Detailed Project Report (DPR) on Chelated Fertilizer (2 MT per day)

CHELATED FERTILIZER

[EIRI/EDPR/4668] J.C.: 2885XL

INTRODUCTION

The word chelate is derived from the Greek word chelé, which refers to a lobster's claw. Hence, chelate refers to the pincer-like way in which a metal nutrient ion is encircled by the larger organic molecule (the claw), usually called a ligand or chelator. Table 1 lists common natural or chemical synthetic ligands (Havlin et al. 2005; Sekhon 2003). Each of the listed ligands, when combined with a micronutrient, can form a chelated fertilizer. Chelated micronutrients are protected from oxidation, precipitation, and immobilization in certain conditions because the organic molecule (the ligand) can combine and form a ring encircling the micronutrient. The pincer-like way the micronutrient is bonded to the ligand changes the micronutrient's surface property and favors the uptake efficiency of foliarly applied micronutrients.

Because soil is heterogeneous and complex, traditional micronutrients are readily oxidized or precipitated. Chelation keeps a micronutrient from undesirable reactions in solution and soil. The chelated fertilizer improves the bioavailability of micronutrients such as Fe, Cu, Mn, and Zn, and in turn contributes to the productivity and profitability of commercial crop production. Chelated fertilizers have a greater potential to increase commercial yield than regular micronutrients if the crop is grown in low-micronutrient stress or soils with a pH greater than 6.5. To grow a good crop, crop nutrient requirements (CNRs), including micronutrients, must be satisfied first from the soil. If the soil cannot meet the CNR, chelated sources need to be used. This approach benefits the plant without increasing the risk of eutrophication.

Several factors reduce the bioavailability of Fe, including high soil pH, high bicarbonate content, plant species (grass species are usually more efficient than other species because they can excrete effective ligands), and abiotic stresses. Plants typically utilize iron as ferrous iron (Fe2+). Ferrous iron can be readily oxidized to the plant-unavailable ferric form (Fe3+) when soil pH is greater than 5.3. Iron deficiency often occurs if soil pH is greater than 7.4. Chelated iron can prevent this conversion from Fe2+ to Fe3+.

Applying nutrients such as Fe, Mn, Zn, and Cu directly to the soil is inefficient because in soil solution they are present as positively charged metal ions and will readily react with oxygen and/or negatively charged hydroxide ions (OH-). If they react with oxygen or hydroxide ions, they form new compounds that are not bioavailable to plants. Both oxygen and hydroxide ions are abundant in soil and soilless growth media. The ligand can protect the micronutrient from oxidization or precipitation. Figure 1 shows examples of the typical iron deficiency symptoms of lychee grown in Homestead, Florida, in which the lychee trees have yellow leaves and small, abnormal fruits. Applying chelated fertilizers is an easy and practical correction method to avoid this nutrient disorder. For example, the oxidized form of iron is ferric (Fe3+), which is not bioavailable to plants and usually forms brown ferric hydroxide precipitation (Fe(OH)3). Ferrous sulfate, which is not a chelated fertilizer, is often used as the iron source. Its solution should be green. If the solution turns brown, the bioavailable form of iron has been oxidized and Fe is therefore unavailable to plants.

In the soil, plant roots can release exudates that contain natural chelates. The nonprotein amino acid, mugineic acid, is one such natural chelate called phytosiderophore (phyto: plant; siderophore: iron carrier) produced by graminaceous (grassy) plants grown in low-iron stress conditions. The exuded chelate works as a vehicle, helping plants absorb nutrients in the root-solution-soil system. A plant-excreted chelate forms a metal complex (i.e., a coordination compound) with a micronutrient ion in soil solution and approaches a root hair. In turn, the chelated micronutrient near the root hair releases the nutrient to the root hair. The chelate is then free and becomes ready to complex with another micronutrient ion in the adjacent soil solution, restarting the cycle.

Chemical reactions between micronutrient chelates and soil can be avoided by using a foliar application. Chelated nutrients also facilitate nutrient uptake efficiency for foliar application because crop leaves are naturally coated with wax that repels water and charged substances, such as ferrous ions. The organic ligand around the chelated micronutrient can penetrate the wax layer, thus increasing iron uptake. Compared to traditional iron fertilization, chelated iron fertilization is significantly more effective and efficient than non-chelated fertilizer sources.

