PRE FEASIBILITY REPORT (PFR)

1.0. INTRODUCTION

Shri Tulsi Phosphate Limited is a Public Company incorporated on 21 August 2008. It is

classified as Indian Non-Government Company and is registered at Registrar of Companies,

Chhattisgarh. Shri Tulsi phosphate has a unit at Birkoni Industrial Area, Birkoni Village,

Mahasamund District, Chhattisgarh State

Shri Tulsi Phosphate is in the field of Manufacturing pesticides and other Agro-inputs and barbed

wire. The existing capacity of Birkoni unit is to produce following:

MT/year

(a) Zinc EDTA as Micronutrients 5000.0

(b) Zinc Sulphate as Micronutrients 5000.0

(c) Mixture of Micronutrients 5000.0

(d) Formulation of Pesticide 5000.0

(e) Barbed wire 3000.0

Shri Tulsi Phosphate proposed to expansion of their unit to meet the growing demand of fertilizer

in domestic market by installing new units of SSP/TSP in the existing premises. Proposed

capacity of SSP/TSP shall be 100,000.00 TPA. The cost of the project is INR 17.5Crores.

2.0. DEMAND AND SUPPLY

The production and consumption of the SSP in the last decade is as follows:-

Table 1: All India production & consumption of SSP

Year Production / MT Consumption /MT

2001-02 2504.60 2590,90

2002-03 2407.78 2390.40

2003-04 2543.40 2449.00

2004-05 2469.10 2472.30

2005-06 2795.20 2705.00

2006-07 2972.00 2928.60

2007-08 2246.30 2244.00

2008-09 2533.60 2614.70

Source: Fertilizer statistics 08-09 of FAI, New Delhi.

3.0. NEED OF THE PROJECT

Super Phosphate (SSP) Fertilizer industry is the pioneering fertilizer in the country and

the first SSP plant is said to have been established by EID Parry in the year 1906.

Manufacturing of SSP is based on perhaps the simplest chemical reaction amongst

chemical fertilizer industry. The main raw materials required are rock phosphate and

sulphuric acid. SSP is a straight Phosphatic multi-nutrient fertilizer which contain 16%

citrate soluble P2O5, 12% Sulphur, 21% calcium and some other essential micro

nutrients in small proportions. SSP is a poor farmer's fertilizer (price-wise), is an option

to optimize the use of phosphatic fertilizer. It also helps to treat Sulphur deficiency in soil

(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,

sugarcanes, fruits and vegetables, tea etc. SSP is an essential fertilizer.

S.S.P. is cheapest among phosphoric fertilizer and essential for cultivation of Sugarcane,

Pulses, Oil seeds, Fruits and vegetables etc. The DOF has indicated that 40% of Indian

soil is deficient of Sulphur, which needs use of SSP. Triple Super Phosphate (TSP) which

is a concentrated form of Single Super Phosphate can also be manufactured in the

existing SSP plant. S.S.P. industries are widespread throughout India, rather-than limited

to any specific location. Presently there are 62 SSP units under the concession scheme as

on 31.3.2009 on the basis of assessment made by PDIL.

Points for need for proposed expansion:

SSP consumption has remained static during last decade.

Chhattisgarh, Maharashtra and Madhya Pradesh accounts for 45% of SSP

consumption in India, which is major marketing zone for unit based in

Chhattisgarh.

It will also enhance the industrial development of the region and provide direct or

indirect employment opportunities to skilled/unskilled manpower. Thus the

proposed project of will certainly contribute towards the economical development

of the country.

4.0. EMPLOYMENT GENERATION

There were upliftments of socio-economic standard of local people surrounding the

project site due to proposed project. During the construction phase work will be

generated for skilled, semiskilled and unskilled labors. Technical persons will be

recruited during the operation phase. It is expected to direct or indirect employ about 90 –

100 people of various skills will be required during construction as well as operation

phase.

5.0. PROJECT DESCRIPTION

The proposed unit is located in premises of existing plant. The plant is located in CSIDC

area of Birkoni industrial area, which has been marked, notified for the industrial

activities. The Google location map of the plant is shown in Figure 1. The layout map of

plant is annexed as Annexure I.

Figure 1: Location map of project location on Google Earth

The total plot area is 4.26 ha. The Environmental settings and infrastructures available

surrounding the proposed project are as follows:

Table 2: Environmental settings and infrastructures available

Env. Settings &

Infrastructure Name & Arial Distance

Town/City Mahasamund city: 14.55 km

Forest There is no forest with in 10 kms radius of proposed

project site, as it is within CSIDC Birkoni industrial

area.

