.1 Food Security

Due to increasing population pressure, the demand for food, feed, fodder, fibre, fuel,

pulses, and oilseed products is rapidly increasing. The challenge of the coming

decades is to feed our burgeoning population. It is anticipated that in India in the

year 2025, total food grains demand will reach 291 million tones comprising 109

million tonnes of rice, 91 million tonnes of wheat, 73 million tonnes of course grains

and 18 million tonnes of pulses. Some years ago, eminent scientist Dr. M. S.

Swaminathan had estimated the theoretical production potential of the country to

be 475 million tonnes grain equivalent. Even based on yield levels achieved in

national demonstrations, the production potential is 560 million tonnes of food

grains. Thus, though the task is formidable, the potential does exist.

2.3.2 Available options

For achieving the goal of increased food grain production, there are two courses

open. One is to increase the area under the plough and the other is to increase

productivity from the available land; or even better would be a combination of both.

So far as expansion in the horizontal direction of increasing land area under

cultivation is concerned, there is very little scope. Thus the main course open is

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through vertical expansion i.e. by increasing productivity per unit area. The strategy,

therefore, should be to produce more food from less land with less water and less

pesticides and with minimum detriment to the environment. Whether the option is

through extensification or intensification of agriculture, the key factor in both cases

is soil fertility and its management. Higher crop yields mean greater removal of

nutrients from the soil. The soil is not an inexhaustible store of plant nutrients and

we cannot over-mine it. Thus fertilizer is the key to success in meeting the challenge

of food security in the next century.

2.3.3 Present level of Fertilizer Consumption

Growth in fertilizer consumption, which was rapid in the 80's has slackened in the

90's. In the second half of 1992-2002, after the enhancement of adhoc concession for

P & K, the total fertilizer consumption increased to 17.36 million tonnes in 2001-02

as against 14.31 million tonnes in 1996-97. All India consumption of total nutrients

reached an all time high of 28.28 million tonnes in 2010-11 (Table 2.1). The

consumption of N at 16.89 million tonnes, P2O5 at 8.00 million tonnes represent

growth of 8.4% and 10% over previous year. However, the consumption of K2O at

3.39 million tonnes in 2010-11 showed a decline of 6.6 % during the period.

The consumption of fertilizers (N+P2O5+K2O) per hectare of arable land in India at a

level of 135 kg is low when compared with the consumption level of countries like

Netherlands (367 kg), Japan (291 kg), Korea-Rep (410 kg), China (288 kg) and Egypt

(438 kg).

Table 2-1 : All India Consumption of Chemical Fertilizers (000 tonnes)

Year N P2O5 K2O Total

1981-82 4068.7 1322.3 676.2 6067.2

1991-92 8046.3 3321.2 1360.6 12728.1

1996-97 10301.8 2976.8 1029.6 14308.1

2001-02 11310.2 4382.4 1667.1 17359.7

2004-05 11713.9 4623.8 2060.7 18398.4

2005-06 12920.0 5260.0 2500.0 20680.0

2008-09 15090.5 6506.2 3312.6 24909.3

2009-10 15580.0 7274.0 3632.4 26486.4

2010-11* 16890.0 8001.4 3390.0 28280.0

*Provisional

There is also wide variation among different states in the level of consumption of

fertilizers. While Punjab ranks first with 237 kg per hectare followed by Andhra

Pradesh (226 kg), Haryana (210 kg), Tamil Nadu (206 kg), Uttar Pradesh (171 kg),

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West Bengal (169 kg), Karnataka (160 kg) and Gujarat (147 kg) have higher level of

consumption than all-India average of 135 kg per hectare. The consumption was

lowest in Nagaland with 2.4 kg followed by Arunachal Pradesh 3 kg respectively.

It is imperative that the level of fertilizer consumption in India has to be increasedso as to attain higher level of production not only to keep pace with the growing

population but also to become self-sufficient in food production. The immediate

need of the hour is at least to match the present level of consumption of Punjab.

2.3.4 Importance of Phosphorous

Phosphorus plays a leading role in living organisms and is said to be the key element

in metabolism. The role of fertilizer phosphorus in increasing crop production in

India is now increasingly being appreciated in the view of the low soil phosphorus

status and continued erosion in soil phosphorus during the past hundreds of years.

With the introduction of high yielding varieties and increase cropping intensity theextent of phosphorus removal by crop has significantly increased. Therefore,

adequate fertilizer phosphorus is to be added to soils to sustain high crop yields for

years to come. Application of fertilizer phosphorus is essential for the purpose of

raising the concentration of available phosphorus in the soil so that the crop

requirement at different stages of growth is met.

2.3.5 Single Superphosphate (SSP)

SSP is a grey coloured straight phosphatic multi-nutrient fertilizer which contains

16% water soluble P2O5, 11% sulphur, 21% calcium and some other essential micro

nutrients in small proportions which provide balanced nutrition to most of the cropsresulting in improved yield and soil health. SSP, which is a poor farmer's fertilizer

(price-wise), is an option to optimise the use of phosphatic fertilizers. It also helps to

treat sulphur deficiency in soils (40% Indian soil sulphur deficient) as well for

further enhancement of yields at the least cost. In various crops, which require more

of sulphur and phosphate like oilseeds, pulses, sugarcane, fruits and vegetables, tea

etc, SSP is an essential fertilizer. It is used in both powder and granular forms.

Powdered SSP (PSSP) is useful in short duration crops (oil seeds, pulses and

vegetables) whereas granulated SSP (GSSP) is useful in long duration crops

(sugarcane, wheat and rice).

2.3.6

Advantages of using SSP for different crops

The growth rate of roots improves ensuring that, the plant extracts maximum

amount of nutrients from the soil.

For leguminous crops like Groundnut, use of SSP, ensures growth of a large

number of nodules on the roots, which fix atmospheric nitrogen directly into the

soil and also increase nitrogen content of the soil.

Oil content of Groundnut and other Oil seeds increases.

The quantity and quality of Oil seeds and different Dals increases.

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In Sugarcane, the quality of the cane juice improves to a large extent, due to

which, we get good quality of Jaggery.

Using SSP on Wheat, Rice, Bajra, Jowar and Sugarcane ensures that, the plants

get a lot of new shoots. For crops such as Jowar and Groundnut, which are grown in non-irrigate lands, if

SSP is applied during sowing followed be required quantity of Urea or

Ammonium Sulphate, then the humidity in the soil can be used for a longer

period.

