INTRODUCTION TO NPK/MIX FERTILIZER PLANT

NPK mixture fertilizers are formulated & recommended by agricultural scientists to enhance the output of the crops by giving it balanced Specific and exclusive blend of plant nutrients. All the major plant nutrients like Nitrogen, Phosphorus and Potash are mixed in different ratios to make it suitable for specific crops. These specific ratios of N P K & S are called grades So there are separate grades for Rice, Wheat, Potato and Sugarcane etc. NPK Complex Fertilizers are in the form of uniform granules from 1 to 4 mm size. They are white, cream, brown, gray or black in colour. There are many NP&K grades produced and marketed like 20:20:10, 10:10:10, 15:15:7.5, 17-17-17, 12-32-16 and 14-35-14.etc. The grades name is a triad whose numbers represent the percentage of N, P2O5 and K2O respectively in the mixture. In India all the state governments have specified the formulations to be manufactured in their territories. It depends upon the major crops grown there. Some of the grades for various crops are given below :

S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CROP PADDY PADDY PADDY PADDY TOP DRESSING SUGAR CANE SUGAR CANE SUGARCANE SPECIAL VEGITABLE VEGITABLE CUCURBITS VEGITABLE POTATO/ COCONUT TEA TEA CHILLIES INDIAN TOBACCO

N 8 10 16 20 12 14 20 15 15

P2O5 8 20 8 0 6 6 10 15 10

K2O 8 20 8 11 6 4 10 15 10

10 10 10 12 5

10 5 5 6 15

20 10 15 6 15

16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32

TOBACCO VIRGINA FCV TOBACCO GROUND NUT GRAPE PEPPER /COCOA PULSES CARDAMOM COFFEE COCONUT RUBBER RUBBER RUBBER RUBBER ROSE COTTON FRUITS

4 6 4 7 10 5 8 12 10 10 12 12 10 5 14 12

12 8 12 10 4 15 8 9 5 10 12 12 10 10 7 6

8 12 12 5 14 5 16 12 20 4 6 12 10 10 0 6

RAW MATERIALS & THEIR SOURCES

Required raw materials for making NPK mixture fertilizer:

: Urea, Di Ammonium Phosphate, Ammonium Chloride, Ammonium Nitrate, Ammonium Sulphate, Mono Ammonium Phosphate Etc.

Phosphorous as P2O5 : Single Super Phosphate , Triple Super Phosphate, D. A. P. etc.. Potash as K2O :Potassium Chloride, Potassium Sulphate etc.

Soil Conditioners & fillers : Gypsum, Sand and Dolomite etc. Coating Agents: Soap stone and clay etc.

Bagging Material : HDPE bags

PROCESS OF MANUFACTURING :

The calculated and measured quantities of the above mentioned raw materials is mixed properly in a mixer. The homogeneous mass is then processed in the granulator drum.. The granulator drum rotates at very low RPM. The material goes up with the wall of granulator for some height and then starts rolling back. A fine spray of water at this stage starts the process of granulation and as the material rolls on, the size of the granules increases. This material is transferred to the dryer drum with the help of a conveyor belt. The Furnace attached to the dryer generates hot air which is made to pass through this wet material. The ingredients with low melting points melt and forms liquid. The liquid gets deposited on the small granules and further enhance the size of the granules. With the hot air stream the material gets dried. The material is then passed through the cooler drum for cooling. The cooled material is transferred to the screens to remove the oversize & undersize granules from the product. The oversize granules after crushing & under size granule are mixed with the raw feed for reprocessing. The product is packed in 50 Kg bags.

PROPERTIES OF NPK FERTILIZERS :

Nature

Free flowing granules Slightly Hygroscopic

Colour Bulk density.( Kg per M3 ) Angle of repose Critical relative humidity at 27 o C. percent

:Off white, Grey & black 865 30-32 60 65%

HANDLING, STORAGE AND PACKING:

Granulated NPK Mixture fertilizers are free flowing and do not normally pose any problem during handling and storage. Coating agent are used to make them resistant to caking. However, exposure for longer period in regions of high humidity can cause caking. NPK complex fertilizers are, therefore, packed in PVC lined HDPE bags to prevent any possible seepage of moisture from the atmosphere which tend to promote caking.

