Detailed Project Report on Mono Calcium Phosphate (Animal Feed Grade-IP Grade)

MONO CALCIUM PHOSPHATE (ANIMAL FEED GRADE -IP GRADE)

[EIRI/EDPR/1702] J.C.528XL

INTRODUCTION

Inorganic feed phosphates (IFP) are inorganic salts of phosphoric acid. The use of inorganic feed phosphates is necessary to meet the phosphorus requirements for animal production: to ensure optimal growth, fertility and bone development.

Feed phosphates are of great importance among the feed materials produced for intensification of livestock farming. They are produced and applied in relatively large quantities, although for several years, both their production and use were often characterized by an unfavorable opinion resulting from the potentially adverse impact on the environment. Emergence of the “mad cow” disease BSE (bovine spongiform encephalopathy) and the Creutzfeldt-Jakob disease, which genesis was considered in the use of meat and bone meal - the main competitor of feed phosphates, have contributed to the change of this opinion. 

The products obtained in the chemical processes appeared to be much safer, which resulted in restrictions, introduced into the European legislation, on the use of products based on the utilization of products derived from slaughter wastes. Feed phosphates are one of the most important factors in the intensification of livestock farming . They enable compensation of phosphorus and calcium deficiency in the feeds. The estimated overall production capacity of worldwide industrial plants is about 4.5 mln Mg/year. The national prospective, differentiated by various experts, indicate the minimum demand of 90 thousand Mg/year, and in the next few years up to 130-150 thousand Mg. Another important problem of the production of feed phosphates is introduction into their composition other chemical components which are essential for intensive methods of livestock farming. The most important are preparations containing calcium, sodium and selenium. Feed additives such as micronutrients or ultra-trace elements are applied in much smaller amounts. In this respect, products containing copper, zinc, iron, magnesium, cobalt and iodine can be distinguished among the feed materials.

The essence of the trends in development of the technology of feed phosphates production observed in recent years is aimed at reduction of manufacturing costs while preserving the basic operating parameters and better adjustability to the physicochemical properties of their operational applications. For this purpose, such issues like power consumption of manufacturing process, source of phosphorus compounds, water consumption balance, optimization of operations and unit processes used in technology, development of new apparatus and equipment used in the manufacturing process, are considered. These endeavors resulted in significant long-term manufacturing costs reduction, achieved by the leading world producers which cause price stabilization or even reduction for these products on global markets. In consequence ongoing elementary and development research of the process and the implementation of innovative alterations in techniques of feed additives manufacturing is required. Manufacturers that have-not changed their technologies in recent years are exposed to significant difficulties in range of relatively increasing production costs what makes their endurance, among the producers in a free market economy in Europe, limited and sometimes even impossible. The same situation can be found also in domestic industry. This paper focuses on several different technological options that allow determining conditions under which the production of feed phosphates at reduced water amount in the process is possible. This is directly related to the possibility of reducing the energy demand of the process and therefore unit costs.

COST ESTIMATION

Plant Capacity            20 MT/Day

Land & Building (10,000 sq.mt.)    Rs. 8.96 Cr

Plant & Machinery                    Rs. 4.56 Cr

Working Capital for 2 Months    Rs. 5.76 Cr

Total Capital Investment          Rs. 20.39 Cr

Rate of Return                          27%

Break Even Point                      49%

CONTENTS

INTRODUCTION

DEVELOPMENT IN TECHNOLOGIES OF FEED PHOSPHATES PRODUCTION

TABLE 1 RESULTS OF LABORATORY TESTS OF FEED CALCIUM HYDROGEN PHOSPHATE PRODUCTION USING CONCENTRATED PHOSPHORIC ACID

TABLE 2 CHARACTERISTICS OF PHOSPHORIC ACID FROM AB LIFOSA USED FOR THE PRE- PARATION OF FEED PHOSPHATES UNDER INDUSTRIAL CONDITIONS

TABLE 3 CHARACTERISTICS OF CALCIUM OXIDE AND CALCIUM CARBONATE FROM ZW KUJAWY USED FOR THE PREPARATION OF FEED PHOSPHATES UNDER INDUSTRIAL CONDITIONS

TABLE 4 CHEMICAL COMPOSITION OF FEED DICALCIUM PHOSPHATE OBTAINED UNDER INDUSTRIAL CONDITIONS

CONCLUSIONS

IMPORTANCE

PRODUCTION OF INORGANIC FEED PHOSPHATES

EXAMPLE OF PHOSPHORIC ACID PRODUCTION

DIFFERENT TYPES OF INORGANIC FEED PHOSPHATES

EXAMPLE OF A CALCIUM FEED PHOSPHATE PRODUCTION

QUALITY

PHOSPHORUS REQUIREMENTS

PREVENTING DEFICIENCIES

PHOSPHORUS METABOLISM

MONOCALCIUM PHOSPHATE FOR ANIMAL AND POULTRY FEED GRADE

MONOCALCIUM PHOSPHATE MCP IP GRADE

MCP IP GRADE MONOCALCIUM PHOSPHATE SPECIFICATIONS: FCC

PACKING: 25 KGS NET PAPER BAGS OR 25 KGS NET PLASTIC WOVEN BAGS.

GENERAL SIDE EFFECTS

MARKET POTENTIAL

COMPOSITION OF BLANCED CATTLE FEED

DIALY DICALCIUM PHOSPHTE REQUIREMENT FOR CATTLE & BUFFALOES

PERCENTAGE MILK PRODUCT (NUTRIENTS REQUIRED PER KG FAR OF MILK)

POPULATION BY 2015

FEED PHOSPHATE MARKET BY TYPE (DICALCIUM PHOSPHATE, MONOCALCIUM PHOSPHATE, TRICALCIUM PHOSPHATE, DEFLUORINATED PHOSPHATE & OTHERS), BY LIVESTOCK (SWINE, CATTLE, POULTRY, AQUATIC ANIMALS & OTHERS), BY GEOGRAPHY - GLOBAL TRENDS & FORECASTS TO 2018

FEED PHOSPHATE MARKET VALUE, BY LIVESTOCK, 2013 VS. 2018 ($MILLION)

SCOPE OF THE REPORT

BY TYPE

BY LIVESTOCK

BY GEOGRAPHY

CUSTOMIZATION OPTIONS:

INDUSTRY ANALYSIS

COMPETITIVE INTELLIGENCE

GLOBALIZATION & TRADE

MANUFACTURING PROCESS (ANIMAL FEED GRADE)

FLOW SHEET

MANUFACTURING PROCESS (IP GRADE)

OTHER COMMERCIAL METHODS

MANUFACTURERS/EXPORTERS/SUPPLIERS OF MONOCALCIUM PHOSPHATE

MANUFACTURERS/SUPPLIERS OF RAW MATERIALS

CURED SINGLE SUPER PHOSPHATE

COMPLETE PLANT SUPPLIERS OF MCP

SUPPLIERS OF PLANT AND EQUIPMENTS

REACTION KETTLES

FILTER PRESS

CONVEYOR BELT

BOILER

D.G. SETS

AUTOMATIC FILLING MACHINE

STORAGE TANK

LABORATORY TESTING EQUIPMENT

MATERIAL HANDLING EQUIPMENTS

PRINCIPLES OF PLANT LAYOUT

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:

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. TERM LOANS:

8. TOTAL LOAD:

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)