Increases yield by 17-41% in food grains, 18-32% in pulses, 16-33% in oilseeds

and 17-45% in vegetables.

Removes soil acidity and compaction and restore soil health.

2.3.7 Advantages of Granulated SSP

Granulated Single Super Phosphate (GSSP) as compared to SSP is in granulated form

and use of granulated product is more beneficial than the use of powder. The

powder gets dissolved immediately in irrigation water and becomes readily

available. Some part of it is used by plants and balance goes to sub soil with water

and remain useless. The powder can be used only during sowing of seeds. It cannot

be used on the growing crops as it get deposited on the leaves of the plants and

being slightly acidic, burns them. The granulated product rolls down the plant and

can be used harmlessly on the standing crops. The biggest advantage in using the

granulated product is that it is available to the crops for a longer time because it gets

dissolved slowly in water.

2.4 Demand Supply Gap

2.4.1 World Scenario of SSP

India ranks third in the global consumption of SSP, next to China and Brazil, as per

the latest data available. Other major SSP consuming countries are New Zealand,

Australia, Egypt, and Vietnam. In Egypt, almost entire quantity of P2O5 consumption

is sourced through SSP. Among other countries, which have large share of SSP to

total P2O5 consumption include, New Zealand (69 per cent), Taiwan-China (46 per

cent), Korea DPR (45 per cent), China (37 per cent), Brazil (29 per cent) andAustralia and Vietnam (25 per cent each) (Table 2.2).

Table 2-2 : Consumption of SSP and its Share to Total P2O5in Selected Countries

Country Consumption of P2O5(000 tonnes) % share of SSP to

total P2O5

consumptionTotal Through SSP

China 9827.0 3650.0 37

Brazil 3410.0 1007.6 29

India 4124.3 407.0 10

New Zealand 494.8 340.0 69Australia 1019.3 250.2 25

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Country Consumption of P2O5(000 tonnes) % share of SSP to

total P2O5

consumptionTotal Through SSP

Egypt 143.9 142.3 99

Vietnam 563.6 141.2 25Poland 338.0 65.0 19

Italy 447.0 36.0 8

Taiwan-china 78.0 36.0 46

Spain 618.0 21.0 3

Korea DPR 44.0 20.0 45

World 35037.5 6290.1 18

2.4.2 SSP Industry in India

The total installed capacity of SSP plants in India is around 8 million tonnes which

constitutes around 20% of the total capacity of phosphatic fertilisers. The major rawmaterials for SSP are rock phosphate and sulphur. Unlike DAP, which is produced

using imported rock phosphate, 65% of the SSP is produced with low-grade rock

phosphate that is available domestically.

Majority of the SSP manufacturers are producing SSP in powder form. However,

around 50 units of the SSP are also manufacturing granular SSP.

SSP industry shows uneven growth in production during the current decade upto

2007-08 with recovery in production from 2008-09. The total production of SSP at

3.631 million tonnes during 2010-11 represented a growth of 17 per cent over the

previous year. The increase in production was partly attributed to enhancement inthe rate of concession and partly on account of higher demand as a result of good

weather.

Table 2-3 : Production of SSP in India (000 tonnes)

Year Production Per cent increase/decrease over the previous year

2000-01 2742.2 -22.4

2001-02 2504.6 -8.7

2002-03 2407.7 -3.9

2003-04 2543.4 5.6

2004-05 2461.1 -3.2

2005-06 2795.2 13.6

2006-07 2972.0 6.3

2007-08 2246.3 -24.4

2008-09 2533.6 12.8

2009-10 3093.0 22.0

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Year Production Per cent increase/decrease over the previous year

2010-11 3631.0 17.4

2.4.3

Share of SSP in total production of P2O5

The share of SSP to total production of P2O5was 100 per cent way back in 1950s,

before the complex fertilizers came in production in India. It declined to 44.8 per

cent during 1970-71 and 23.4 per cent during 1980-81. Some improvement was

noticed during 1990-91, when it touched 28.5 per cent. It started declining from

1991-92, with marginal improvement occasionally. The share of SSP to total

production of P2O5 reduced from 18.6 per cent during 1991-92 to a low of 10.3 per

cent during the year 2005-06. It showed some improvement in 2010-11 at 13.3%.

2.4.4 Capacity Utilization

All India capacity utilization of SSP increased from 42.6 per cent during 2009-10 to

49.5 per cent during 2010-11. Despite improvement in the capacity utilization of SSP

during 2010-11, still there is a significant underutilization of capacity at the

aggregate level. It is interesting to note that out of 67 operating plants in the

country, 25 plants operated above 60 per cent capacity utilization level, and

remaining 41 plants below 60 per cent during 2010-11. During 2010-11, out of 67

operating plants, three plants operated above 100% capacity utilisation. Only one

between 90 to 100% and six plants operated between 80 to 90%.

Table 2-4 : SSP Plants in Various Ranges of Capacity Utilization

Capacity Utilisation Range

(%)

Number of Plants

2009-10 2010-11

Above 100 2 3

91-100 2 1

81-90 2 6

71-80 5 4

61-70 9 11

51-60 8 15

41-50 12 10

Below 50 30 17Nil/Not Available 10 15

Total No. of Plants 80 82

2.4.5 Government Policies for SSP

The production of SSP witnessed uneven growth during the major part of the decade

of 2000 until 2007-08 due to unfavourable policy. It showed sign of recovery from

2008-09 with the introduction of New Policy which made provision for

o Fixation of uniform MRP throughout the country.

o

Monthly revision in the concession rates to reflect the variation in prices ofraw materials vis--vis imported rock phosphate and imported sulphur,

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o Recognition of sulphur content in SSP while fixing MRP.

The policy continued upto September, 2009. With effect from October, 2009, the SSP

policy once again changed. Under the revised policy, the government decided to

leave the selling price of SSP open with an adhoc concession of Rs.2000 per tonne.The SSP industry witnessed a major breakthrough after the introduction of Nutrient

Based Subsidy (NBS) on SSP w.e.f. 1st May, 2010.

As per the NBS, the government has offered a fixed per kg subsidy for application on

N, P, K and S as well as micronutrients with multi-fold objectives:

o Increase availability of secondary and micronutrients in the soil by

encouraging the producers to innovate and experiment with customised

fertilizers, leading to higher demand due to higher response.

o Reduce the subsidy bill by decontrolling the prices.

o

NBS has bought the price parity to the farmers for P & K fertilizers based on

nutrient content.

