IRC Agrochemicals (IRCA) produces phosphate-based fertilizers in Haldia, which is located in the state of West Bengal in India. Its first Di-Ammonium Phosphate (DAP) plant was set up in 1985 and subsequently a complex fertilizer line was installed to produce DAP and NPK fertilizers, along with a plant to produce SSP fertilizers. Sulphuric acid is also manufactured at Haldia which is sold in the merchant market. The site has a production capacity of 1800 TPD of DAP, 3000 TPD of NPK, or a combination of the two as per the domestic market’s requirement. The SSP production capacity is 600 TPD.
IRCA’s fertilizer business is conducted under the umbrella brand of Paras, which is a premier brand in Eastern India. Paras has a very strong brand equity supported by its unique specifications, quality, and customer support.
600 KTA (DAP equivalent)
|Key Raw Materials||Phosphoric Acid, Sulphur, Rock Phosphate, Ammonia, Muriate of Potash (MOP)|
|# of Employees||c. 300|
Process Plants at the Haldia Phosphate Fertiliser facility
Sulphuric Acid Plant:
The Haldia Phosphate facility has two Sulphuric acid plants, named SAP-1 and SAP-2, with capacity of 450 TPD and 300 TPD respectively. The main raw material for production of Sulphuric Acid is Sulphur, which is imported in granular solid form or in molten condition. The process is called Double Contact Double Absorption (DCDA). The sulphur is burnt in presence of excess air to form Sulphur di-oxide, which is converted to Sulphur tri-oxide in presence of a catalyst. The Sulphur tri-oxide is then absorbed in towers with circulating acid to obtain 98.5% Sulphuric acid product. The process of conversion from Sulphur to Sulphur di-oxide and then to Sulphur tri-oxide is highly exothermic and as a result steam is produced from the process as by-product, which is used in generation of power and as process steam.
Click here to see process flow chart of Sulphuric Acid plant
Complex Phosphatic Fertilizer Plants (DAP/ NPK):
There are two complex Phosphate Fertilizer (CPF) plants, named CPF-1 and CPF-2. Both the plants have flexibility to produce Di-Ammonium Phosphate (DAP) as well as NPK products. The capacity of CPF-1 plant is 900 TPD of DAP and CPF-2 is 1650 TPD of NPK10. The raw materials for DAP production are ammonia and phosphoric acid, while for NPK are ammonia, phosphoric acid and murate of potash (MOP). The basic process is the reaction between anhydrous ammonia and phosphoric acid to form Mono-Ammonium Phosphate (MAP) and then Di-Ammonium Phosphate (DAP). The PN reactor and pipe reactor slurry which is a combination of these two salts (DAP and MAP) is sprayed on to a bed of recycled fines in the granulator. The granular mass is then dried in a rotary drum dryer. The dried product is then screened and the desired sized product is transferred to the packaging plant after cooling the granules in a Fluidised Bed Cooler (FBC). The oversized granules are pulverized and mixed with undersize material and then recycled back to the granulator. For NPK production, MOP is mixed in recycle stream and sent back to granulator.
Click here to see process flow chart of DAP/NPK plant
Single Super-Phosphate Plant (SSP):
he plant has capacity to produce 600 TPD of SSP fertilizer in powder form. The raw materials for production of SSP are rock phosphate and sulphuric acid. Rock phosphate is first ground and then mixed with 98.5% strong sulphuric acid.
Click here to see process flow chart of SSP plant