NTrial & Commercial Production - R0.pptx

Trail Run

1. NP-14:28 Grade Development & Commercial Production 1

2. Why NP-14:28 Grade 1 Non-viability of DAP production due to exponential rise of raw material price 2 Non potassic grade (NP) fertilizer with low P2O5 compare to DAP makes it commercially viable and alternative of DAP in current raw material pricing scenario 3 High margin product compare to DAP and NP20 with current raw material price 4 New and innovative grade, available market and comparatively less competition 5 Included in NBS scheme since April’2020

3. All about NP-14:28 Only complex fertilizer with 1:2 ratio of NP in India Slow releasing nature Provides balanced nutrition to plant-Ammoniacal Nitrogen and Phosphorous Helps crops in utilising moisture better Helps water retention in soil Increase plant uptake of nutrients essential for healthy plant growth. Increase overall yield by 12 to 15% Minimum loss of Nitrogen (Ammoniacal form) due to leaching As per crop wise standard recommendation and soil test values Used in basal application due to slow releasing nature Main fertilizer for all major crops, Highly suitable for pulses, oil seed crops (Soybean, Gram, Groundnut) , wheat and vegetables . Used as a supplementary dressing for long duration crops Can be applied in basal application due to its slow releasing nature Chemical Nature Benefits & Advantages Doses & re-commendation

4. Steps in development & production Brainstorming and development by cross Functional team of Strategy, Production, TS, R&D and QC Theoretical grade formulation and working on specific consumption of raw materials for the grade Methodology development for production trial Sampling and analysis procedure Scale trial at R&D Development of process parameters based on inhouse expertise Design & procurement of packaging material Commencement of trial, stabilizing major parameters & nutrient Challenges faced and action plan for continuing the production on sustainable basis Preparation Activities Execution

5. Theoretical Grade formulation Acid Specs. Dry Basis % Strong Weak Feed Acid H3PO4 Consumption 70% 30%     P 2 O 5 49.9 26.4 42.85 59.13 Fe 2 O 3 0.24 0.09 0.20 0.20 F 1.13 2.33 1.49 1.49 Al 2 O 3 0.43 0.14 0.34 0.34 MgO 0.73 0.33 0.61 0.61 CaO 0.91 0.29 0.72 0.72 SO 4 3.91 2.17 3.39 3.39 Solid 0.97 0.23 0.75 0.75 Solid/P2O5 1.55 Sulphuric acid liberated/P2O5 0.081 Flourine/P2O5 0.035 Basis Product kg 1000 Grade     Nitrogen % 14% P2O5 % 28% Moisture % 1.5% P2O5 in product     WS P2O5 % 24% WS % 86% CS % 1.5% Theoretical RM consumption     Ammonia kg 170 P2O5 kg 284 Sulphuric Acid kg 123 Filler kg 250 Product Mole Ratio     Solid in product kg 985 Solid from NH3, Phos. Acid & Filler kg 862 Balance solid from Sulphuric acid kg 123 NH3 react with H2SO4 kg 43 NH3 react with H2SO5 lib kg 8.0 NH3 react with fluorine Kg 4.4 Balance ammonia for P2O5 kg 115 MR   1.97 25% Raw material is sand in the formulation. Sulphuric acid requirement is 123 Kg/MT for fixation of nitrogen due to N dilution by sand, though S is not under NBS for this grade

6. Commercial Production Based on process developed in-house & efforts put in by respective team, we have started manufacturing of NP-14:28:00 at our plant with the available resources. Production Started from 21st June 2022 in C train, parameters and grade were stabilized in shortest time On 22nd June D train was also changed over to NP-14:28 from NP-20 Parameters June’22 July’22 C Train D Train C Train Production (MT) 9140 8780 15075 Running Hours 189 179 292 Rate MT/Hrs 48.5 49 51.7 Average Grade 14.2 / 28.4 13.9/28.2 Product MR 1.8 1.8 1.8 CS (Kgf) 2.14 2.51 2.87 Product Size (mm)       +4 6 6 6 +3.35 11 12 13 +2 66 68 64 [phone] 1.5 Total Production till date: 32995 MT RM Specific Consumption:- NH3: 173 kg, P2O5: 286 kg, H2SO4: 100 kg, Filler: 250 kg

7. Production Campaigns Trial & Commencement of Production Production Rate: 48-49 TPH Crushing Strength: 2.2-2.5 kgf Target to increase Throughput (Planned) Production Rate: 55 TPH Crushing Strength: 3.0 kgf Campaign #1 Campaign #2 Campaign #3 Production Stabilization Production Rate: 51 TPH Crushing Strength: 2.87 kgf

8. Moisture absorption test As the product is new, moisture absorption and cacking tendency is unknown to us Test was carried out to know the moisture absorption behavior of NP-14:28 sample by Laboratory Absorption- Penetration test The principle of the test is simply to expose a bulk fertilizer surface of known area to a moving area at a controlled temperature and humidity & to measure the rate of moisture absorption at regular interval Simultaneous tests were carried out for 96 hrs. on the samples of NP-14 and NP-20 without anticaking coating to compare the test values. Parameters NP-14:28 NP:20 Test Duration, Hr 96 96 A average moisture penetration, cm 1 .13 1.28 Moisture penetration, % 13.14 14.38 M A, mg/cm2 (@ 96 Hrs) 121 142 M HC, mg/cm3 (at avg. penetration) 107 1 11 Test Result: Moisture absorption and penetration in NP-14:28 comparatively lower than NP-20, i.e. NP-14:28 is less hygroscopic than NP-20

9. Major challenges In NP-14:28 product formulation filler consumption is more compared to other grades produced at DAP/NPK plant. High moisture ~ 5% and high Silica SiO2~ 91% in the Filler (Sweet river sand) used in NP-14:28 formulation created frequent chutes chocking and erosion issues due to abrasion. Erosion by particles occurs in chutes, bends and diversions due to Impingement abrasion at dry sections basically in OSP inlet chutes- Develops holes and leakages Screen mesh worn out Dryer discharge to primary elevator chute thinned Similarly equipment erosion observed at wet section Slurry nozzle leaks PS pump impeller erosion Due to above challenges faced during the production, on-stream hours and availability of plant was less compared to other grades resulting in low production throughput.

10. Major challenges

11. Action plan for sustainable production SN Major Concerns Action Plan 1 Frequent chocking of chutes due to moisture in filler Provision for sand drying to be made as filler handling is more in this particular grade. 2 Erosions in dry section due to sliding and impingement abrasion caused by sand Abrasion resistance material lining at the affected area Teflon or Belzona lining may be applied which are proven materials f or areas of extreme wear due to abrasion. 3 Erosion in wet section MOC with high hardness for impellers and nozzles for improved durability in abrasive media.