With effect from 1st April, 2011, per tonne NBS for SSP (0-16-0-11) for 2011-12

would be Rs.5359 and henceforth, the DoF is authorised to revise MRP of SSP from

time to time in future keeping in view the international price trend of sulphur as

well as the nutrient price of 'phosphate' in DAP. Manufacturers / marketers are

required to ensure the product is transported up to the retail point. The market

price of SSP is open and will be announced by the manufacturers.

2.4.6 Future Demand-Supply Scenario

Demand Forecasts

Fertilizer consumption / demand is affected by a large number of factors such as its

own demand in the previous period, the expected price of crops, its own price,

geographical factors, government policies, market forces, climatic and other factors.

Other factors that might be expected to influence the use of fertilizer are: area under

high-yielding varieties (HYVs), irrigation, cropping intensity, per capita income, etc.

As such, the estimation of demand for fertilizers in the future years becomes a

difficult work. Yet, it is important that future demand/ consumption estimates are

made for planning the installation of new manufacturing units and for determiningthe level of imports etc.

Several agencies, from time to time, have came out with their estimates based on

various methods viz. straight-line fit, quadratic fit, agricultural growth rate

approach, population nutrition method, cropped area and recommended dose

method etc. Experience has shown that more often than not, the estimates do not

conform to actual consumption figures. This is mainly due to the fact that the

assumption of normal conditions in methods adopted does not hold good because of

abnormal weather conditions, physical controls, lack of supply, unprecedent price

hike, advance input-output ratios etc. However, serious efforts in this direction

continue and the organisation like Planning Commission, Department of Agriculture

& Co-operation, Fertilizer Association of India, National Informatics Centre, and

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National Council of Applied Economic Research havecame out with their estimates

at different points of time.

FAI demand estimates are based on the multiple regression model. The variables

considered to the model are irrigated area, area under HYV, Fertilizer consumption,rainfall and prices of fertilizer nutrients. A time series data have been used in the

model. The projections made by FAI in respect of nutrient P2O5 during 12th Five

Year Plan and onwards are summarised below in Table 2.5.

Table 2-5 : Demand Projections of Nutrient P2O5('000 tonnes of P2O5)

Year Projected Demand Year Projected Demand

2012-13 8576 2017-18 9868

2013-14 8814 2020-21 10543

2014-15 9051 2022-23 11113

2015-16 9285 2023-24 113242016-17 9517 2024-25 11530

The projections made by FAI in respect of SSP are summarised below in Table 2.6. It

has been assumed that the share of SSP to total P2O5 will progresively increase from

the current level of 7 per cent to 10 per cent by the end of the 12th Plan.

Table 2-6 : Demand Projections of SSP('000 tonnes)

Year Projected Demand Year Projected Demand

2012-13 4288 2017-18 6476

2013-14 4682 2020-21 7248

2014-15 5091 2022-23 7814

2015-16 5513 2023-24 8139

2016-17 5948 2024-25 8467

Future Supply Estimates

As there is subsidy on SSP on sold quantity acknowledging SSP as key phosphattic

fertilizer at par with DAP on nutrient content due to price advantage and huge

demand of SSP, it is expected that many large fertilizer companies are entering this

sector. Mergers and acquisitions have also so far been beneficial for long run. The

public sector companies like Rashtriya Chemicals & Fertilizers Limited (RCF),National Fertilizers Limited (NFL), Madras Fertilizers Limited (MFL), Fertilizers &

Chemicals Travancore Limited (FACT), FCIAravali Gypsum & Minerals India Limited

(FAGMIL) have plans for entering in the field of production of SSP in near future.

Besides these, many other companies have plans for expansion of existing facilities

or new capacities. Some of the companies has submitted proposals for

environmental clearance. The details of new or expansion capacity are given in the

Table 2.7

The increase in production of SSP in the country is also expected from improved

capacity utilization of existing plants. Considering 70% capacity utilisation of the

existing effective capacity, total supply of SSP is expected to increase to a level of

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5150 thousand tonnes. The projected demand supply gap of SSP in the country

would be in the range of 8 lakh tonnes by the year 2016-17.

Moreover, there is consistently sizeable supply gap of P2O5 in the country is

indication that, given an acceptable product, any additional production ofphosphatic fertilizer products in the country will not suffer for want of a market. In

fact, unless indigenous production of phosphatic fertilizers sufficiently expands,

imports are likely to rise further as a result of the efforts presently being made to

raise the consumption of P2O5 to attain a better NPK ratio.

It is apparent that DAP is a strategic commodity and capacity of international market

is rather limited to meet significant increase in demand. An additional demand of

even 1-2 million tonnes would cause serious imbalance and prices would shoot up.

Higher levels of demand could result in a situation when DAP would not be available

in spot markets at any price.

Table 2-7 : Proposals for New / Additional Capacity of SSP

Company Tentative Location of

SSP Plant

Capacity

(MTPD)

Status

RCFL Thal (Maharashtra) 1500 Planning

NFL Not Available 800 Planning

MFL Manali (Tamil Nadu) 600 Planning

FACT Cochin (Kerala) 500 Planning

FAGMIL Rajasthan 600 Planning

CFCL Gadepan (Rajasthan) 800 EnvironmentalClearance

Bodal Chemicals

Limited

Padra, Vadodara

(Gujarat)

800 Commissioning

Golden Futures

Fertilizers Ltd.

Udaipur (Rajasthan) 600 Environmental

Clearance

Coromandal

International

Punjab 800 Planning

Patel Phoschem Pvt.

Ltd.

Udaipur (Rajasthan) 300 Environmental

Clearance

Khaitan Chemicals &Fertilizers Ltd.

Bharauch (Gujarat) 600 EnvironmentalClearance

KPR Fertilizers Ltd. Koppal Karnataka) 200 Environmental

Clearance

India Phosphate Ltd. Udaipur (Rajasthan) 400

(Additional)

Environmental

Clearance

Rama Phosphate Ltd. Indore

(Madhya Pradesh)

300

(Additional)

Environmental

Clearance

Therefore, it would not be prudent to depend on imports for more than 1 million

tonnes of DAP. This in other words means that the country shall be required to have

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in place additional domestic capacity of phosphatic fertilizer products for indigenous

consumption.

Moreover, with increased use of high analysis fertilizers like Urea and DAP for the

nitrogen and phosphorous needs, the sulphur removed from the soils throughintensive farming was not getting replenished.

