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By
BEC Fertilizer
(Unit of Bhilai Engineering Corporation Ltd)
At
Plot No. 96
Sector A, Sirgitti, CSIDC Industrial Estate
Bilaspur (Chhattisgarh)
Description
Page
no.
1.0
EXECUTIVE SUMMARY
2.0
2.1
Project Proponent
2.2
2.3
Employment Generation
3.0
Project description
3.1
3.2
Manufacturing Process
3.2.1
3.2.2
3.2.2(A)
11
3.2.3
12
3.2.4
13
3.2.5
13
3.3
14
3.4
15
3.5
Air Emission
16
3.6
16
3.7
17
4.0
Site Analysis
17
4.1
Connectivity
17
4.2
17
4.3
Infrastructure
18
5.0
Planning brief
18
6.0
18
7.0
19
8.0
19
9.0
Analysis of project
19
LIST OF FIGURES
Sr. No.
Description of Figure
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
1.0
EXECUTIVE SUMMARY
Description
Quantity
Project Location
5(a) A
Project cost
75.00 Crores
Plot area
Raw Material
Resources
(i)
Electricity Requirement
(ii)
D. G. Sets
T.G. Set
Water consumption
Source of water
CSIDC SirgittiBilaspur.
Mode of disposal
(ii)
Fuel
2.0
Since 1985 BECF is in the field of Manufacturing fertilizers and other Agro-inputs.
We already have two units to manufacture Single Super Phosphate (SSP) at Bilaspur
(CG) and Pulgaon (Dist. Wardha, Maharastra) of production capacity 140000 TPA
and 66000 TPA respectively.
The existing capacity of Bilaspur unit is to produce following:
01. Sulphuric Acid
02. Single Super Phosphate
03. Granulated NPK Fertilizer
40,000 TPA
1,40,000 TPA
45,000 TPA
BECF proposes to expand the capacity of Bilaspur unit by installing new plants in
the existing premises. Proposed capacity shall be:
01.
02.
03.
2.1
Sulphuric Acid
Single/ Triple/ Boronated Super Phosphate
Granulated Fertilizer
(SSP/TSP / NPK /CustomizedFertilizer)
1,40,000 TPA
4,40,000 TPA
4,40,000 TPA
Project Proponent
M/s. BEC Fertilizers (BECF) a unit of Bhilai Engineering Corporation Ltd. BEC Ltd.
has five units located in Raipur and Bhilai cities of the Chhattisgarh State, India.
There are 5 Regional offices in New Delhi, Mumbai, Kolkata, Chennai and Bangalore
to facilitate and support various projects and develop corporate relations. BEC is the
most successful Engineering, Procurement and Construction (EPC) Company
including Heavy Equipment supplier in India. It undertakes complete project
implementation including Mechanical, Structural, Electrical and Civil jobs. BEC Ltd.
has group companies namely Vishva Vishal Engineering Limited, BEC Food and BEC
Fertilizers.
Fertilizers and Agro Chemicals Industry in India is keys to the Agriculture sector.
BEC Fertilizers include a modern technology Fertilizers manufacturing complex at
Bilaspur C.G., and the second fertilizer unit at Pulgaon, Maharashtra State to
manufacture "ANAND" Single Super Phosphate and NPK Fertilizers.
The proposed project will be started after receiving statutory clearances from
authority. Production Capacity, raw material and proposed product is discussed in
para 3.0 of the report.
2.2
Demand Supply
The production and consumption of the SSP in the last decade is as follows: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
Chhatisgarh
158850 MT
Maharashtra
587520 MT
Madhya Pradesh
513580 MT
Total
2.3
1259950 MT
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.
Employment Generation
PROJECT DESCRIPTION
M/s. BEC Fertilizers (BECF) proposes to expand unit at Sirgitti CSIDC Industrial
Estate, Sirgitti, Bilaspur (CG) is notified industrial estate. Location map of Sirgitti
CSIDC Industrial Estate is attached as Figure 1. Plant layout of existing and
proposed fertilizer project is attached as Figure 2.
Total plot area is 47.66 Acres. Existing plant is located in about 12 Acres area so
sufficient land is available for expansion of the unit. Environmental settings and
infrastructures available surrounding the proposed project is as under,
Env. Settings
& Infrastructure
Town/City
Bilaspur 10 Kms
Forest
There
is
no
forest
with
in
10
kms.
radius
Village
Sirgitti
Railway station
Bilaspur - 05 Kms.
National Highway
NH 200 (5Kms.)
