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Amir Alvi & Satya Subrahmanyam 23 rd June 2017 Circular Economy in Phosphatic Fertilisers Coromandel Experience
Amir Alvi & Satya Subrahmanyam
23rd June 2017
Circular Economy in Phosphatic Fertilisers
Coromandel Experience
Contents
1 Introduction to Murugappa Group
2 About Coromandel International
3 Fertiliser Business - Circular Economy
RM & Utilities efficiency
Wealth from Waste
4 Case Study 1 Gypsum
5 Case study 2 Organic Fertilser
6 Way Forward
2
$4.5 Bn. Diversified Group with presence in 3 key sectors
Workforce
40,000+
28 Businesses
9 listed entities
Revenue
$4.5 Bn.
Market Cap
$6.2 Bn 55
Locations
Agriculture
Engineering
Financial Services 116 years in
Business
Murugappa Group - Introduction
3
Murugappa Group – Major Companies
4
Coromandel International Limited – Future Positive
Visakhapatnam
Kakinada
Jammu
Ankleshwar
Ennore
Sarigam
Pali
Udaipur
Kota Rae Bareli
Vadodara
Hospet
Ranipet
Nimrani Dahej
Crop Protection Plants
Fertiliser Plants - Complexes
Fertiliser Plants - SSP
India’s largest private sector
Phosphatic Fertiliser company
5th largest Agro Chem Indian
company
India’s largest Single Super
Phosphate (SSP) company
Pioneers & market leaders in
Specialty Nutrients
No. 1 Organic Manure player in
India
Largest Rural Retail Chain across India
Coromandel’s Manufacturing Presence
Part of USD 4.5 billion Murugappa Group 6
About Coromandel
Turnover: USD 1.6 billion (FY16-17)
Market Cap: USD 1.8 billion (May 2017)
Strong credit rating: ‘AA + (Stable outlook) with CRISIL India
Employees: 4300 & equal no. of contract employees
International Linkages: FOSKOR, GCT, CANPOTEX, SQM, GETAX, QAFCO, ICL, OCP, YANMAR etc
International Markets: Latin America, Africa, China, South East Asia, Middle East.
Strong Brand Equity Cost effective production Doing it Responsibly Bringing Prosperity R&D Focus 7
About Coromandel
Fertiliser Business Units
Phosphatic Fertilisers
Specialty
Nutrients & Organic fert
DAP
Complex Fertilisers
SSP/MOP
G-Sulphur
Water Soluble Ferts
Organic Manure
Fertiliser Business
Segments
8
• Solid – Gypsum, Sludge
• Liquid - Effluent • Air- Fluorine, Steam
• Raw materials ( Solid/ Liquid) • Utilities (Power/Water/Fuel)
Best Raw Material & Utilities efficiency
Wealth out of waste
Circular Economy – Fertilisers
9
Best Raw Material & Utilities efficiency
• Operates at Raw material 95 - 99.5 % Efficiency. • Usage of Screw unloader for solid RM that
reduces dust emissions by 95% at port. • Pipe conveyors usage for minimal material
emissions during transfer. • Minimised Phos-acid Sludge level by reuse into
complex fertiliser plant.
Raw Material Energy
Water Others
• Specific steam generation increased from 1.15 MT/MT to 1.2 MT/MT (Rs.10 Cr investment made).
• Captive power generation with waste steam that meets 60 -70% power requirement
• Purchasing “Green Power” at 3-5% of total requirement.
• Multi effect desalination unit of 1000M3/Day at Ennore unit.
• Specific fuel consumption reduction by continuous improvement projects.
• Zero liquid Discharge plant (Kakinada & Ennore), Vizag unit heading towards ZLD.
• Specific consumption of Water norm decreasing by 12-15% YOY.
• Effluent treatment plant and Sludge treatment units
Vizag unit won “Best PAP Production Unit” from FAI 16 times in last 20 years for efficient operation of PAP Plant
Circular Economy – Fertilisers
10
Energy Material
Emissions Others
• Revenue Generation from Gypsum. • Usage of sugar plant waste as filler in the product. • ETP and STP sludge reusage. • P205 from Sludge recovery in the possible efficient
way.
• Revenue generation from Fluro Silicilic acid. • New train construction with state of art
technology for NH3 emissions <50mg/Nm3. • SAP plant operating at low SO2 emission of
0.65kg /MT of Sulfuric acid against norm of 2.5 kg/MT.
Wealth out of Waste
• Air Preheater technology for drying of product from Waste steam generation.
• Power generation at 0.15 Ps per unit cost from Waste steam generated.
• “Turning Factory into Bird Sanctuary” ,a documentary video presented on UNDP website
• Greening of Phosphogypsum sediments
Utilisation of Wastes Like Gypsum, Fluoro Silicilic Acid and Sugar Plant Waste to generate Revenues
Greening of Phospho-gypsum Sediments
11
• A barren greyish land with no vegetation or life had become a bone of contention.
• Very Low PH, Chlorides in sediment and water pools below one foot Microorganisms growing on media plates
Microorganisms Fungi Bacteria
Penicillium sp Pseudomonas sp
Aspergillus sp
Bacillus sp
Trichoderma sp
E. coli
Verticillium sp
The promising Innovation
Developed sediment & plant suitable consortium of
Bacteria and Mycorrhiza.
Bridged the gap between plant roots and harsh
sediment particles through symbiotic relationship to
draw nutrients
Experimentation
Developed specific
plantation management
principles
plant species selection
plantation nursery
practices
special training to
workmen
0ptimum water irrigation
Innovative Solution to A Global Gypsum Problem
Greening of Phospho-gypsum Sediments
12
• IFA appreciated Coromandel for sharing the project details
• PG working group acclaimed Coromandel for a “Breakthrough“
• IFA team invited all member country representatives to visit Visak plant to witness the unique project.