In India, the number of sulphur-deficient districts has risen from 88 in 1980 to 250

now, with the annual unmet requirement put at 9.6 lakh tonnes.

View against the background of sulphur deficient soils and continuing gap for P2O5

as also the long-term objective of achieving self-sufficiency in agricultural

production and thereby minimum imports, the proposal for installation of SSP plant,

it is felt, would be a right step. This would not only help in boosting the production

of SSP for sulphur deficient soils but will also reduce the demand pressure for DAP.

2.5

Imports Vs Indigenous Production

The project proposal does not envisage import for SSP fertilizer as demand for SSP

will be met through indigenous production only. The raw materials, viz. phosphate

rock and elemental sulphur will, however, be imported.

2.6 Export Possibility

Export of fertilizers is banned in India.

2.7

Domestic / Export markets

As adequate demand for the product exists in the domestic market, the product will

be marketed in the domestic market specially in the states in North India.

2.8

Employment generation

The execution of the project has to pass through different phases like pre-project

activities, design and engineering, procurement, civil works and erection, pre-

commissioning, trial run/commissioning till the project finally goes in to commercial

production. The success of the project will depend on the strength of the owners

project management cell that will monitor the various activities with vendors &

detailed engineering contractor.

The project will generate direct and indirect employment opportunities. Direct

employment will be in the form of skilled, semi-skilled and un-skilled work force

required for operation of the facilities. The project will also provide indirect

employment generation in service sectors. The plants will be operated in 3 shifts.

However, loading, un-loading and grinding operations will be performed during day

time only.

Table 2-8 : Skilled Manpower Requirement

Sl. No. Department Nos.

i.

Operation 16ii.

Maintenance 7

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Sl. No. Department Nos.

iii. Technical Services 2

iv. Materials Management 8

v. Finance & Accounts 1

vi.

Personnel & Administration 1

vii.

Marketing 1

TOTAL 36

The skilled manpower will be permanent employees of the project, and semi-skilled

and un-skilled work force will be drawn from local population on contract basis. A

tentative skilled manpower requirement for the proposed project is shown in Table

2.8.

The above estimated figures are tentative and detailed analysis is required for fixing

the precise requirement to ensure trouble free and efficient management of the

plants and facilities.

In addition to the above, approx. 40 semi-skilled and un-skilled persons will be

required, on contract basis, for operation of the plants and facilities.

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3.

Project Description

3.1

Type of projectThe proposed project is to be set up for the production of SSP as end product. It

comprises main facilities such as SSP plant and associated facilities like curing

building for intermediate product, bagging unit and storage for raw material and

final product. The main raw materials are Rock Phosphate and Sulphuric acid.

Required sulphuric acid shall be procured from Hindustan Zinc Limited, Chittorgarh

while rock phosphate shall be imported at Dahej port and transported by rail/road

to the project site.

3.2

Location

The proposed project site, comprising 11.01 hectares land (Plot No. 2615), is located

in Village Pandoli, Tehsil & District Chittorgarh, Rajasthan. It is Government land,

reserved for industrial purpose, and was allotted to FAMIL for establishing the SSP

project (Annex-8). The plot is located adjacent to State Highway No. 9,

approximately6kms away from Chittorgarh.Geographically, the project site is

located at latitude 2405527 N and longitude 7403342 E. Elevation of the plot

varies from 423 to 427 m above MSL. Maps showing general & specific location,

project boundary and project layout plan have been presented in Annexures 1 to 4.

3.3

Alternate sites considered

The ideal project location will be the location from where the cost of production &

distribution is minimum and the same will depend on many factors like availability

of raw materials, markets and distribution centres immediate to the project location,

transportation etc.

Rock phosphate and Sulphuric Acid are the basic raw materials for manufacturing of

SSP. Presence of Rock Phosphate reserves in Rajasthan and Madhya Pradesh has

made easy availability ofRock Phosphate in these states and hence most of the SSP

Plants are concentrated in these states only. Rajasthan and Madhya Pradesh have

total of 17 and 14 plants respectively. Some of the plants are also located near the

ports along the coastal lines of Andhra Pradesh, Gujarat, Maharashtra and WestBengal using indigenous as well as imported rock phosphate. A large quantity of by-

product sulphuric acid is available at Hindustan Zinc Limited smelter plant in

Udaipur.

The following five locations have been considered for setting up the proposed SSP

project.

I. Udaipur

II. Suratgarh

III.

Jodhpur

IV.

Chittaurgarh

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V. Existing premises of FACT

A meeting was held between FAGMIL and PDIL officials on 26th September 2011 at

Jodhpur office of FAGMIL to discuss about the alternative sites for setting up SSP

project. Accordingly, a joint team visited Udaipur, Chittorgarh and also outskirts ofJodhpur in search of suitable sites. For sites in Suratgarh, information have been

gathered through FAGMIL officials stationed at Suratgarh. One of the alternates is

the FACTs existing premises at Cochin. Though the site at Cochin has not been

physically assessed but information made available by FACT has been used for

assessment.

Rajasthan State Industrial Development and Investment Corporation (RIICO), the

sole government agency in the State involved in development of land for industrial

enterprisesa has informed FAGMIL that presently there is no land available in

Jodhpur for the proposed SSP project and such land could be available after 1.5 to 2

years. The Cost of land for industrial purpose in Jodhpur would be around Rs. 6 to 8lakhs per Bighai.eRs. 15 to 20 lakhs per acre.

While the sites located in Udaipur and Chittorgarh are considered to get imported

rock phosphate through Dahej port, sites located in Jodhpur and Suratgarh will get

imported rock phosphate through Kandla port. Site located in Cochin will get

imported rock through Kochi port.

The site located in Chittorgarh is nearest to sulphuric acid supplier. In Suratgarh,

FAGMIL has its own operating office for gypsum. The site near Suratgarh could be

better site with respect to product evacuation. The target markets for the product

i.e. the states of Punjab, Haryana and Uttar Pradesh are nearer than any location viz.Jodhpur, Udaipur and Chittorgarh. Also, the cost of land would be cheapest in

Suratgarh compared to Jodhpur, Udaipur and Chittorgarh. Cochin, the FACTs

existing site is also considered as one of the site for evaluation purpose.

All the site locations namely Udaipur, Suratgarh, Jodhpur, Chittorgarh and FACT

Cochin have been studied. The criteria for selection of ideal site are as follows:

Cheaper availability of raw materials such as sulphuric acid and rock phosphate.