3.1
Capacity of the existing and proposed plants along with raw material requirements is
as follows:
A)
Products
SN
PRODUCT / PLANT
EXISTING CAP
(MT PA)
PROPOSED CAP
(MT PA MAX
01
Sulphuric Acid
40,000
1,40,000
2 A
1,40,000
4,40,000
1,00,000
40,000
Granulated Fertilizer
45,000 (NPK)
4,40,000
03
REMARKS
B)
SN
RAW MATERIALS
EXISTING
(MT/PA)
PROPOSED
(MT/PA)
01
Sulphur
13,500
47,000
02
Rock Phosphate
78,000
2,46.000
03
50,000
1,58,000
04
36,000
iii.
iv.
3.2
3.2.1
Sulphur is the basic raw material for the production of Sulphuric Acid. Sulphuric
acid produced in the plant shall be utilized for manufacturing Single Super
Phosphate Fertilizer.
Raw material consumption
Sulphur - 335 Kg PMT of Sulphuric Acid.
The major steps involved in the process are as follows:
01.
02.
03.
04.
05.
S+O2 = SO3
SO2 + O2 = SO3
SO3 + H2O = H2SO4
Manufacturing Process
Sulphur used as raw material is in solid form, which is first converted into
liquid form using steam. It is purified in the settling pit before sending to
furnace for combustion. In the Furnace,Sulphur burns with air to form
Sulphur Dioxide. As the process is Exothermic so temperature of the gases
in the furnace rises to above 1000C.
Hot gases from the furnace are cooled in the waste heat boiler (01) to
produce steam. Gases after cooling are filtered and sent to convertor. In the
convertor SO2 gets converted into SO3 in presence of catalyst (Vanadium
Pentoxide).SO3 gasesafter third pass, are further sent to intermediate
absorption tower where SO3 gases are absorbed in directly with water to
form Sulphuric Acid. Unconverted gases are again sent to fourth pass of
the convertor to convert remaining gases to SO3. SO3 is again absorption
in the final absorption tower to form Sulphuric Acid. Finally gases from
absorption tower are let-out to atmosphere through stack.
Sulphuric acid produced is further cooled in the cooler before being sent to
Acid storage tanks.
Alkali Scrubber
SO2 in the stack gases are maintained as per the norms prescribed.
During plant start-up SO2 in the exit gases may rise above norms, so it is
treated in the Alkali scrubber with caustic solution to form Sodium
Sulphide. And clean gases are let-out to atmosphere through Chimney.
Reaction
2NaOH + SO2 = Na2SO3 + H2O
Process flow diagram for manufacturing of Sulphuric Acid is attached as
Fig.3
Specifications of SulphuricAcid - Technical Grade (IS 266:1993)
1
98%
Residue on ignition.
0.2%
0.05%
0.005%
0.004%
Power Generation
Steam is generated in the boiler with the waste heat of the system. Part of the steam
is utilized in the process but major part (About 85%) after super heating is utilized to
generate power using condensing Turbo Generator set (Capacity-2500 KVA)
All the power requirement of the Acid Plant shall be fully met through captive power
generation. Surplus power available shall be utilized to meet the part requirement of
Fertilizer Plant.
3.2.2
- 360 Kg.
10
Manufacturing process
Rock Phosphate is ground to fine powder (90% of 100mesh) in a Milling section and it
is conveyed through Screw Conveyor and Bucket Elevator to the Mixer where
reactions take place. ParallelySulphuric. Acid, water and recycledFlouro Silicic Acid
liquer are also added in the mixer in a pre-determined ratio. The Rock Phosphate,
Acid and dilution liquor react together in the Mixer (Reactor) to produce single Super
Phosphate.
01.
Chemical reaction
Reaction - I
CaF2.3[Ca3{Po4}3] + 7H2SO4 + 3H2O
Rock Phosphate
Sulphuric Acid
SiO2.H2O + 2H2SiF6
Silica
Sod.Silico-fluoride
12.0
4.00
14.50
16.00
11.00
11
1.
2.
3.
4.
5.
6.
7.
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 other chemical industry and thus reduce nation's
cost of effluent disposal.
3.2.2(A)
Boronated Single Super Phosphate (BSSP)
Manufacturing process of BSSP is same as that of SSP. It shall also be manufactured
in the existing SSP plant. Rock Phosphate and Sulphuric are the main raw material
for manufacturing SSP. For BSSP Sodium Borate Penta hydrate (Na2B4O7.5H2O) is
added extra as per the requirement along with water in the Mixer. The remaining
process is same.
Boron is a micronutrient, which is also necessary for the growth of plants to increase
the yield. As per FCO (Fertilizer Control Order), the Boron contained in the BSSP
should be 0.15% to 0.20%. Above 10 Kg/MT of Sodium Borate is added to get desired
Boron in the product. BECF shall manufacture Boronated SSP also in the existing
SSP plant.
