Retools India Muzaffarnagar, Uttar Pradesh

The use of granulated product is more beneficial than the use of powder. The powder get dissolved immediately in irrigation water and becomes readily available. Some part of it is used by plants and balance goes to sub soil with water and remain useless. The powder can be used only during sowing of seeds. It cannot be used on the growing crops as it get deposited on the leaves of the plants and being slightly acidic, burns them. The granulated product rolls down the plant and can be used harmlessly on the standing crops. The biggest advantage in using the granulated product is that it is available to the crops for a longer time because it get dissolved slowly in water.

Process Description

The cured Single Super Phosphate is Screened. The powder is taken directly and the lumps are taken after crushing, for granulation . The soil conditioner gypsum is a added . The material is taken to granulation drum where very fine spray of water is done on rolling material at its angle of repose. Some coating of powder over the small nuclei / particles takes place. This duration of this process is controlled as per requirement. The material is then taken to dryer drum where the hot air generated in the furnace is passed through it. The material is cooled in cooler drum by passing ambient air through it. The ID fans connected to dryer & cooler sucks air from the drums so some dust also comes with it. The dust is separated in the cyclones and finally scrubbed in wet scrubber. The cooled material is screened through under size & over size screens. The product of 1 - 4 mm size is separated and precisely packed. The oversize material after crushing and the under size are recycled and work as nucleus for next cycle

Single superphosphate (SSP) was the first commercial mineral fertilizer, and it led to the development of the modern plant nutrient industry. This material was once the most commonly used fertilizer, but other phosphorus (P) fertilizers have largely replaced SSP because of its relatively low P content.

The modern fertilizer industry was launched in the 1840s with discovery that the addition of sulfuric acid to naturally occurring phosphate produced an excellent soluble fertilizer, given the name “superphosphate.” Ground animal bones were first used in this reaction, but natural deposits of rock phosphate (apatite) soon replaced the limited supply of bones. Making SSP is similar to what naturally occurs with bones or apatite in acid soils. The basic technique has changed very little in the past century. Ground phosphate rock is reacted with sulfuric acid to form a semi-solid, which cools for several hours in a den. The plastic-like material is then conveyed to a storage pile for several weeks of additional curing. The hardened material is then milled and screened to the appropriate particle size or granulated. The general chemical reaction is Ca(PO) [rock phosphate] + 2 HSO [sulfuric acid] → Ca(HPO4) [monocalcium phosphate] + 2 CaSO [gypsum].

SSP can easily be produced on a small scale to meet regional needs. Since SSP contains both monocalcium phosphate (MCP, also called calcium dihydrogen phosphate) and gypsum, no problems arise with phosphogypsum byproduct disposal unlike the manufacture of other common P fertilizers.

SSP is also known as ordinary superphosphate and normal superphosphate. It’s sometimes confused with triple superphosphate (TSP) production, which results from reacting rock phosphate with phosphoric acid.

Chemical Property of SSP

Agricultural use

• SSP is an excellent source of three plant nutrients. The P component reacts in soil similarly to other soluble fertilizers.
• The presence of both P and sulfur (S) in SSP can offer an agronomic advantage where both of these nutrients are deficient. In agronomic studies where SSP is demonstrated to be superior to other P fertilizers, it’s usually because of the S, Ca (or both) that it contains. When locally available, SSP has found widespread use in fertilizing pastures where both P and S are low. As a source of P alone, SSP often costs more than other, more concentrated fertilizers; therefore it has declined in popularity.

Management practices

• No special agronomic or handling precautions are required for SSP. Its agronomic effectiveness is similar to other dry or liquid phosphate fertilizers.
• The loss of P in surface runoff from fertilized fields can contribute to water quality problems. Growers should implement farm practices that minimize this loss.

Non-agricultural uses

SSP is primarily used as a crop nutrient source. However, MCP and gypsum (the two primary ingredients in SSP) appear in many products. For example, MCP is commonly added to enrich animal feed, and bakers routinely use it as a leavening agent. Gypsum is widely used in the construction industry, as well as in the food and pharmaceuticals world.

Straight Fertilizer such as Calcium Ammonium Nitrate (CAN), Ammonium Nitrate (AN), Urea, Single Super Phosphate (SSP), Triple Super Phosphate (TSP), Potash

(Potassium Nitrate), and combined type types such as Mono Ammonium Phosphate (MAP), Di – Ammonium Phosphate (DAP) are well – defined product made using well- defined process.

Compound or complex fertilizer such as NPK, are more difficult to define as there is an infinite number of N/P/K ratio and the process applied in their production are numerous.

The product name ‘NPK’ is normally followed by three numbers to indicate the percentage of N, P2O5, and K2O which the product contains. In addition, the Fertilizer may contain Magnesium, Boron, Sulphur, Micronutrients etc.

Manufacturing Process :

• First we store the different raw material in different hopper with the help of raw material conveying system after that with the help of programmable rotary vane feeder, programmable rotary vane feeder discharge the raw material on discharge belt conveyor in control way as per grade of NPK. Discharge belt conveyor feed the raw material as per NPK grade in to paddle mixture, paddle mixer, mix all raw material homogenously and feed that raw material to granulator feed belt that granulator feed belt feed the material to rotary granulator to granulate the material. In the granulator a jet of water is sprayed at the angle of repose of NPK raw material, the quantity of water spry control the size of granule. After making the granules we shift the granules to the dryer with the help of belt conveyor to dry that ma
• The granulated material is taken to the Dryer to remove moisture from the material. A hot stream of hot air is passed through the material in the dryer. The
• hot air generated in the furnace by burning Furnace oil/ HSD/ Gas. The material gets dried. The material is cooled in the cooler drum by passing ambient air through the material. The hot and cold air streams form exit of dryer and cooler are taken to cyclone and wet scrubber to remove dust particle going to the atmosphere. The air is discharged in the atmosphere through chimney.
• The cooled material is taken to oversize and undersize screens to segregate the product, under size material and oversize material. The oversize materials after crushing and undersize material are sending to recycle. This recycle provide the nucleus for further granulation. The product is packed in 50 kg bags or as per requirement of the market.