PARTICLE SIZE :

90% of the product should be between 1 and 4 mm size. And there should be not more than 5% fines (below 1.0 mm )
ENVIRONMENTAL ASPECTS

The dust emission are generally low in NPK plants due to adequate practices, such as use of high efficiency dust collectors scrubbers and good house keeping etc.

Dust control equipments are provided to keep the pollution level below 150 mg /NM 3 in the factory building. Efficient pollution control equipments of the NPK plants are offered by us to maintain a very low dust emission level and to have a good control over the environmental aspects. Covered storage shed are made for Raw Materials. Constant house cleaning efforts are applied to maintain a clean plant.

Pollution Control in NPKS Plant

We, at Megatech International, take extreme care to make our plant environment friendly. We design two parallel system to control pollution from the plant and second for controlling fumes and dust emission in the plant. There are two processes which may create pollution :
1.

The drying system contains furnace where F.O. is burnt. The emission of flue gases and dust may take place..

The cooling system where the hot dried material is cooled by blowing ambient air through this material also create dusting. To take care of these two target systems a set of cyclonic separator with Induced draught Fan is fitted with Dryer system and another with cooling system. These pollution control system induce the draught in the dryer Drum, Furnace and cooler Drum and draws all dust and fumes in cyclones where most of the dust is separated. Then both of the streams are jointly taken to a wet scrubber. This is a three stage scrubber and the water is sprayed on this stream. The fine dust particle become wet and retained with water. So, only dust free stream is allowed to be discharged through a chimney at 15 meter height from the ground.
2.

The efficiency of the system is above 90 %. To control the ambient air quality in the plant another system is designed and supplied. The equipments which emits dust during operation are provided with another dust control system. A cyclonic separator with Induced Draught Fan sucks the dusted air from these machines. The cyclonic separator separate most of the dust particles. This stream is also taken to the wet scrubber where it is washed out of dusting. So, The ambient air is of good quality. The dust separated in the cyclone is recycled and mixed with the raw material The fine dust make mud in the scrubber. It is reused after drying.

These two systems make the plant environment friendly.

SPECIALITY OF OUR PROJECT

1. State of art, tried, tested, fuel efficient technology. 2. Our plants are performing above par in 17 countries worldwide. 3. We export the project in agreed time. 4. We erect and commission the plant in time with tools and tackles supplied by us. 5. We supply workshop with the plant so do not need local market support. 6. Spares supplied by us or fabricated in the plant. So, no dependence on local Market for spares also. 7. We send core technicians to erect, take trials, commissioning of the plant. 8. We run the plant for one month in our supervision after erection and commissioning. We run the plant for more time if the client desires and pays for the staff. 9. We train the manpower for running and maintenance of the plant and hand over the running plant to the trained technicians. 10. We help our clients to adopt to the local conditions and market. 11.We provide technical support to our clients after handing over.

FLOW DIAGRAM-NPK SSP GRANULATION PLANT

COOLER DRUM FOR NPK

NPK PLANT

Our Clients location

We have supplied cement and fertilizer plants in various countries

Rwanda Bangladesh Sudan Port of Sudan Mozambique Iran Azerbaijan Madagascar Uganda Ghana Tanzania

CONTACT US :Megatech International Private Limited

Mr. Praveen Sharma : +(91)-9772214144 Mr. Rajneesh Raghuyal : +(91)-9811019495 Mr. Puneet Sharma : +(91)-8875199482 Address : G-1,1428, RIICO Industrial Estate, Phase V, Bhiwadi Alwar, Rajasthan-301019 India Phone No : +(91)-(1493)-512430 Fax No : +(91)-(120)-245803 E-mail : megatech2003@yahoo.com, megatech2003@gmail.com pks@megatech2003.com