Specifications of BSSP (Powder) as per FCO
I
II
III
IV
12.0
4.0
16.0
0.15 to 0.20
Chemical reaction
460 Kgs
360 Kgs.
12
Reaction - I
CaF2.3[Ca3{Po4}3] + 14H3PO4 + 3H2O
Rock Phosphate
Phosphoric Acid Acid
10CaH4(PO4)2
+ 2HF
Triple Supher Phosphate
Reaction - II
4HF + 3SiO2 + H2O
SiO2.H2O + 2H2SiF6
Silica
Sod.Silico-fluoride
Air emission
Rock Phosphate contains Silica and Fluorine as impurities, which contributes to the
gas emission in the process. Rock Phosphate consumption for manufacturing TSP is
only 460 Kgs PMT compared to 560 Kgs PMT for SSP, which is lower by 18%.
Consequently gas emission in this TSP manufacturing will get reduced by 18%
compared to SSP production. The flow diagram of scrubbing system is as per Fig. 7.
Specification of Triple Super Phosphate (TSP)
1
12.0
3.00
42.50
46.00
13
To produce granulated SSP, only SSP Powder will be the raw material. For NPK
Mixture manufacture Urea, DAP, SSP, MOP, etc are the raw materials. For
Customized Fertilizers, in addition to the above, micro nutrients viz, Boron, Zinc &
the other cation minerals in very small quantities will be added in the granulation
process.
Process flow diagram of SSP/TSP/NPK/Customized Fert.is attached as Figure 5.
Specification of GSSP:
1
5.0
14.50
16.00
11.00
Particle size
4.00
Not less than 90 % of the material shall pass through 4 mm IS sieve and
shall be retained on 1 mm IS sieve. Not more than 5 % shall pass
through 1 mm IS sieve.
3.2.5
The gaseous effluent generated in the Single Super Phosphate plant is absorbed in
the scrubber section using water to convert into Hydro FluoroSilicio Acid. This acid is
pumped out from the settling tank of the venturi and received at Sodium Silico
Fluoride Plant.
The production facilities are installed in most of the SSP plants mainly to convert the
liquid effluent (H2SiF6) in to a salable by-product. Hence it is primarily a pollution
control process to treat the liquid effluent.
Here the acidic fluoric acid is reacted with Soda Ash solution to neutralize it to
generate Sodium Silico Fluoride crystals and neutral water.
```
FluoroSilicio Acid is received in a rubber lined Mild Steel reactor. This reactor is
calibrated one and fitted with an agitator. In a row two such reactors are installed.
While one is under reaction process the other is made ready for next batch.
Separately in a Soda Ash solution preparation tank Soda Ash is dissolved in fresh
water and the concentration is analyzed. Metered quantity of soda ash solution is
slowly added into the reactor while the liquor is under agitation. The acid is
neutralized by the alkaline soda solution and sodium silico fluoride crystals separate
from the solution. The pH of the reaction mass is checked and when pH reach 7 soda
addition is stopped. After thorough agitation the solution is allowed to settle. The
14
clear top solution (water) is decanted and the settled mass is taken to a centrifuge to
separate water from the SSF crystal.
The wet mass is dried in a tray dryer and finally packed in 50 kg bag after quality
analysis and approval. The collected water from centrifuge and reactors is stored and
used in SSP plant for dilution of H2SO4.
Process flow diagram of Sodium Silico Fluoride is attached as Figure 6.
Specification of Sodium Silico Fluoride:
1
Technical Grade
Purity (On
percent
1.00
1.00
3.3
dry
Min.
98.00
Water
Water requirement after proposed expansion of the project for domestic and
industrial activity during operation phase will be 1550 KLD. The water requirement
will be met through CSIDC water supply pipeline.
Water Consumption Activities
Domestic
Processing
Washing + Floor Cleaning
Total
Power / Energy
Existing water
Consumption
Proposed water
Consumption
(M3/day)
(M3/day)
10
20
320
1500
20
30
350
1550
15
Fuel
Coal Existing 5.0MT/Day Proposed 30 MT/Day for Granulation plant.
3.4 Waste Water Generation and utilization
Water Consumption
Activities
Existing
Waste Water
Generation
Proposed Waste
Water
Generation
(M3/day)
(M3/day)
Domestic
10
20
Soaked
Processing
20
70
10
30
40
120
Total
End Use
Do -
To treat the sewage generated due to domestic activities will be disposed through
septic tank following by soak pit.
Floor washing, spillages and oil & grease etc from plants need to be treated. These
floor washing and spillages are collected and taken through an exclusive pipe line to
the final effluent treatment section for treatment. Similarly floor washing liquid
effluent from SSF plant is diverted to final effluent treatment plant for neutralization,
etc. Total effluent generated in the project is 120 M3/D. It shall be utilized for
irrigation purpose inside the factory premises.