COST ESTIMATION

Plant Capacity            2 MT/Day  

Land & Building (1000 sq.mt.)    Rs. 1.79 Cr    

Plant & Machinery                    Rs. 1.05 Cr 

Working Capital for 2 Months    Rs. 2.62 Cr 

Total Capital Investment          Rs. 5.62 Cr 

Rate of Return                          24%

Break Even Point                      55%

CONTENTS

INTRODUCTION

CROP NEED CHELATED FERTILIZER

CHELATED MICRONUTRIENTS

PROPERTIES

USES AND APPLICATIONS

ROLE OF ZINC IN PLANT GROWTH:

THE MAIN FIELDS OF APPLICATION OF CHELATION REACTION ARE:

BENEFITS OF CHEALATED MICRONUTRIENTS

IMPROVED ABSORPTION:

INCREASED STABILITY:

REDUCED TOXICITY:

ENHANCED PLANT GROWTH:

COMMON CHELATED MICRONUTRIENTS

CHELATED ZNC 12% AND ITS APPLICATION AND COMPOSITION

CHELATED ZINC 12%

METHOD OF APPLICATION OF CHELATED ZINC 12%

COMPOSITION OF CHELATED ZINC 12%

MOST IMPORTANT ASPECT OF CHELATED ZINC 12%

ADVANTAGE OF CHELATED ZINC 12%

CHELATE AND ITS ACTIVITIES

SYMPTONS ON ZINC DEFICIENCY

MARKET OVERVIEW OF CHELATED FERTILIZER

CHELATE FERTILIZER MARKET DRIVERS:

CHELATE FERTILIZER MARKET CHALLENGES:

GLOBAL CHELATE FERTILIZER INDUSTRY OUTLOOK

AGRICULTRURAL CHELATE MARKET ANALYSIS

AGRICULTURAL CHELATES MARKET TRENDS

INCREASING PREFERENCE FOR EDTA IN AGRICULTURE

ASIA-PACIFIC DOMINATES THE MARKET

FEW MARKET LEADERS

AGRICULTURAL CHELATES MARKET NEWS

AGRICULTURAL CHELATES INDUSTRY SEGMENTATION

PRESENT MANUFACTURERS/EXPORTERS OF ZN EDTA

FACTORS AFFECTING STABILITY OF THE CHELATED COMPOUND

PH EFFECTS

METAL BUFFERING

ACCORDING TO EQUATION

SOLUBILIZATION

ZINC DEFICIENCY AND ITS FUNCTION

FUNCTIONS OF ZINC IN PLANTS

ZINC DEFICIENCY AND TOXICITY

ZINC IN SOILS

AVAILABLE ZINC

FACTOR AFFECTING AVAILABILITY AND MOVEMENT OF ZINC

INTERACTIONS WITH OTHER ELEMENTS

ZINC INTERACTION WITH OTHER NUTRIENTS

ZINC INTERACTION WITH OTHER TRACE ELEMENTS

ZINC FERTILIZER AND CORRECTION OF DEFICIENCIES

EVALUATION OF ZINC AVAILABILITY TO PLANTS

SOIL TEST AND PLANT ANALYSIS

CORRECTION OF DEFICIENCIES

ZINC FERTILIZERS

ZINC FERTILIZERS CAN BE GROUPED INTO FOUR CLASSES:

GEOGRAPHIC DISTRIBUTION OF ZN DEFICIENCY

RAW MATERIALS

THE STRUCTURE OF EDTA [(CH2COOH) 2 NCH2CH2N (CH2COOH)2] IS AS FOLLOWS

THE DONOR ATOMS OF EDTA ARE N AND O.

ZINC HYDROXIDE (ZN(OH)2)

RAW MATERIALS CONSUMPTION OF CHELATED FERTILIZER (MICRO NUTRIENT)

CALCULATIONS OF RAW MATERIALS REQUIRED FOR ZINC EDTA

THE EQUATION OF THE REACTION IS AS FOLLOWS

FOR 1.5 TON/DAY

THEREFORE, RAW MATERIALS REQUIRED/MONTHS ARE

MANUFACTURING PROCESS

PROCESS

SEPARATION METHODS

DRYING

PROCESS FLOW CHART OF CHELATED ZINC SOLUTION

PROCESS FLOW CHART FOR THE FORMATION OF CHELATED ZINC

GENERAL METHOD OF PREPARATION CHELATED COMPOUND

PRODUCTION PROCESS OF METAL CHELATES

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF FOREIGN PLANT AND EQUIPMENTS

FILTER PRESS

ROTARY DRUM DRYER

STORAGE TANKS

SUPPLIERS OF RAW MATERIALS

EDTA (ETHYLENE DIAMINE TETRA ACETIC ACID)

ZINC HYDROXIDE

SOLVENT (ACETONE)

LABORATORY CHEMICALS & MISC CONSUMABLES

PACKAGING MATERIALS

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

REACTOR

FILTER PRESS

LABORATORY TESTING EQUIPMENTS

AUTOMATIC PACKAGING MACHINES

STORAGE TANK

CENTRIFUGE

ROTARY DRUM DRYER

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)