The finished product SSP does not have to be transported for longer distance,

consequently lower freight and distribution costs, to a considerable extent, the

disadvantages of lower primary nutrient content.

A comparative statement showing advantages and disadvantages in procurement of

raw materials and distribution of finished product at different plant locations is

presented in Table 3.1.

It can be observed from the table that the profitability of the proposed project is

highest if plant location is Chittorgarh followed by Udaipur. Hence, Chittorgarh can

be considered as the ideal location for the proposed project.

Availability of land, free from litigation, is one of the major environmental

considerations of site for locating a project. The environmental considerations in

favour of the site near Chittorgarh are as follows:

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Availability of Govt. land, reserved for industrial purpose, free from litigations;

Proximity to and connectivity with the source of Sulphuric acid;

Away from densely inhabited areas;

No sensitive areas located in proximity;

No reserve forest, sanctuary or major water body located within 10 km distance

from the site;

Availability of semi-skilled and un-skilled work force in neighboring villages;

Better connectivity by rail and road - Chittorgarh and Chanderia Railway Station,

with railway siding, are located within 9 km from the site; State Highway (SH - 9)

is located adjacent to the site.

Table 3-1 : A comparative statement showing profitability of the proposedproject at different locations

Particulars Jodhpur Chittorgarh Udaipur Suratgarh Cochin

Distance from Sulphuric

Acid source i.e.

Chittorgarh* (km)

300 40 120 600 2000

Distance from nearest

Port (km)

600

(Kandla)

560

(Dahej)

450

(Dahej)

1030

(Kandla)

80

(Kochi)

Landed Price of Raw

Materials

Rock Phosphate

(Rs./MT)

9156 9076 8856 10016 8056

Sulphuric Acid (Rs./MT) 4209 3559 3759 4959 6759

Project Capital Cost (Rs.

Lakhs)

7075 7095 7241 6915 9054

Working Capital

(Rs. Lakhs)

6701 6584 6549 7059 7042

Cost of Production

(Rs./MT)

8469 8185 8134 9244 8880

Sale Price of GSSP 8735 8820 8637 8925 8905

IRR (Post-Tax) 12.06% 19.73% 16.85% -ve 6.23%

Pay Back period ( Years) 7.93 4.24 5.14 15.0 14.16

*By-product Sulphuric acid available from Hindustan Zinc Ltd. has been considered.

3.4 Size & Magnitude of the project

Main product : Granulated SSP; 240,000 TPA

Intermediate products

SSP powder : 240,000 TPA

Fluosilicic acid (15%) : 4,500 KL/year

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3.5

Process Description

3.5.1 Single Super Phosphate Plant

PROCESS TECHNOLOGY:

The process of manufacturing of SSP consists of reaction of Ground Rock Phosphate

of required fineness and P2O5 content with Sulphuric Acid in specified proportion.

The product of acidulation of Rock Phosphate is called Green Super Phosphate which

is allowed to cure for 2 to 3 weeks before the same is ready for packing or further

processing.

The phosphate rock from different sources, used for SSP production, is mainly

fluorapatite, (Ca5(PO4)3F). The actual composition of the phosphate rock varies with

the source.The main chemical reactions involved in the manufacturing of SSP from

rock phosphate and Sulphuric acid are as follows:

3Ca3(PO4)2+ 6H2SO4+ 3H2O 3Ca(H2PO4)2.H2O + 6CaSO4

CaF2+ H2SO4 CaSO4+ 2HF

4HF + SiO2 SiF4+ 2H2O

3SiF4+ 3H2O 2H2SiF6+ SiO2.H2O

Ca3(PO4)2+ 2H2SiF6+ 4H2O Ca(H2PO4)2+ CaSiF6.2H2O

Schematic flow diagram of manufacturing of SSP has been presented in Annex-5.

PHOSPHATE ROCK BLENDING AND GRINDING:

Phosphate rocks, from different sources have different phosphate, fluoride and silica

contents. These rocks are mixed in the blending plant to produce a product with a

total phosphate concentration of 31.5%. The phosphate rock mixture is passed

through a ball/hammer mill which reduces the particle size to 0.5cm or less. The

coarsely ground rock is then passed through an air swept roller mill (Bradley Mill)

to attain a rock grist of approximately 75% less than 75 microns. The powdered rock

is stored in a large hopper. Fine Phosphate is transported to ground Phosphate

Hopper to be used for PSSP production.

The grinding of rock phosphate leads to emission of dust. A Pulse jet dust collector

(Bag filter) will be provided to control dust emissions. A stack will be provided at theball mill for discharge of gaseous effluent from the dust collector.

SULHURICACID DILUTION:

Dilution and Cooling Systems are used to dilute the concentrated Sulphuric Acid

98.5% to 70% concentration, and to cool down the produced Diluted Acid (178C),

because the Dilution Process is exothermic. Dilution Process (as a result of mixing

water with Conc. Acid) and cooling system is sophisticated systems due to the highly

corrosive effect of the Diluted Acid. For that, all parts in contact with Diluted Acid

made from special Graphite can bear the operating conditions such as:

Diluted acid inlet Temperature: 178 C

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Pressure inside the cooler: > 2 bars

This system is fully automated and provides all the safety precautions necessary to

guarantee safe operation not only for operators but also for the Graphite Cooler and

cable to control the outlet concentration and temperature. The Diluted Acid (DSA) isstored in Storage Tank lined with Rubber and acid bricks. The cooling water

necessary to cool the DSA is re-circulated in water Cooling Tower to minimize the

consumed water and in turn the waste water.

POWDER SUPERPHOSPHATE MANUFACTURE:

Diluted Acid is pumped to PSSP production plant using special chemical pumps.

PSSP plant is designed to use 70% Sulphuric Acid, recycled scrubber liquor and

ground phosphate rock. It is based on the most technically and economically up to

date feasible process and is compatible with Environment Protection Requirements

Feed Metering is achieved with Automatic Control System. The ground rock andsulfuric acid are reacted in a horizontal mixer. A continuous flow of the sloppy mix

drops out of the mixer into the Broad field Den. Broad Field Mixer developed

specially for PSSP manufacture is a large two stage horizontal paddle mixer, the two

stage design ensures complete mixing and good chemical reaction (quality) of SSP

powder. Varying speed drive and adjustable paddle configuration allows selection of

optimum mixing conditions for all phosphate rocks with Acid.

