Purchase Department

Raw Material Purchased

Raw Material Phosphoric Acid Ammonia Murat Potash Naphtha Sulphuric Acid Import Destination Morocco Qatar Baltic Croatia Israel Bombay Lead time 17 days 7 days 30 days As per the requirement

Production Department
As Agriculture is the backbone our country the fertiliser manufactured in India is not enough meet the needs of the farmers even though India is the second largest fertiliser producer it is in the world it is not sufficient. production capacity of the plants cannot be increased due to many factors rise in the prices of raw materials non availability of the raw materials in such circumstances exporting becomes cheaper.as the plants run 24hours the workers work in three shifts morning , evening ,night The annual installed capacity of the plant is 946000 metric tonnes of fertilisers It consist of a single stream of ammonia plant which a capacity of 660 tonnes of ammonia per day, a urea plant with an installed capacity of 1140 tonnes per day 350000 Metric Tonnes annually and a DAP Plant with an installed capacity of 140 tonnes per day350000 Metric Tonnes annually along with modern offsite facilities as well as generation of steam and power. As all the fertilisers companies in India are dependent on government subsidies.

Raw Material Consumption of NPK-A NPK-B Plant

1 Liquid Ammonia
2 Phosphorc acid (with 54% P2 O5)

3 Sulphuric Acid (H2 SO4) 4 Filler 5 Furnace oil

Production Composition
Grades 18:46:0 10:26:26 14:35:14 20:20:0
12:32:16

Composition ( Samrat ) Nitrogen Nitrogen Nitrogen Ammonium Nitrogen Phosphate Phosphate Phosphate Phosphate Phosphate

(Sampatti )

Potassium Potassium Sulphate Potassium

NPK-A and NPK-B unit operations and processes involved

There follows the description of a number of unit operations and processes which pertain to the granulation process. Because of the non-specific character of these descriptions, no particular reference to the plant is made unless necessary.
The Dorraco Granulation Process

Slurry from the wet system is mixed with recirculating solids before drying and screening .Slurry solids are deposited on the surface of the recirculated granules resulting in an increase of granule size .in general two types of granulation mechanisms occur namely

The Layering Process

The layering process occurs when a nucleus is coated with a layer of slurry in the granulating device and then dried. The resulting nodules are recycled through the granulating device and drier several times until each nodule is built up to the correct screen size to pass into the product section of the screen hopper .This is the principal granulation mechanisms when the producing compounds such as diammonium phosphate, where no dry solids such as KCL are added to the recirculating fertiliser .Granules produced by layering are quite round and uniform.

The Agglomeration Process

When dry solids such as KCL and filler are added to the recirculating fertiliser, there is much granulation by Agglomeration process of coating and cementing small crystal of fertilizer, potash and filler with the slurry from preneutraliser to form nodules in the granulating device .The nodules are then dried and screened with the undersize fraction being recycled. The coatings deposited at each cycle are relatively thick and several agglomerated nuclei may be cemented together with the envelope. Urea, which is extremely soluble probably goes mostly into solution in the granulation, and does not act as an added solid like KCL. Some oversize granules are always produced when near product size nodules are recirculated .These oversize granules are broken down in the pulveriser and recycled acting as nuclei for formation of new granules. The principal control of the size of the product granules is through selection of the mesh size of the screen .However the ratio of recirculated fertiliser to product, and the viscosity of the slurry from the wet system also exert considerable effect .DAP is produced by layering process

Ammonium Phosphate Slurry Production

When producing ammonium phosphate based fertilizers, phosphoric acid and water are fed to the scrubbing system for purposes of ammonia recovery Phosphoric acid scrubber solution and ammonia are fed to the preneutraliser for further ammoniation to a point of near maximum solubility of ammonium phosphate .This makes for ease of slurry handling and for assurance that solids deposition will be facilitated when further ammoniation is practiced in the granulating device as in the granulating device Due to the exothermic nature of the neutralisation reaction, the slurry in the preneutraliser boils violently and a large quantity of vapour is produced .fumes and vapour is exhausted from the preneutraliser to the fume scrubbing system by the fumes fan. It is important to maintain the preneutraliser slurry in the range of 83% to 85% solids for DAP and close to this NPK grades being made .Higher water content will increase the amount of recycle required and ultimately reduce the capacity . On the other hand, if the slurry contains too little water it can become too viscous to pump .it should be noted here that the use of a small amount of deformer will aid in the pumping of the slurry with the maximum solids content which will ensure plant operation at the highest possible rate.

Granulation
The function of the granulation station is to mix recirculated materialfluids and solids from the fines conveyor with the reaction slurry from the wet system to achieve granulation by either of the techniques mentioned in section 3.5.1 this is accomplished in this plant by a drum granulater .mixing Is very through, and the discharge mass from the granulating device consists mainly of individual nodules coated with slurry Added solids, such as urea KCL and filler are added to the fines conveyor where conveyor where they are mixed with recirculated fertiliser enroute to the granulator. The operator of the granulation station controls the amount of moisture in the discharge mass by varying the recirculation ratio ,by adjusting the amount of the product exported which will change the amount of the product exported which adjusted to suit the current needs ,the product exported which will have to be adjusted again so as to match the product make .A correct granulation mix will minimise the formation large agglomerated lumps in the dryer .Any lumps which are produced however, are retained in the dryer grizzly and automatically added to the circulating load after being crushed in the dryer itself . About 25%-35% of the total ammonia fed to the system is added to the granulation station .this is done to reach the highest mole ratio in the product at the same time evaporating water during granulation step , which reduces the recycle required station .Water vapour and fumes from the granulation station are exhausted to the scrubbing system .

