Sterlite Copper’s Phosphoric Acid plant can produce about 2,30,000 MT of P2O5 per annum. The entire tonnage is sold within and outside India.
Phosphoric acid is produced through a reaction between sulphuric acid and rock phosphate. Sterlite Copper imports rock phosphate from major rock mining companies around the world.
Technology and Basic Engineering for the plant has been sourced from Hydro Agri International, UK, and the process used is known as Hemi-Hydrate Di Hydrate Process.
Phosphoric Acid is majorly used in Fertilizer manufacturing like Diammonium Phosphate (DAP) and NPK manufacturing and it is also used in fertigation.
Phosphoric Acid is also used in making animal feeds like Di-Calcium phosphate (DCP) and Mono Dibasic Calcium Phosphate (MDCP).
At Sterlite Copper the sulphur dioxide gases generated during copper smelting process is collected and ducted to the Sulphuric Acid Plant. Set up with basic engineering from Kvaerner Chemetics, Canada, the plant is based on the absorption process known as DCDA, and can produce about 12,00,000 tonnes of Sulphuric Acid per annum. Most of the produced sulphuric acid quantity is used by the in-house Phosphoric Acid Plant for Phosphoric Acid generation. Balance quantities of Sulphuric Acid are sold within and outside India by the company.
| Parameters | Sulphuric Acid Specification |
|---|---|
| Concentration | 98% minimum |
| Specific Gravity | 1.82 to 1.84 |
| Arsenic | 2.5 ppm (max) |
| Mercury | 1 ppm (max) |
| Lead | 2 ppm (max) |
| Cadmium | 5 ppm (max) |
| Residue on Ignition | 0.20 % (max) |
| Iron | 0.05 % (max) |
| SO2 | Less than 50 ppm |
Sulphuric acid is a widely used industrial chemical. While its largest use is in the manufacture of fertilizers and phosphoric acid. Sulphuric acid is also a raw material in the production of other industrial chemicals such as titanium dioxide and hydrogen fluoride. It is also an important input in the mining, oil refining, pulp and paper, detergent manufacturing and steel industries.
Hydrofluorosilicic Acid, also known as FSA or HFS, is a transparent, colorless, aqueous solution that is used in a variety of applications. One of its most common uses is in the fluoridation of water. FSA is produced during the concentration of phosphoric acid in an evaporation process unique to the phosphate industry. The vapor stream from the phosphoric acid reaction is scrubbed with water to form FSA from the naturally occurring silica and fluorine in the phosphoric acid. The final product is collected, stored and tested prior to release for sale. Sterlite Copper produces about 10,000 metric tonne of FSA per annum for sale.
| Parameters | Hydrofluorosilicic Acid Specification |
|---|---|
| Specific Gravity | 1.15 to 1.20 |
| H2SiF6 | 18 to 24 % |
| P2O5 | 200 ppm (max) |
Ferro Sand (also known as Copper Slag) is a by-product generated during pyro-metallurgical process to produce Copper. Sterlite Copper produce approximately 6,00,000 MT of Copper Slag per annum.
Ferro Sand is non-toxic, non-leachable and non hazardous material in nature. Central Pollution Control Board (CPCB) has recommended usage of Ferro Sand as building and road construction material, for land filling applications and in Cement Industry.
The physical properties of Ferro Sand is similar to that of the river sand and the same is being used as the replacement to river sand (in proportion) in most of the countries like USA, Singapore, China etc. With increasing scarcity and ever raising prices of river sand & m-sand across the country there is need for alternative material for replacement which is reliable as well as economical. Ferro Sand will fit the requirement suitably as it is 100% environmental friendly, economical and available throughout the year.
| Parameters | Ferro Sand Specification |
|---|---|
| Apperance | Black Galssy Granules |
| Colour and Grain Shape | Black and Granular |
| pH of aqueous solution of aqueous extract as per ISO 11 127 | 6.6 – 7.2 |
| Water soluble chloride content as per ISO 11 127- 7 | 11 ppm |
| Specific Gravity | 3.5 – 3.8 |
| Bulk Density | 1.9 |
| Hardness | 6 – 7 MoH Scale |
| Chemical Composition | |
| Fe2O3 | 55-60 % |
| SiO2 | 27-33 % |
| CaO | 1-3.5 % |
| Al2O3 | 3% |
| Cu | Traces – 1% |
| Free Moisture | 1-2 % |
| Sieve Size (in mm) | Ferro Sand Size |
| > 4.0 | 1.34 |
| 4 – 3.35 | 0.66 |
| 3.35 – 2.80 | 0.02 |
| 2.80 – 1.70 | 11.06 |
| 1.70 – 1.40 | 6.95 |
| 1.40 – 1.18 | 7.29 |
| 1.18 – 1.00 | 13.93 |
| 1.00 – 0.85 | 9.8 |
| 0.85 – 0.30 | 46.19 |
| < 0.30 | 2.76 |
| Total | 100 |
Across years Sterlite Copper has conducted major research studies in collaboration with premium institutions of our country to ascertain the sustainable applications of copper slag in construction sectors.
Phospho Gypsum is produced as a by-product at Sterlite Copper while manufacturing Phosphoric Acid from Rock Phosphate and Sulphuric Acid. Phospho Gypsum produced at Sterlite Copper is of better quality when compared to other Phospho Gypsum plants in the world, with lesser P2O5 content in it due to Hemi Di Hydrate technology.
Sterlite Copper is the only manufacturer in India to have Hemi Di Hydrate technology. Sterlite Copper can produce about one million metric ton of quality Phospho Gypsum per annum.
Phospho Gypsum obtained through above mentioned technology does not contain any heavy metals and has a purity of about 90%. It is further processed using raw water inorder to reduce impurities. At Sterlite Copper the generated Phospho Gypsum is been dry stacked and hence the moisture levels of Sterlite Copper Phospho Gypsum are considerably lower than the market available as most of the other producers in India use Wet Ponding Technique.
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| Parameters | Phospho Gypsum Specification |
|---|---|
| Apperance | Black Galssy Granules |
| Colour and Grain Shape | Black and Granular |
| pH of aqueous solution of aqueous extract as per ISO 11 127 | 6.6 – 7.2 |
| Water soluble chloride content as per ISO 11 127- 7 | 11 ppm |
| Specific Gravity | 3.5 – 3.8 |
| Bulk Density | 1.9 |
| Hardness | 6 – 7 MoH Scale |
| Chemical Composition | |
| Fe2O3 | 55-60 % |
| SiO2 | 27-33 % |
| CaO | 1-3.5 % |
| Al2O3 | 3% |
| Cu | Traces – 1% |
| Free Moisture | 1-2 % |
| Sieve Size (in mm) | Ferro Sand Size |
| > 4.0 | 1.34 |
| 4 – 3.35 | 0.66 |
| 3.35 – 2.80 | 0.02 |
| 2.80 – 1.70 | 11.06 |
| 1.70 – 1.40 | 6.95 |
| 1.40 – 1.18 | 7.29 |
| 1.18 – 1.00 | 13.93 |
| 1.00 – 0.85 | 9.8 |
| 0.85 – 0.30 | 46.19 |
| < 0.30 | 2.76 |
| Total | 100 |
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Phospho Gypsum is majorly being used in Cement Industries, Brick Manufacturers and Plaster of Paris manufacturing. Phospho Gypsum is an economical and quality substitute for natural gypsum and other varieties of Gypsum.
Sterlite Copper Phospho Gypsum is widely used in Fertilizer applications for Soil Reclamation/ Conditioning and as nutrient for growth of Oil Crops.