River Mahanadi River – 3.0 km Village Khattidih Village: 1.50 km

Ghodadi Village: 3.10 km

Barbaspur Village: 3.50 km

Kanpa Village: 3.60 km Railway station and

Airport Railway Station:

Belsonda– 02.50 km

Mahasamund–12.50 km

Airport:

Env. Settings &

Infrastructure Name & Arial Distance

Swami Vivekananda Airport Raipur – 40.00 km

National Highway NH – 6 (adjacent to the plant)

6.0. PRODUCT AND RAW MATERIAL

Capacity of the existing and proposed plants along with raw material requirements is as

follows:

Existing Products and Raw Material

Product Capacity:

MT/year

(a) Zinc EDTA as Micronutrients 5000.0

(b) Zinc Sulphate as Micronutrients 5000.0

(c) Mixture of Micronutrients 5000.0

(d) Formulation of Pesticide 5000.0

(e) Barbed wire 3000.0

Raw Material:

S.No. COMMON NAME Quantity

in kg/5.0 MT of Water

1 2,4-DB acid (2,4) 2.0

2 2,4-DB butoxyethyl ester (4) 5.0

3 Arsenic acid (4) 2.0

4 Azinphos-methyl 2.0

5 Barban (2) 2.0

6 Bromoxynil butyrate ester (4) 2.0

7 Bromoxynil octanoate ester (4) 3.0

8 Butachlor (2) 3.0

9 Butylate 1.0

10 Captafol (2) 2.0

11 Captan 2.0

12 Carbaryl 2.0

13 Carbon disulfide (2) 4.0

14 Carbophenothion (2) 2.0

15 Carboxin 2.0

16 Chlordane (2) 2.0

17 DCNA 1.0

18 DCPA dacthal parent (5) 2.0

19 Oxamyl 2.0

20 Phorate 2.0

21 Resmethrin (2) 2.0

S.No. COMMON NAME Quantity

in kg/5.0 MT of Water

22 Rotenone (2) 2.0

23 Sethoxydim 2.0

24 Streptomycin sulfate (8) 2.0

25 Sulprofos 2.0

26 Temephos 2.0

27 Triclopyr ester (4,9) 2.0

28 Tricyclazole (2,4) 2.0

29 Tridiphane 2.0

30 Trifluralin 2.0

31 Trimethacarb 2.0

Proposed Product and Raw Material

Product Capacity:

Single Super Phosphate (SSP) / Triple Super Phosphate (TSP): 100,000.00 TPA

Raw Material:

S.No. Raw Material PROPOSED

(MT/PA) Source

1 Sulphur 15,000 Domestic

Market/Import

from Foreign

Countries

2 Rock Phosphate 90,000

3 Sulphuric Acid (Con. 98%) 75,000

4 Phsopharic Acid P2O5 100% basis) 10,000

7.0. MANUFACTURING PROCESS

Single Super Phosphate

Single Super Phosphate (SSP) manufacturing is a simple process. By digesting the Rock

Phosphate with Sulphuric Acid it is produced. During the reaction the insoluble

Phosphates are converted into water soluble phosphates thus when SSP is applied in field

the Phosphates are readily available in the soil and absorbed by plants for its growth.

Raw material consumption (PMT of SSP)

A) Rock Phosphate - 560 Kg.

B) Sulphuric Acid (Conc. 98%) - 360 Kg.

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 recycled Flouro

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.

As a result of reaction, fluorine containing gas is generated and by using a scrubber

blower continuously the gases are sucked in closed circuit and sent to gas Scrubbing

Section. The produced Single Super Phosphate (SSP) in a semi solid mass is conveyed

through a moving reactor called Den and solidify. SSP it is cut by a revolving cutter to a

powdery mass and conveyed to the product yard for curing. Product is packed in 50 Kg.

bags.

Specification of SSP: As per FCO (Fertilizer Control Order) Ministry of Agriculture,

Government of India has amended specifications of Single Super Phosphate (Powder) /

G.S.S.P. effective from 10.05.2011.

1 Moisture, percent by weight, maximum 12

2 Free Phosphoric acid (As P2O5), percent by weight maximum 4

3

Water soluble phosphates (As P2O5) percent by weight

minimum 14.5

4 Citrate soluble phosphates (As P2O5) % by wt minimum 16

5 Sulphur (As S), percent by weight, minimum 11

Advantages of SSP Fertilizer:

Provides 15% of total phosphate requirement of the country.

Lowest price fertilizer preferred by small and marginal farmers.

Multi-nutrient fertilizer containing P2O5 as primary nutrient and Sulphur and Calcium as

secondary nutrients.

It is the cheapest source of Sulphur for the soil.

Only phosphatic fertilizer which can utilize Indian rock phosphate deposits.

Least foreign exchange per unit of P205

Utilize acid, effluent from

Process flow diagram of SSP is given below as Figure 2.

