Detailed Project Report (DPR) on Di-Calcium Phosphate (Powder)

DI-CALCIUM PHOSPHATE (POWDER)

[EIRI/EDPR/4350] J.C.: 2535XL

Introduction

Dicalcium phosphate is also known as the calcium hydrogen phosphate dehydrate or dibasic calcium phosphate with the molecular formula CaHPO4. The ‘di’ prefix indicates the formation of the HPO42– anion, which involves the removal of two protons from phosphoric acid (H3PO4). Dicalcium phosphate is mostly used as a dietary supplement. It is commonly found as a dehydrate; however, it can be converted into an anhydrous form by applying heat. It is insoluble in water and biomaterial in nature. Dicalcium phosphate contains a minimum 19% of phosphorus content and maximum 28% of calcium content; therefore, it is used as a source of phosphorus and calcium. 

Rock phosphates are natural sources of calcium phosphate in the form of tricalcium phosphate. Acidification of tricalcium phosphate with mineral acids yields phosphates and phosphoric acids. Acidification of rock salt with hydrochloric acid produces mono calcium phosphate which remains in solution which is treated to remove fluorides as precipitates. 

The supernatant liquid containing monocalcium phosphate is treated with lime to obtain dicalcium phosphate and calcium chloride which is considered as a by-product. Phosphoric acids which are obtained on acidification of natural phosphates are purified and then neutralized to produce dicalcium phosphate.

Animal-feed grade Di-Calcium Phosphate is made from wet process acid that has been treated to reduce fluorine content to an acceptable level.

It is intended to prepare a Feasibility Report to install 600 MT/Year Di-Calcium Phosphate (Powder) production facilities as a Brown Field Project. 

2. Uses /Applications

• Di-calcium phosphate is mainly used as a dietary supplement in prepared breakfast cereals, dog treats, enriched flour and noodle products. 

• It is also used as a tableting agent in some pharmaceutical preparations, including some products meant to eliminate body odor.

• Di-calcium phosphate is also found in some dietary calcium supplements 

• It is used in poultry feed. 

• It is also used in some tooth pastes as a tartar control agent

• Heating dicalcium phosphate gives dicalcium diphosphate, a useful polishing agent

3. Market Overview

Dicalcium phosphate is of three types i.e., feed grade, fertilizer grade, and food grade. The feed grade is used for animals owing to provide proper fertility, growth, and bone development. Dicalcium phosphate helps in curing infertility caused due to lack of dietary minerals in order to reduce the inter-calving period. It helps to maintain calcium in the body, increases milk production, enhances fiber digestion, and improves resistance to prevent ruminal disorders and other diseases like mastitis. Dicalcium phosphate is used in various applications such as animal feed industry, fertilizer industry, and food industry. It is widely used in animal feed industry owing to various properties such as ease in feed digestibility and improves the nutritional quality.

The worldwide market for dicalcium phosphate is expected to register CAGR of around 4.1% over the next ten years and will be valued at US$980 Million in 2028. High cost of phosphorus owing to less availability is a factor challenging growth of the global market. Increasing findings in R&D for development of new product with high functionalities is a factor creating a lucrative opportunity for manufacturers operating in the global dicalcium phosphate market.

Growing industrialization, coupled with increasing animal feed, fertilizer, pharmaceutical, cosmetics, and other industries, rapid urbanization, coupled with high purchasing power, increasing consumption of processed and convenience food owing to hectic lifestyle, are factors proliferating demand for  dicalcium phosphate. In addition, favorable regulation and statutes, increasing investments in various industries, and growing awareness among consumers for a healthy diet, have a positive impact on the global dicalcium phosphate market.

The market is segmented on the basis of geography such as North America, Europe, Asia-Pacific, Latin America, and Middle East and Africa. Rapid industrialization, coupled with growing various end-use industries such as food, fertilizer, and animal feed in countries such as China, India, Bangladesh, and others which in turn increase demand for dicalcium phosphate in the Asia Pacific region. Additionally, favorable government regulations, increasing consumer base, availability of raw material, and presence of major players are among some of the other factors driving demand for dicalcium phosphate. Increasing investments in various end-use industries, coupled with growing cosmetics and pharmaceutical industries in emerging countries such as Russia, Spain, Germany, France, and Italy has a positive impact on the dicalcium phosphate market in Europe. Increasing food and pharmaceutical industries in countries such as the US and Canada and high spending capacity are factors augmenting demand for dicalcium phosphate i

n the North America region.

