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tkIS India - the Phosphatic Fertilizers Growth Story

The Background

For an agrarian economy like India, that houses a population of 1.36 billion people, the use of fertilizers in the production of food is mandatory. Fertilizers impact soil quality and consequently boost plant yield. It is also evident that the excessive use of Nitrogenous fertilizers, available from the predominantly nitrogenous fertilizer plants in the country, deteriorate the soil quality. The need of the hour, thus, was to prevent further damage and at the same time improve the plant yield. Phosphatic fertilizers fit the bill but even then, India was reliant on imports to take care of its phosphatic fertilizer needs. This need directed the fertilizer companies in India to start investing in plants for phosphatic fertilizers viz. Mono-, Di- Ammonium Phosphates as also compound fertilizers with varying quantities of Nitrogen, Phosphorus, Potassium (NPK) according to the requirements of the soil.

Addressing the Need of the Hour

By 90s, Uhde India was making inroads into the caustic soda and petrochemical businesses. It had also built plants for Nitrogenous Fertilizers for some of India’s fertilizer majors. Therefore, addressing their concerns by venturing into a new field came as no surprise. Identifying a world-class licensor for phosphatic fertilizers then became a priority. The Pipe Reactor technology of a leading Spain-based plant licensor with plant operating experience of its own, was most suited to undertake projects for DAP-NPK.

The collaboration first fructified with a NPK Complex for Coromandel International Limited in Vizag in 1998. This was closely followed in 1999 with an LSTK order from Gujarat State Fertilizers and Chemicals (GSFC) for DAP Plant and associated facilities.

In the last two decades, the number of plants in the country has grown steadily. tkIS India has had its fair share in implementing a large number of these projects (see timeline). In parallel, with its growing expertise in the field, it has implemented, along with its partner, plants of a major size in countries outside India, even as Indian manufacturers began to invest in plants offshore in countries like Morocco and other African countries with rich deposits of rock phosphate, a key ingredient for the manufacture of phosphatic fertilizers.

World-class NPK Plants

 Till the mid 90’s, DAP/NPK plants were based on conventional process. These plants were robust RCC buildings as tall as 45-50 meters. With the introduction of the new “Pipe Reactor” Technology, for a given capacity of the plant, the equipment sizes were considerably reduced as compared to conventional process thereby reducing the footprint of the plant. Consequently, this also reduced the capital cost of the plant. In addition to this, the consumption of utilities mainly fuel oil/natural gas also reduced leading to better operating expenses figures. 

This was of huge benefit to the fertilizer manufacturers who were until then operating the plants on threshold managing the fixed MRP of the product owing to the government policies and the uncertainty around the availability of raw material.

 

Factors contributing to success of the Plants

  • Technology associate has more than 40 years’ experience in designing plants having capacity ranging from 10 MTPH to 75MTPH and has till date built around 150 plants

  • Technology uses different sources of phosphoric acid as a raw material.

  • The process is capable to produce different NPK grades such as 10:26:26, 12:32:16, 14:35:14,20:20:0:13, etc. suitable to the requirements of the clients

  • The technology is compatible with solid raw materials such as DAP, MAP, TSP, SSP, Ammonium Nitrate, etc.

  • Technology associate has strong ties in its group, and utilizes this operational experience in their designing of the plant.

  • Regular technology in terms of product quality (based on client’s requirement) are undertaken. Similarly, the emission norms which continue to become stringent year by year are taken care of by upgrading their scrubbing systems to meet these environment norms. 

tkIS India’s approach at integration with ‘Lessons Learned” coupled with “Value Engineering” has resulted in optimized solutions/ layouts/ MOC’s for the equipment to suit Indian conditions or specific requirements of Indian clients. 

Leading supplier

 What started out as a new area for tkIS India in the 90s, has resulted into a leadership position, with the company having a domestic market share of almost 70% market share of the installed DAP-NPK fertilizer plants in the country and abroad. 

To top this up, and to ascertain client’s requirements of ensuring continuous supply of raw materials which were required for production of phosphatic fertilizers, tkIS India, in association with a Belgium Licensor, has undertaken Phosphoric acid projects at two locations in the country. Out of these two, tkIS India has successfully commissioned the 450 TPD Phosphoric acid plant for Coromandel in 2019. tkIS India is currently executing another plant for 450 TPD Phosphoric acid for Paradip Phosphates. 

The company sees itself as being in a good position to further its footprint in the sector by implementing some of the upcoming projects in the country, even as India continues its import of phosphatic fertilizers.

