Department of Chemistry

University of Chittagong

Course Code: Chem-3712

Course Title: Field Work and Industrial Tour
TSP Complex LImited 13th December 2022
North Patenga, Chattogram Tuesday

SUBMITTED TO:
Professor Dr. Sayeda Halima Begum
Chairman, Exammination Committee
Submitted By:
Third Year B.Sc. (Hon’s) Examination, 2021
Name : Sabbir Ahmed
ID : 19202051
Date of Submission: 2nd January, 2023 Session: 2018-19
 PREFACE

Fertilizer is a chemical or natural material that is given to soil or land to increase its
productivity by providing feed or nutrients to plants. Fertilizers are used in
agriculture to increase crop yield (the amount of crop produced per acre). From the
viewpoint of our country, TSP Complex Limited is leading the fertilizer area,
operated by Bangladesh Chemical Industries Corporation (BCIC).
 Acknowledgement

All the praises admiration and appreciation to the Almighty Allah who has enabled
us to go on this tour and learn these valuable knowledges.

During this knowledge dispersing industrial tour we learned a lot of about the
chemical processes that are used in different industries and companies. I express my
sincere gratitude to our respected teachers,
1. Dr. Shamim Akhtar,
2. Dr. M. Abdul Mannan,
3. Dr. Syeda Khurshida Begum,
4. Dr. Sayeda Halima Begum,
5. Dr. Mohammad Nasir Uddin,
6. Dr. Mohammad Ismail Hossain
7. Dr. Md. Kamrul Hossain,
8. Dr. Foni Bushon Biswas,
9. Ms. Jannatul Ferdous,
for arranging a visit in such a recognized company

We are also grateful to the chairman of Department of Chemistry, Professor Dr.

Debashis Palit.

We are also grateful to all the teacher of Department of Chemistry who provided us
their knowledge.
Contents:
 Introduction
 PRODUCTS
 Production Capability
 Total manpower
 Management System
 Plant description
 Plant Capacity
 Raw materials
 Manufacturing process
 GYPSUM (a by-product)
 Advantages and Disadvantages
 INTRODUCTION
Introduction The consumption of chemical fertilizer in Bangladesh since its
introduction in 1951-52 has steadily increased as the country has been modernizing
its agriculture for attaining autarky in food grain production thereby ensuring food
security and improving nutritional status. Triple Super Phosphate Complex Limited
(TSPCL) is a public sector enterprise registered as a private Limited Co. situated at
Patenga, Chittagong, under the administrative control of Bangladesh Chemical
Industries Corporation (BCIC). TSP Complex was established with the objective of
producing TSP fertilizer. Accordingly 2 (Two) units viz TSP-I and TSP-II-1, 20,000
MT respectively). Among the units TSP-II was commissioned earlier. TSP-I unit
went into commercial production in April 1977 and TSP-II in September, 1974. TSP
Complex is the only Phosphatic Fertilizer Factory of the country. Initially the factory
started with production of TSP. Later on since 1990 manufacturing of SSP Fertilizer
was started and his already established itself as a major fertilizer of the country. On
account of technical problem in TSP-I unit, the Phosphoric Acid (PA) Plant of the
unit was abandoned and closed. Due to increasing demand of SSP Fertilizer in the
country, the facilities of TSP-I were then converted to produce SSP. In TSP-II Unit,
necessary TSP-I and TSP-II plants are now known as Unit-I and Unit-II respectively.
Production of this factory is increasing day by day and in 2002-2003 total production
of 2,00,528 MT Phosphatic Fertilizer was achieved.
PRODUCTS:
1. Main Products: Triple Super Phosphate (TSP) Fertilizer, Single Super
Phosphate (SSP) Fertilizer and Mixed Fertilizer (NPKS).
2. Intermediate Products: Sulphuric Acid, Phosphoric Acid.
3. By-product: Gypsum

Production Capability:
The achievable production capacity of TSP fertilizer in Unit-II is 1,00,000
MT as Unit-I is completely closed since 2009.

Total manpower:
OFFICERS: 189
STAFFS: 234
WORKERS: 427
TOTAL: 850

Management System:
The responsibility of managing the company is vested with managing director who
act as the chief executive. He exercises all Powers of Administrative, commercial
and financial as delegated by Bangladesh chemical Industries Corporation (BCIC).
The divisional head lookes after different divisions such as operations, engineering,
technical, commercial, accounts and administration being responsible for their
respective field of Management and assist the chief executive in decision making.
There is a board of directors of the company comprising of seven directors including
the Managing Director. Chairman of BCIC is presently the chairman of the board of
directors.

Plant description:
The TSPCL has two unit of production plant. UNIT-I & UNIT-II. UNIT-1 has
been completely closed since 06-05-2009 as per Govt. instruction. After that,
TSP production going on in UNIT-II only. This plant consist of a sulphuric
acid plant, phosphoric acid plant, TSP plant and SSP plant.