Global Dicalcium Phosphate Market: Segmentation

The global dicalcium phosphate market can be segmented based on process, application, and region. In terms of process, the market can be bifurcated into phosphoric acid and hydrochloric acid. The phosphoric acid segment is projected to expand at a rapid pace during the forecast period.  This process requires low capital investment and yields high purity product. This is estimated to increase the demand for dicalcium phosphate during the forecast period.

Based on application, the dicalcium phosphate market can be classified into animal feed, fertilizers, food & beverage, pharmaceuticals, cosmetics, and others. The fertilizers segment is projected to expand at a rapid pace during the forecast period. Rising demand for dicalcium phosphate-based fertilizers and continuous developments in the agriculture segment is projected to fuel the demand for dicalcium phosphate during the forecast period. 

Dicalcium phosphate is mostly used as dietary supplements, especially to prepare breakfast cereals, dog treats, enriched flour, and noodle products due to its rich calcium and phosphate content. Increasing awareness related to health, rising consumption of dietary products, and growing population are expected to propel the market during the forecast period. Additionally, dicalcium phosphate is used as food additive; rapid expansion of the dairy & food industry and rise in meat consumption in emerging economies are projected to boost the demand for dicalcium phosphate during the forecast period.

Global Dicalcium Phosphate Market: Regional Outlook

In terms of region, the global dicalcium phosphate market can be divided into Asia Pacific, Europe, Latin America, North America, and Middle East & Africa. North America is expected to remain a leading region of the market during the forecast period. Growing awareness related to health and increasing demand for dietary products, and rising population are projected to drive the market in the region. Increasing usage of dicalcium phosphate in the manufacture of medicines and other health care products is estimated to drive the demand for this phosphate during the forecast period. The market in South Africa is anticipated to expand at a sluggish pace due to poor economy and lack of technological advancements in the country during the forecast period.

COST ESTIMATION

Plant Capacity                                    2 MT/Day

Land & Building (1450 sq.mt.)  Rs. 1.45 Cr

Plant & Machinery                             Rs. 2.49 Cr

Working Capital for 1 Month      Rs. 26.85 Lac

Total Capital Investment                   Rs. 4.46 Cr

Rate of Return                                    18%

Break Even Point                               69%

CONTENTS

INTRODUCTION

USES/APPLICATIONS

MARKET OVERVIEW

GLOBAL DICALCIUM PHOSPHATE MARKET: REGIONAL OUTLOOK

GLOBAL DICALCIUM PHOSPHATE MARKET: KEY PLAYERS

PRODUCT SPECIFICATIONS

DICALCIUM PHOSPHATE

CALCIUM CHLORIDE

HYDROFLUORIC ACID

BIS SPECIFICATION

FORMULATION

REACTION – (A)

REACTION – (B)

RAW MATERIALS

ROCK PHOSPHATE

HYDROCHLORIC ACID (>30%)

PHYSICAL PROPERTIES

CALCIUM HYDROXIDE

RAW MATERIAL/CHEMICALS SUPPLIERS

ROCK PHOSPHATE

ACID

HYDRATED LIME

LABORATORY CHEMICALS

MANUFACTURING PROCESS STEPS/PROCESS FLOW/QUALITY CONTROL

PROCESS FLOW

QUALITY CONTROL

USE OF MACHINERY (CRITICAL)

GRINDING

BALL MILL

FEEDING SYSTEM

FILTRATION

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

STP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT & MACHINERY

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

GRINDER

REACTORS

EVAPORATORS

MIXER

DRYER

STORAGE TANKS

CENTRIFUGE

PULVERIZERS

MATERIAL HANDLING EQUIPMENTS

BOILERS

INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

D.G. SETS

EOT CRANES

POWER TRANSFORMERS

COOLING TOWER

ETP PLANTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

PLATEFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE PROCESS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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)