Project Timeline

 

1990s

  • 1998 - DAP-NPK project for Coromandel International Limited on EPCM Basis

  • 1999 –  3rd Train for Di-Ammonium Phosphate and associated facilities for Gujarat State Fertilizers and Chemicals on LSTK basis

 

2000s

  • 2001 – Revamp and capacity augmentation of existing plant (A & B trains) for Godavari Fertilizers and chemicals Limited, Kakinada on LSTK basis

  • 2001 – Revamp and capacity augmentation of existing plant for Mangalore chemicals and Fertilizers Limited, Mangalore on EPCM Basis

  • 2008 – Two trains for DAP/MAP/TSP plant for Bunge Maroc Phosphore, Morocco

 

2010s

  • 2011 – New C-train for DAP/NPK plant for Coromandel International Limited, Kakinada on LSTK basis

  • 2011 – Revamp and capacity augmentation of existing plant (A & B trains) for Zuari Fertilizers

  • 2013 – Two trains for NPK Granulation plant for Deepak Fertilizers and Petro chemicals Corporation Limited, Taloja on EPCM basis

  • 2014 – Revamp of NPK Fertilizer Plant New DAP/NPK plant for ETI Bakir, Turkey

  • 2015 – New DAP/NPK plant for Petro Vietnam fertilizers and Chemicals Corporation, Vietnam on LSTK Basis

 

tkIS India’s commendable performance in the field has resulted in being selected as preferred partner on foreign shores for a couple of projects in Morocco and Turkey.

Landmark Projects

Coromandel International, India
PVFCCo, Vietnam
GSFC, Sikka, India
Bunge Maroc Phosphore, Morocco
Deepak Fertilizers and Petrochemicals, India
Coromandel International, India

Mangalore Chemicals & Fertilisers Ltd (MCFL) availed the services of tkIS for the last five decades in the installation of different DAP-NPK and Urea plants and these projects were successfully executed meeting all contractual guarantees. tKIS has set highest standards in the project management functions and adopts collaborative approach in addressing the aspirations and challenges of chemical industries.

Mr. Prabhakar Rao Mangalore Chemicals & Fertilisers Ltd.

One of Our Highlights - in Depth

Coromandel International Limited, the second largest fertiliser producer in India has the capacity to produce more than 3 Million DAP/NPK fertiliser from their three plant locations; Kakinada, Vizag in Andhra Pradesh and Ennore in Tamilnadu. tkIS India has had the privilege to introduce the Pipe Reactor technology in Coromandel’s Vizag plant in 1998. In 2011, Coromandel planned to augment the capacity of their existing Kakinada fertiliser complex by adding one more train of 1650 TPD DAP/NPK plant. Coromandel was convinced with engineering capabilities of tkIS India. Therefore, Coromandel awarded this project to tkIS India on nomination basis to be executed on EPC basis.

Project Cost - 25 Mio Euro

Project Scope - Battery limit DAP/NPK plant

  •    Bagging Plant along with Screen House

  •    Raw Material Shed

  •   Product Bulk Silo

  •    Railway Siding

Key Quantities: 

  • P & I D’s: 24

  • Isometrics: 445

  • Plot Plan & Piping Plan: 150

  • Civil Drawings: 588

  • Concrete: 22750 m3

  • Structural Steel: 600MT

  • Piles, Nos.: 640

  • Piping Length: 30,000 IM

Coromandel has 22 years of continuous support from tkIS. Excellent company with highest standards in design and execution. Executed many projects and awarding repeat orders is testimony of their excellence.

Mr. A. Ramachandra Rao Sr. Vice President- Projects Coromandel International Ltd.

Nitrates & Phosphates (N & P) – Footprint

It gives me a sense of pride that the projects we have executed in India as well as abroad directly contribute to the efforts of the phosphatic fertilizer manufacturing fraternity and indirectly to the well-being of the citizens of the country through the improved yield of fertilizer crops. Our association with our Spain-based technology associate covers over two decades, and covers their own projects as well as projects won by us and successfully implemented with their cooperation. The faith our clients have shown in us over the years is proof enough of the robustness of the technology and the engineering expertise of tkIS India. The technology is modern, economical, flexible and ideally suited to Indian conditions and available feedstock. It offers an edge in terms of cost competitiveness. Our teams have assimilated the technology well, and this reflects in the project schedules and optimization of efforts. 
Mr PV Chepe
Chief Eng Officer & ED-Engineering
To enjoy a leadership position involving approximately 70% market share of the Phosphatic Fertilizer market in a competitive market speaks volumes of the efforts of our teams. Our efforts continue to be directed at improving the customer experience and improving every single day, to give the clients what they need in the best possible manner. Our clients have time and again reposed their faith in us, and made us push our boundaries. A clear indication of this is the backward integration we have achieved in Phosphoric acid plants with another technology provider, after attaining a leadership position in DAP NPK plants. Going further, we hope to keep enriching these associations and keep building plants that contribute to the growth of the country’ economy.  
Mr K S Rao
Chief Sales Officer and ED-Business Development, Sales, Proposals & Industrial Services
I experience an immense sense of pride when I see a Phosphatic fertilizer implemented by us. Being with the project from its inception to its realization, over the years, we have assimilated the requirements of our clients and planned our activities around these requirements. The flexibility of the Pipe Reactor technology coupled with its numerous benefits in terms of various offerings of the NPK grade, lower CAPEX, OPEX, Utility consumptions and Schedules makes it an attractive proposition to the clients who have grown to trust in the association of tkIS India with its Spain Based Technology associate. The flexibility of the technology have kept it relevant amidst the growing competitive scenario.The Phosphoric acid plants currently been set up in the country by tkIS India in association with the Belgium Licensor are also a step further in our growth journey of Phosphatic fertilizers. We value our association with our licensors and our customers.
Ms. Nita Samant
Deputy General Manager - Sales (Technologies)