The den consists of a slowly moving floor (approx. 300 mm/min), built from steel

tee slats, with polypropylene sealing strips, to prevent leakage, to enable setting of

the cake and reciprocating sides, lined with cement fondu (special tile) and are

driven by two geared motor units through two heavy crank arms which prevent the

superphosphate adhering to the walls. The partially matured superphosphate cake

is cut out of the den with a rotating cutter wheel after a retention time of

approximately 30 minutes.

A sturdy steel framework carries the den and mixer. A rotary cutter excavates the

SSP cake from Den. Stainless steel blades are mounted on a steel frame and shaft

carried on externally mounted Plummer block bearings. The outlet PSSP fertilizer

conveyed to storage area where remaining reaction of the SSP is completed by

spreading the cut lumps on the floor and reshuffling the hips by means of a over

head crane situated in the curing building. The SSP is allowed to complete the

reaction and attain the powdered form which takes around 21 days. After curing, the

powder SSP is transferred to the granulation plant for further processing.

SCRUBBING:

The SiF4 fumes and fine dust of ground rock, generated during the reaction between

phosphate rock and Sulphuric acid, are drawn from the Den by induced draft fans.

The SiF4 fumes and dust are passed through the scrubbing system, comprising a

venturi scrubber followed by three stage scrubbers.In the scrubbing system, fluoride

content of the air stream is reduced to below 25 mg/Nm3. Effluent air from the

scrubbing system is discharged into the atmosphere through a chimney. Fluo-silicic

acid (H2SiF6) is separated from sludge in a Sump. Sludge thus separated will be

reused as a filler in SSP and clear scrubbed liquor (approx.. 15% H 2SiF6)is recycled

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to the mixer which reduces consumption of Sulphuric Acid and dilution water.

Process flow diagram of the Scrubbing Section has been presented inAnnexure-6.

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3.5.2 Granulation Plant

Cured Single super phosphate is fed to the granulation Plant through a Cutter/ Lump

Breaker and fed to Granulator through Feed Belt Conveyor. In granulator drum,

water is sprinkled and granules are formed, which are fed to the Dryer Drum wherethe Granules of SSP are heated by hot air generated through a Fuel oil fired Furnace.

Hot granulated SSP is fed to Cooler drum through Belt Conveyor and the product is

cooled. The Dryer and Cooler Drums are attached to ID Fans through Cyclone

Separator and Chimney. The cyclones collect the Dust from the system and the

effluent air is discharged through Chimney.

The product granulated SSP is passed through Vibrating Screens, where under-size

and oversize materials are separated, and the desired size product is sent to the

automatic packing and bagging plant, where from the product is packed in 50 kgs

HDPE laminated bags and stored for dispatches.

The under size material is recycled in the Granulator and the oversize material is

crushed through Twin Roller Hammer Mill and is recycled to the Granulator.

Process flow diagram of manufacturing of Granular SSP has been presented in

Annexure-7.

3.6

Raw Materials & Transport

3.6.1 Consumption Norms

The requirement of raw materials and utilities for the proposed GSSP project of 800

MTPD has been worked out on the basis of rated capacity operation of the plant. The

annual requirements of various inputs of proposed project are presented below in

Table- 3.2.The annual requirement of Rock Phosphate and Sulphuric acid include

margin for over consumption and handling losses.

Table 3-2 : Annual Raw Material & Utility Requirement

Sl. No. Raw Material/Utilities Unit Annual Requirement

1.0 Rock Phosphate MT 139200

2.0 Sulphuric Acid MT 86400

3.0 Power MWh 6000

4.0 Fuel Oil MT 2640

5.0 Water 100 m3 696

3.6.2 Rock Phosphate

For the proposed project near Chittorgarh, rock phosphate will be sourced from

various countries like Jordan, Iran, Egypt and Togo. It is envisaged that Rock

Phosphate can be used from all these sources including rocks available from

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indigenous sources like Rajasthan State Minerals and Mining Limited (RSMML) &

Madhya Pradesh State Mining Corporation Limited (MPSMCL).

The requisite quantities of rock will be unloaded at Dahej port and from there; it will

be transported by rail/road to the proposed project site.Unloading and port handling charges of around 200 Rs/MT of Rock Phosphate has

been considered.

3.6.3 Sulphuric Acid

Sulphuric Acid for the proposed project has been considered to be procured from

Hindustan Zinc Limited (HZL), Udaipur and shall be transported through road

transport. Base price of 3000 Rs/MT of sulphuric acid has been considered for the

proposed project.

3.6.4

Power

Power supply for the proposed project has been considered from State electricity

Board. In addition to this, power is considered to be supplied to plant through DG set

in case of emergency.

3.6.5 Fuel Oil

Fuel Oil for the proposed project has been considered to be transported from near

by oil supplier through rail/road transport.

3.6.6 Water

The total requirement of process water for the project is envisaged to be around

9.67 m3/hr. As Chittorgarh Block has been declared as dark zone, make-up water

requirements of the project and facilities will be met from surface/ground water

from neighbouring areas, brought to the site in tankers.

3.6.7 Bags

Granulated SSP will be sold in 50 kg bags. The provision has been made for the use

of polyethylene bags. The delivered price of bag & thread has been considered as rs.

13.30/bag

3.6.8

Finished Products

The proposed facilities will produce 800 TPD (240,000 TPA) granulated single super

phosphate. Finished granulated SSP will be transported up to Chanderia/

Chittorgarh railway station by road route, and from there to the destinations by rail

route.

3.7

Resource Optimization

3.7.1 Energy Conservation

The granulation plant will be designed to achieve maximum utilization of heat

generated in the Hot Air Generator for drying of granulated material.

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3.7.2 Water Conservation

The plant will be operated on zero discharge of waste water. Blow down (waste

water containing approx. 15% H2SiF6) from the scrubbing system in the SSP plant

will be recycled quantitatively to the mixer in SSP plant, which would also reduceconsumption of Sulphuric acid in the acidulation process.

3.7.3 Waste Minimization

Precipitated silica from the scrubbing system, after centrifuge and atmospheric

drying, will be used as filler to the product.

3.8 Water and Electricity

3.8.1 Water

Source:

The initial feasibility of the projectwas based on the assumption that fresh water

requirement of the project during construction and operation phases will be met from

ground water, drawn through bore wells. However, as Chittorgarh Block has been

declared as dark zone, make-up water requirements of the project and facilities will be

met from surface/ground water from neighbouring areas, brought to the site in tankers.