Drying
Drying problems are related to the chemical composition of the product, the physical properties of thegranules, and the size of the circulating load .low density porous granules are difficult to dry, while,and hard spherical granules are easier to dry. At high circulating loads slurry coating is thin and the drying rate is rapid .conversely, with low circulating loads, the coating is thick and the drying rate is slower. However, with low circulating loads the dryer throughput is decreased and the retention time is increased as compared to high circulating loads. The net effect of the increased dryer retention time is to offset the slower drying rate. In the case of lumps or agglomerates ,the water may not be evaporated the lump may look dry due to a case hardening effect but if broken up it will be found to be damp and sticky .lump formation may be minimised by increasing the recirculation rate and smoothing out the flow of slurry to the granulator . The normal dryer outlet solids temperature for DAP based compounds is 85degree Celsius to 90degree Celsius although some plants are operating slightly above this .normally the outlet gas temperature is nearly the solids temperature ,but it is necessary in the early stages of the start -up to determine the solids temperature to check this figure ,against the gas temperature .too high solids outlet temperature can lead to product decomposition and excessive ammonia losses .85degreecelsius to 90degreecelsius outlet temperature is satisfactory for a few percent of urea in the product .however for urea DAP grades containing

more than a few percentages of urea, solids outlet temperatures should be in the 70degreecelsius 75degreecelsius range . The grizzly at the discharge end of the dryer is provided for sculpting off lumps that might cause trouble in the elevator and at the screens .pieces off scale might break off in the dryer from time to time and come through .if any appreciable amount of grizzly oversize is produced, it is a size of improper granulation .

Recycle screening
At the screening station, the circulating load is divided into three fractions ; affine fraction for return to the granulation station ,an intermediate fraction which is the product and an oversize fraction , which is pulverized and then returned to the granulation station. The screens are double- surface ,electrically vibrated screens .the screens are supplied with screening surfaces of the proper mesh to yield a product confirming to -4mm+1mm=90%Wt (min) analysis. The product is taken from a product compartment and excess product-size material overflows to the screen hopper .this system helps to prevent depletion of the circulating load .

Cooling
The storage properties of fertilisers ,particularly those containing urea and KCL,are improved by cooling to about 46degreecelcius after drying .in this plant the cooling is effected by the product cooler , a horizontal rotary machine in which the fertiliser is cascaded through the counter current stream of cool air .the inlet air to the cooler will generally be at ambient temperature .warm air leaving the product cooler is discharged to the atmosphere via the cooler cyclone ,cooler fan cooler scrubber in the scrubbing system.

Coating
Urea- Ammonium phosphates have a tendency to cake in storage in humid climate coating with an inert ,very finely divided solid reduces granule to granule contact and improves storage properties . the coating drum is designed to promote intimate contact and adherence between the fertiliser granules and the coating agent .some types of coating agents do not adhere well to the granules .in such cases a coating oil (machine oil with special properties or equivalent) is sprayed into the granules in the coating drum to improve the adherence of the coating agent.

Polishing Screening
This final screening operation is made on the product before it is sent to the storage and bagging section by the polishing screen .the screens are each double surface, electrically vibrated screen .the screens are supplied with screening surfaces of proper mesh to yield product of desired mesh size. Oversize and undersize fractions are returned to recycle

Packing/Bagging
The finished product goes to the hopper from there it weighed/ measured with the weighing machine in 50 kilo gram polyethylene bags and then stitched with the help of stitching machines and finally it is transported either by trucks or trains

QUALITY DEPARTMENT
The Laboratory is well equipped to provide detailed analysis of all compositions as required by the process. Its manpower works in rotational shifts round the clock and has schedule of various analysis which are to be carried out, offline on periodic basis .in some plants, there are facilities of automatic analyser to analyse the composition of the end product of some of the products manufactured by the company. most of the instruments are of the latest microprocessor based origin fidelity and accuracy .some of the instruments are gas chromatographs, spectrophotometers, digital titrators, electronic balances pH and conductivity monitors etc. other forms of analysis through reagents, titrations and dedicated reactions are carried out to determine and counter-check various compositions .the complete data is logged through computers and stored in its database. The laboratory operating personnel have fixed schedules to give the process data analysis of the respective plants at predetermined times to the plant operators.

Marketing Department
India has a strong agricultural orientation as a country, with an economy that is highly dependent on agricultural outputs. Naturally, the demand for effective and affordable fertilisers is immense. Zuari Industries Ltd has marketing offices spread over a wide marketing area covering the states of Goa, Maharashtra, Karnataka, Andhra Pradesh and Tamil Nadu. Our marketing head office is based at Zuarinagar Goa. The wide area of our operations cover s to ensures that we are able to meet the needs of the Indian farmer. Zuari Industries Ltd has over 2000 dealers and 5000 sub dealers that market its various brands of fertilisers and other agri inputs Throughout our marketing territories, Zuari seeks to facilitate farming and farmers, guiding them in scientific agricultural practices that help .in improving crop yields On its own Goa is a small market for fertilizer industry because of its small land base it could not have any marketing potential and its low demand for fertilizer project .besides traditional crops cultivated in Goa do not need substantial intake of fertilizer unlike cash crops like cotton sugarcane or grapes. Despite this Goa was ideally situated for distribution .The neighbouring states of Maharashtra and Andhra are known for prosperous agriculture and large demand for fertilizer. All the three states have large areas under cultivation of sugarcane cotton and groundnuts .Goa is an excellent focal point for distribution of fertilizers Companys marketing areas cover the states of Goa, Karnataka, Maharashtra, Andhra -Pradesh and parts of Tamil Nadu .

MARKETING DISTRICTS AND REGIONS

Pune

Maharashtra

Kolhapur

Aurangabad

Amravati

Bellary

Karnataka

Hubli

Bangalore

Hyderabad

Andhra-Pradesh

Vijayawada

Kurnool