Figure 2: Manufacturing Process Flow diagram for SSP

Triple Super Phosphate (TSP)

Triple Super Phosphate is manufactured by digesting rock phosphate with phosphoric

acid. Manufacturing process of TSP is same as of Single Super Phosphate (SSP) except

Phosphoric acid used for TSP in place of Sulphuric Acid used for SSP. TSP is considered

as the concentrated form of Single Super Phosphate.

Raw Material consumption (PMT of TSP):

A) Rock Phosphate 460 Kgs

B) Phosphoric Acid (P2O5 100%) 360 Kgs.

Chemical Reaction:

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.

Specification of Triple Super Phosphate (TSP):

1 Moisture, percent by weight, maximum 12

2 Free Phosphoric acid (As P2O5), percent by weight maximum 3

3

Water soluble phosphates (As P2O5) percent by weight

minimum 42.5

4 Total phosphates (As P2O5) % by wt minimum 46

Process flow diagram for manufacturing of Triple Super Phosphate is attached as Figure 3.

Figure 3: Flow diagram for manufacturing of Triple Single Super Phosphate

8.0. RESOURCE REQUIREMENT

Water

The water requirement the proposed plant is mainly for the essential purpose of equipment

cooling as well as for drinking, sanitary and fire fighting purposes. The water requirement is as

follows:

Construction Phase: 15.0 kLD

Operation Phase: 30.0 kLD

Water Consumption

Activities

Water Requirement

(KLD)

Processing and Washing 20

Domestic (drinking

water, kitchen,

gardening etc)

10

Total 30

The water requirement will be met through CSIDC water supply pipeline.

Power / Energy and Fuel

Power requirement of proposed project will be made available through Chhattisgarh State

Electricity Board (CSEB) and Capacitive Power Plant (for emergency requirement) within the

premises.

Construction Phase: 2000 kW

Operation phase: 4000 kW

The fuel requirement is 2.0 kLD Furnace Oil from IOC for equivalent wood / biomass from local

sources.

9.0. WASTE WATER GENERATION AND UTILIZATION

Water Consumption

Activities

Proposed Waste

Water

Generation

(KLD)

End Use

Domestic 8.0 Septic tank followed by soak pit

Processing and Washing 5.0 Treated effluent shall be used

for watering for green belt in

Water Consumption

Activities

Proposed Waste

Water

Generation

(KLD)

End Use

the existing plant premises

Sewage sludge 1.0 It will used as biofertilizer for

plantation and gardening.

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

SSP/TSP plant is diverted to final effluent treatment plant for neutralization, etc. Effluent

generated from floor washings etc shall be utilized for irrigation purpose inside the factory

premises. All the effluent water from cooling towers bleed, boiler blowdown etc shall be recycled

and utilized fully in the SSP / TSP Plants for processing. No water from factory premises shall be

discharged outside factory premises hence it will be a ZERO effluent discharge unit.

10.0. AIR EMISSION

The stack heights of DG sets and process stack are provided as per the guidelines of CPCB for

effective stack heights. The gases generated from the mixing section will be scrubbed in ventury

scrubbers (in series) and after scrubbing the flue gas will be ventied through chimney. The scrub-

liquor formed during the process of scrubbing will be used for dilution of sulphuric acid or

Phosphoric acid and recycled back to process.

11.0. NOISE POLLUTION

Noise is anticipated from motors, compressors and DG set. The DG shall be kept in a separate

enclosed room with acoustic enclosure. The motors and compressors shall be provided with

guards and shall be mounted adequately to ensure the reduction of noise and vibration. The

employees working in noise generating areas shall be provided with earplugs. The employees

shall be trained in the mitigation measures and personal protection measures to be taken to avoid

noise related health impacts.

12.0. SOLID WASTE GENERATION AND DISPOSAL

No Solid wastes are generated from the process. Waste oil from DG sets; used batteries from DG

sets are generated. The hazardous wastes of waste oil and used batteries shall be sent to authorize

recyclers.

13.0. PURPOSE OF EIA STUDY

The applicability of the SO 1533 for the proposed project was explored by considering different

possibilities & provision made in the said notification. Schedule I of the SO 1533 was referred &

categories covered under the schedule I are examined for applicability of the notification.

Considering the products & project location of the proposed project it is noticed that the proposed

project falls under Category 5 (a) “A” of the Schedule-I of EIA Notification SO 1533. As per the

provision of the SO 1533, it is necessary to get Environmental Clearance by applying to DoEF

along with the Rapid Environmental Impacts Assessment Study Report for the proposed

expansion project prior to commissioning of the project activities. Therefore the EIA is required

to conduct to comply with provisions of SO 1533 made for Category 5(a) “A” of schedule –I of

the notification.

Annexure I: Plant Layout Map