Construction phase requirement:

Average water requirement during construction phase is estimated as 20 KLD,

comprising 17 KLD for construction and 3 KLD for domestic usage.

Operation phase requirement:

The one time water requirement during operation of the facilities for the manufacturing

of proposed product will be approximately 262 KLD. However, under normal operation,

the total water demand is approximately 232 KLD. Water balance for normal operation

of the facilities is presented in Table-3.3.

Table 3-3 : Water consumption during normal operation

Water requirement Quantity (KLD)

Fresh water to SSP plant Mixer, excluding recycled wastewater

from of blow-down from scrubber unit

98

Make-up water to scrubbing unit 35

Process water to granulation drum 80

Domestic usage 10

Dust suppression 2

Green belt 7

Total Water requirement 232

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3.8.2 Electric Power

The annual power requirement of the plant and facilities, including auxiliaries,

materials, handling, utilities and lighting load, has been estimated as 6000 MWh,

which is equivalent to 20 MWh/day or 0.83 MWh/h. Power supply for the proposedproject has been considered from State electricity Board.

To meet the emergency power requirements during power cuts, a DG sets of 125

KVA capacity will be installed. The SSP plant scrubber unit will be interlocked with

alternative power, i.e. DG set, to prevent release to toxic gases to atmosphere in case

of power failure.

3.9

Generation and Management of Wastes

3.9.1 Solid & hazardous wastes

Silica from Scrubber: The silica precipitated in the scrubber unit of SSP plant(reaction between SiF4 and water) will be settled and separated in a sump, washed,

and added to the granulation drum as filler in the product.

Spent oil:Used oil, decanted from pumps, compressors and other equipment, will

be stored in metallic containers and disposed through CPCB/RSPCB authorized

recyclers.

Used Containers: Used containers will be stored and disposed through

CPCB/RSPCB authorized recyclers.

3.9.2 Liquid effluents

The plants will be operated on zero effluent basis. Blow-down from the scrubber

unit in SSP plant, approx. 30 KLD, containing approx. 15% H2SiF6, will be recycled

quantitatively to the Mixer for conservation of water and acid.

Sanitary waste water, approx. 8 KLD, will be treated in septic tanks, followed by

disposal in soak pits within premises.

3.9.3 Gaseous emissions

Exact details of emissions from the different sources will be available at detailed

engineering stage. However, the emission details, based on experience with other

similar plants, are presented below.

ROCK PHOSPHATE GRINDING:

Ground mass from the grinding mill will be drawn pneumatically with air and the

ground mass collected in a cyclone separator. Major portion of the air exiting the

cyclone will be circulated to the grinding mill, and a fraction will be passed through

pulse jet bag filter for collection of fine dust. Effluent air from the bag filter will be

discharged into the atmosphere through a stack. The expected details of emissions

are as follows:

Volumetric flow rate : 24,000 Nm3/hr

Stack height : 30 metres above GL

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Particulate matter concentration : 125 mg/Nm3max.

Particulate matter emission : 3.0 kg/hr

GASES FROM MIXER &DEN IN SSPPLANT:

Fluorine bearing gases, particulate matter and water vapour generated in the Mixer

and the Den will be drawn with an ID fan, and passed through the scrubbing system

for control of fluorine bearing gases. The proposed scrubbing unit will consist of a

ventury scrubber, followed by 3-stage cross-flow scrubbers. Fresh water will be

added as make-up water to the system. A portion of the circulating water, approx.

15% H2SiF6will be drawn from the 1st scrubber and recycled to the Mixer, where it

will react with rock phosphate and reduce fresh water consumption. Tail gas from

the scrubbing system, with fluorine content less than 25 mg/Nm3 will be discharged

into the atmosphere through a stack. Expected details of emission are as follows:

Volumetric flow rate : 36,000 Nm3

/hr


Fluoride concentration : 25 mg/Nm3max.

Fluoride emission : 0.90 kg/hr max.



GRANULATION PLANT EMISSIONS:

Drying and cooling air from Drying and Cooling operations will be passed through

respective cyclones, and discharged through a common stack. Product dust carried

with the air streams will be collected in cyclones and recycled to the process. Flue

gases from the hot air generator, product of HSD combustion, will also be discharged

through the same stack. Details of emissions are as follows:

Volumetric flow rate : 30,000 Nm3/hr




3.10

Information of EIA Purpose

As per the EIA Notification 2006 of Ministry of Environment & Forests, Government

of India and its amendment, the proposed SSP manufacturing unit has to obtain

prior environmental clearance. The proposed project is covered under Category 'B'

as per the Schedule of EIA Notification and hence requires environmental clearance

from State Level Environmental Impact Assessment Authority (SEIAA) of Rajasthan.

The process for obtaining prior Environmental Clearance for the proposed project as

per EIA Notification-2006 is as follows.

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1. Submission of application (Form I, Pre-feasibility report and proposed Terms of

Reference TOR) to State Environmental Impact Assessment Authority (SEIAA);

2.

Scoping and communication of TOR for EIA study by SEIAA;

3. Undertaking EIA study as per TOR, and preparation & submission of draft EIA report

to State Pollution Control Board for conduct of Public Hearing;

4. Conduction of Public Hearing by State Pollution Control Board, and recording of

Public Hearing Proceedings;

5. Revision of EIA report taking the Public Hearing proceedings into account, and

submission of final EIA report to SEIAA;

6. Appraisal by SEIAA;

7. Grant of Prior Environmental Clearance.

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4.

Site Analysis

4.1

ConnectivityThe site is adjacent to State Highway (SH-9) from Udaipur to Chittorgarh, at a

distance of 3 kms from its junction with NH-79. Chittorgarh and Chanderia Railway

Stations, both with loading and unloading facilities, are located within 9 km distance

from the project site. The nearest airport (with regular flights) is MaharanaPratap

Airport, Udaipur, at approx. 100 km from project site. The project site is at a distance

of 560Kms from Dahej Port, which is the port proposed for import of rock

phosphate.

4.2

Land form, Land use and Land ownership

The plot of land identified for locating the project lies in Pandoli Village of

Chittorgarh District of Rajasthan. The land is rocky, uneven and sloping from central

ridge on the two sides.

The plot of land was under Government ownership, reserved for industrial purpose.