• Coromandel developed bio-remediation methodology was adopted by M/S Agrium, Canada
• Skoch Renaissance Award
• Frost & Sullivan - Project of year Award.
Plantation could with stand – 170 KM PH wind speed ( Cyclone HUD HUD )
Coromandel, while addressing a “Local issue” came out with
“An innovative solution,”
had wider national and international application.
Before – lifeless After – back to nature
Global Applications and Recognition
Bio Remediation Methodology
Bird Sanctuary in A factory - Kakinada
13
• Total Bird Species – 95 • Breeding Species – 13 • Long Distance Migratory Birds – 24 species • Maximum Numbers recorded within
Coromandel Premises alone- 6000 • Total period of utilization – Throughout the year
A short video on Kakinada plant – ”Turning A Factory Into a Bird Sanctuary” at UNDP (UN Development Program) Website. This was shot by people from EGREE (East Godavari River Estuarine Ecosystem) and shows our plant as a Success Story.
https://www.youtube.com/watch?v=Q0FDLaQUQ18
Unique Concept of Bio Diversity and Co-Existence
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• Raw materials ( Solid/ Liquid) • Utilities (Power/Water/Fuel)
• Solid – Gypsum,Sludge • Liquid - Effluent • Air- Fluorine,Steam
Best Raw Material & Utilities efficiency
Wealth out of waste
Case Study 1- Phosphoric acid Unit
• Gypsum
Gypsum Is a by-product of Phosphoric Acid Manufacturing
One Ton of Phos acid gives 4.5 Tons
of Gypsum
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Worldwide Gypsum Disposal Methods are Either Stacking or Disposal Into Sea
Gypsum – National Scenario
World over PG Stacks 30 to 40 meters height
• Phospho Gypsum generation increased
from 4 Million Tons per year to 8 Million Tons per year over past 15years.
• Huge Disposal issues.
• Wet Disposal Method was prevailing
among most of Phosphoric acid manufacturing units.
• Stringent Gypsum Disposal norms in India as compared to other Nations.
• Challenges being faced till today
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Very Strict Norms (Recently Revised) for Storage and Handling of Gypsum
Switch from Wet Disposal to Dry Gypsum Generation
Phosphoric acid Plant Horizontal Belt Filter
HDPE lines area Dry Gypsum Handling
Coromandel shifted to Dry Gypsum method during 2006-08 much before it was made mandatory
17
Leaching of Gypsum and Acid into Soil is a Natural Phenomena
Entire Leachate collected from the gypsum storage area is reused into plant.
Gypsum Storage and Handling
HDPE geo-membrane minimum thickness of 1.5 mm
Compacted clay layer of thickness 60 cm
The permeability of the layers less than 1x10E-7 m/sec as
per CPCB guidelines
18
Strict Quality Control and Processing is Required to make Gypsum Sale Worthy
Waste to Wealth - Gypsum Management
Fertiliser For Agriculture
Cement for Construction
19
Dedicated Teams are Working towards Handling and Sales of Gypsum to Generate Wealth
17.98 million MTs disposed
Balance old stock of approx 3.1 lakh MT will be disposed by March’ 18
Gypsum Disposal
20
21
• Raw materials ( Solid/ Liquid) • Utilities (Power/Water/Fuel)
• Solid – Gypsum,Sludge • Liquid - Effluent • Air- Fluorine,Steam
Best Raw Material & Utilities efficiency
Wealth out of waste
Case Study 2 - Organic Fertilser
Wealth out of Waste: Organic Fertilser
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India is the second largest nation
in the world, with a population of
1.21 billion, accounting for
nearly 18% of world’s human population, but it does not have enough resources or a systems in place to treat its
Solid Wastes ……………………
Rapid urbanization and industrialization has
caused tremendous increase of municipal solid waste generation in
developing countries.
The per capita waste generation rate in India has increased from 440 gm/day in 2001 to 500 gm/day in 2011, fuelled by changing lifestyles and increased purchasing power of urban Indians
Organic Farming has Grown almost 7 fold in last 10 years - Increasing Demand for Organic Food Products
Organic Fertilser- Composting
23
Composting Process Composting Operations
Tied up with Vizag Municipal Cooperation for Municipal Waste Recycling Project
Coromandel Organic Manure: Enriching Soil Health
Organic Fertilisers
Bio compost (Soil Health Enabler)
Bio/Microbial and Organic
Fertiliser P – Phosgold
(Compost + Rock P)
N – Nrich (oil cake)
K – Kash (Molasses)
Press Mud (By prod Sugarcane)
City compost
Oil Cakes
• Waste generated beyond boundaries – conversion to
Wealth.
Soil Health Focus - Sustainable Agriculture.
Consumption shift - Green Food.
Product Portfolio
0.2
1.31
FY09 FY17
Organic Vol (in Lakh MT)
26% CAGR
Pioneers in Organic
Fertilisers
Market leaders ~30% value
share
Efficient sourcing &
distribution
24 Coromandel has grown by 26% in last year and are market leaders with 30% value share
Way Forward
25
Zero Liquid Discharge – Vizag manufacturing unit.
Continuous Improvement in the Specific consumption norms of Resources through Operational improvement Projects.
Tie up with Vizag GVMC for the project Municipal Waste to Wealth (Organic Soil conditioner/Fertiliser)
Improving the quality of Gypsum.
Granulation of Gypsum for Soil conditioning