All the effluent water from cooling towers bleed, boiler blowdown and RO plant of
Sulphuric Acid plant shall be recycled and utilized fully in the SSP / TSP Plants for
processing.
The granulation plant does not generate any effluent as it is a dry mixing process.
No water from factory premises shall be discharged outside factory premises hence it
will be a ZERO effluent discharge unit.
Schematic flow diagram of ETP is attached as Figure 8.
3.5
Air Emission
Sr.
Stack Attached
to
No.
1
Diameter
Air Pollution
Control system
Expected
pollutants
15 meter
600 mm
Twin Cyclone
(m)
Height from
ground (m)
Process Stack
(A)
30 meter
1000 mm
Cyclone
separator
Multi stage scrubber
system with venturi
and spraying towers
SPM, Fluorine
(B)
30 meter
1000 mm
Alkali
scrubber,
demister and miseliminators
16
3.6
During manufacturing process of Sulphuric Acid, SSP, TSP fertilizer and granulation
of SSP/TSP fertilizers, following solid / hazardous will be generated, which will be
disposed as detailed below on the basis of guidelines provided by Chhattisgarh
Environment Conservation Board (CECB)
Sr.
No.
Name of waste
Quantity
Category of Waste
(Schedule - I)
Mode of disposal
E.T.P. Sludge
1 MT/PM
34.3
Used oil
3000 Liters
/PA
5.1
Empty
Containers
50Nos/PA
33.3
Sulphur sludge
40 MT/PM
Catalyst (V2O5)
3000 Ltrs/PA
3.7
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.
4.0 SITE ANALYSIS
4.1
Connectivity
CSIDC Sirgitti Industrial area, Bilaspur is notified industrial estate and well
connected with road, rail and air route. Details about the connectivity with proposed
project site is shown in below table.
Sr.
No.
Description of Connectivity
Distance in Kms.
17
4.2
Sirgitti is located 10 Kms from west of Arpa river. Terrain of land is plain flat.
Proposed project site is in notified industrial area, thus land use pattern of project
site is non- agricultural and used only for industrial activities. The economy of Sirgitti
is dependent on agriculture.
No other forests, national park or wild life sanctuary located within 10 kms
periphery of the proposed project site. No change in land use as the proposed
expansion project shall be established in CSIDC Sirgitti industrial area. Topography
map of Bilaspur District is attached in Fig 9
4.3
Infrastructure
5.0
Description
Available
within
around the project
Marine Sanctuary
No
Stream / Rivers
Airports
Railway station
Bus Station
Yes
National Highways
Bank
Yes
Social Infrastructure
Primary / High School
Yes
Religious Place
Yes
10
km
PLANNING BRIEF
Proposed plant expansion activities will be started after getting statutory clearance
form related authorities. The project will be completed within two years.
Further proposed project activities will take care of all the rules and regulation of
statutory authority and provide the control measure and devices to achieve the
standard norms.
6.0
Sr.
No.
EXISTING/PROPOSED INFRASTRUCTURE
Infrastructure
Description
47.66Acres (Existing)
Green belt
Social Infrastructure
Connectivity
18
Sr.
No.
Infrastructure
Description
10
Power
source
requirement
&
Supply
Existing infrastructure
BEC Fertilizer, Bilaspur is a running unit since 1985. It has created all necessary
infrastructures for the operation of the unit. It is planning to carry out expansion of
the unit by installation of new plants in the existing premises.
The total plot area is 47.66 acres. Existing plant is installed in the area of about
12Acres. Additional area required for expansion is about 12 Acres. Remaining area
available shall be utilized for future expansion. Presently surplus land is being
utilized by plantation of various types of trees. Treated effluent of plant is being used
for irrigation.
All the existing facilities e.g. administrative building, raw material / finished goods
storage, raw water storage, roads / drains, weighbridge. Canteen, workshop, DG sets,
Laboratories etc. shall be utilized during installation and operation of the new plant.
During construction of plant, essential requirements of power, water, skilled &
unskilled manpower and other services will also be available. Apart from that,
communication and transportation will also be made available.
It will help in smooth and timely execution of the project.
7.0
Proposed project activities will be started after getting statutory clearance form
related authorities. The project will be completed within two years.
8.1
Particulate
Estimate cost
(in Crores)
Existing 22.00
Proposed 97.00
19
3
9.0
ANALYSIS OF PROPOSAL
We have analyzed our proposal and found following financial & social benefits to the
local people in the project area.
01. Employment to approx. 100 - 150 local people is direct benefit to local people.
02. Farmers will get benefit of procuring locally made, high quality fertilizer.
03. Govt. will get revenue.