It has been allotted to the project proponent for establishment of SSP plant. Cost of

land fixed by the State Government has already been paid.

4.3

Topography

The topography of the plot is extremely rugged. Elevation of the plot varies from

approx. 423 m to 427 m above MSL. The maximum height is observed along thecentral ridge, sloping all along towards the two sides.

4.4 Existing Land use Pattern

As stated earlier, the land belonged to the State Government, and its designated land

use is reserved for industrial purpose.

4.5

Existing Infrastructure

The proposal is for a grass root project, to be developed on a plot of land which was

reserved for industrial use. Thus, no infrastructure exists at the site.

4.6

Soil Classification

There is practically no soil cover over the plot identified for locating the project. The

entire area is covered by spurs of rocks.

4.7 Climate of the area

The climate of area is quite dry and parched. The summer season extends from April

to June and is quite hot. The average temperature in summers falls between 43.8 C

to 23.8 C. The winter season lasts from October to February. Chittorgarh weather in

the winters is pretty cool. The temperature averages around 28.4 C to 11.6 C. Themonsoon season falls during the months of June to August. As far as climatic

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conditions of Chittorgarh, Rajasthan in monsoon are concerned, there is only slight

rainfall that averages around 800mm. The best time to visit Chittorgarh is between

September to March.

The climatological normal data for Chittorgarh Observatory, approximately 8 kmfrom the site, are summarized in Table-4.1 and 4.2.

Table 4-1 : Climatological Normal Data for ChittorgarhWind Direction and

Speed

Month Percentage no. of days with wind from Mean wind

speed, kmphN NE E SE S SW W NW Calm

January I 19 21 2 1 3 4 1 1 483.9

II 20 27 3 1 3 8 6 10 22

February I 16 18 1 3 10 6 3 3 40

4.2II 16 24 2 3 6 13 8 17 11

March I 10 14 1 4 15 10 4 3 394.7

II 12 11 3 3 7 18 17 19 10

April I 7 7 1 5 24 16 6 3 315.4

II 10 5 1 1 8 27 24 20 4

May I 3 3 2 3 28 37 8 3 137.0

II 7 3 2 2 12 33 21 16 4

June I 2 3 1 2 23 50 12 2 59.3

II 7 5 2 3 15 39 18 9 2

July I 2 2 1 2 26 49 8 1 9

7.8II 3 4 3 3 16 47 15 3 6

August I 4 4 0 2 21 39 7 4 196.3

II 4 6 2 4 17 38 13 6 10

September I 7 7 1 3 22 27 4 2 274.5

II 9 10 3 2 12 29 11 11 13

October I 7 7 2 3 19 9 4 2 473.2

II 11 18 4 2 8 13 8 11 25

November I 14 16 2 1 5 4 3 2 533.2

II 14 27 4 3 4 5 3 7 33

December I 19 19 1 0 3 2 2 3 51 3.4II 17 28 3 1 3 4 3 4 37

Annual I 9 10 1 2 17 21 5 2 325.2

II 11 14 3 2 9 23 12 11 15

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Table 4-2 : Climatological Normal data for ChittorgarhTemperature &

Rainfall

Month Mean of Air temperature, 0C Rainfall

Daily

max

Daily

min

Highest

in the

month

Lowest

in the

month

Monthly

total, mm

No. of

rainy

days

January 24.5 6.7 28.9 2.2 4.3 0.4

February 26.7 8.6 32.2 3.3 4.2 0.6

March 33.0 14.3 38.0 8.8 1.7 0.3

April 38.2 20.4 42.1 15.1 3.1 0.4

May 40.7 24.6 43.6 20.5 14.3 1.4

June 38.5 25.3 43.4 21.2 70.7 4.6

July 32.5 23.6 37.9 21.0 227.2 10.0

August 30.6 22.5 34.7 20.7 323.8 12.3

September 32.9 21.2 36.4 18.7 105.1 5.2

October 33.9 16.8 36.8 12.0 19.4 0.9

November 29.7 11.6 3.4 7.1 21.2 1.1

December 25.8 7.5 29.6 3.2 5.5 0.3

Annual 32.3 16.9 44.1 1.9 800.5 37.5

4.8

Available Social Infrastructure

Chittorgarh city is located within 6 to 10 Kms from the site, in western direction.Chittorgarh is an old city, and infrastructure available in the city satisfactory.

4.8.1 Houses

Houses are built on either side of the roads in the villages. Some of them are located

near their fields. Most of the houses in the villages are pucca with few a kuchha

houses.

4.8.2 Water supply

Villages mostly rely on hand pumps, wells and pond water. Ground water in the area

is available at a depth60-70 m below ground level. Water collected in the ponds anddrawn from tube wells is also used for irrigation.

4.8.3 Transport and Communication

Transport accessibility is one of the important factors required for the overall

development of the area. All the villages have roads and means of transportation to

the towns are by Bus, auto, two-wheelers, jeeps, etc. All villages in the area are well

connected to SH-9 and NH-79.

4.8.4 Market Facilities

Commercial activities form the backbone of the economy. The study tends to tell thekind of employment it generates for the people of the area and the kind of

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employment it generates for the people of the area and the kind of services it

provides for the attainment of a better living. Market facilities available at

Chittorgarh cater to the needs of the area, and are adequate.

4.8.5

Health Facility

Health is one of the most important development indicators, which needs to be

studied to know the quality of life in the area. The site and surrounding villages are

well connected to Chittorgarh City and Chanderia. Health care facilities available in

the area include Primary health centers in villages, government and private

hospitals in Chittorgarh City, and Hospitals operated by Hindustan Zinc Limited and

Birla Cement Works.

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5. Planning Brief

5.1

Planning Concept

The demand for the fertilizer due to the expanding agricultural production,

improvement in technology and growing awareness among farmers has led to the

increased consumption of agrochemicals. Fertilizers are key ingredients in ensuring

the food security of the country, as it increases the production and productivity of

the soil. The demand for domestic food grain production has been increase and will

continue to increase with population growth. The target of higher productivity can

be achieved through improved farming practice, expansion of irrigation, better seeds

and extensive and balanced use of fertilizers. A definite growth in the fertilizer

industry in India is required. In view of this and seeing bright future of fertilizers

industry in country the management of M/s FCI Aravali Gypsum and Minerals

India Limited (a Govt. of India Enterprise) proposes to set up a 800 MT/day

granulated SSP plant.

5.2

Populati

Documents

Fci Aravali Pfr 22012014