Plant Capacity:
1. Sulphuric Acid - 400MTD
2. Phosphoric Acid -270MT
3. TSP – 400 MTD
4. SSP – 500 MTD

Raw materials:
Raw material sources:
1. Rock Sulphur: Iraq, Iran, Canada, Morocco, Saudi Arabia, Poland
2. Rock Phosphate: Jordan, Morocco, Egypt, China, Algeria, Syria
3. Phosphoric Acid: Tunisia, Poland, Iran, Morocco, India.
Raw materials for sulphuric acid production:
1. Rock Sulphur

2. Air (O2)

3. Deme Water

Raw materials for Phosphoric acid production:

1. Higher grade rock Phosphate.
2. Sulphuric acid.

Raw materials for TSP plant:

1. Low grade rock Phosphate.
2. Phosphoric acid.

Raw materials for SSP plant:

1. Low grade rock phosphate
2. Sulphuric acid.
Manufacturing process:

1.Sulphuric Acid Plant: Sulphuric acid is required for manufacturing of phosphoric

acid which is produced by ‘Monsanto Contact Process’.
In this process, rock sulphur is melted in a melter and burnt in a furnace in
presence of dried air where sulphur is oxidized to sulphur dioxide (SO2) gas.
This gas is then converted into sulphur trioxide (SO3) gas in a converter in
presence of catalyst, V2O5 under optimum conditions.
SO3 gas is then absorbed in 98.5% H2SO4 in an absorbing Tower. Strength of
the absorbing acid is thereby raised which in turn is diluted by adding
demineralized water to maintain the desired strength.
The quantity of acid in absorbing Tower is thus continuously increased and
the increased portion is sent to the storage tanks as 98.5% H2SO4.

Reactions: S + O2 = SO2, SO2 + ½ O2 = SO3, SO3 + H2 O = H2SO4

2.Phosphoric Acid Plant:

Phosphoric Acid required for production of TSP is manufactured by ‘Hemihydrate-
Dehydrate processes.
In this process, rock phosphate ground to the fineness of 70%, passing through
200 Tyler mesh is mixed thoroughly with Sulphuric Acid (70%) and dilute
Phosphoric Acid (19-21%) in a tank to acidulate.
The reacted slurry is passed into a series of tanks successively to
decomposition of rock, crystallization of gypsum and completion of
reaction. Slurry in each reacting vessel is constantly agitated with agitators.
Temperature and solid-liquid ratio and acid concentration are kept at
standard levels.
From the last reacting vessel, the slurry is pumped into a Vacuum Filter to
separate the acid form the Gypsum. The residue is the filter cake (Gypsum)
which is sent to Gypsum Yard after final washing with hot water. This residue
is the by-product ‘Gypsum (CaSO4.2H2O)’.
 Reaction: Ca3(PO4 )2 + 3H2SO4 + 6H2O = 2H3PO4 + 3CaSO4 .2H2O

Primary Digester First Second

Material Crystallizatio Crystallizatio
n n

Concentration Filter Third

48% Crystallizatio
H3PO4 n

3.TSP Plant:
Triple Super Phosphate is manufactured by decomposition of rock phosphate
ground to the fineness of 80% pass through 200 Tyler mesh in a Ball Mill, with
phosphoric acid (50% P2O5) in a Reaction Den under standard conditions. The
Den product is known as Green TSP.
Green TSP is fed in a Granulator through conveying system, where granules
are formed through the principle of agglomeration with steam and process
water. Granular TSP is then dried with hot air which is generated by
combustion of natural gas and then bagged to get finished product of granular
TSP.
Reaction: Ca3 (PO4 )2 + 4 H3PO4 + 3 H2O =3CaH4 (PO4)2 .H2O

4.SSP Plant:
SSP is manufactured by acidulating finely ground phosphate rock with 70-75%
sulphuric acid in Reaction Den under standard conditions of temperature and
flow rate. The outlet Den product known as Green SSP is kept in a curing house
for about three weeks for completion of the reactions. The cured SSP is then
dried by natural air and bagged to get finished product of powder SSP.

[N.B. Production of SSP in powder form started since 1988 in Unit No. 1. But
with the rising trend of use of SSP in agriculture, arrangement was made to
produce SSP through Unit No. 2 also.]
Reaction: Ca3(PO4 )2 + 2H2SO4+ 5H2O = 2CaSO4 .2H2O + CaH4(PO4)2 .H2O

5.Gypsum:
Gypsum (CaSO4 .2H2O) is a by-product of Phosphoric acid manufacturing
process has been used as a supplementary fertilizer for soil treatment. It is
generally used in sulphur deficient land/areas.

6.Mixed fertilizer (NPKS):

From the year 2002, TSPC is experimentally producing one grade of mixed
fertilizer for paddy grade as per recommendation of Bangladesh Agricultural
Research Council (BARC).
Marketing of this fertilizer has already been started for use at farmer’s end. We
are also working for production of NPKS suitable for tea production. This
fertilizer will increase the fertility of land and also production. The basic raw
materials are TSP, SSP, Ammonium Sulfate (AS), Di-ammonium Phosphate
(DAP) and Murate of Potash (MOP).

SULPHURIC ACID (H2 SO4):

Annual production: 62704 MT H2 SO4 98%
Color: Turbid White

USES:
Sulfuric acid is an intermediate product. It is mainly used for manufacturing
SSP and for production of phosphoric Acid, required for manufacturing TSP,
Sulphuric acid is an essential item for all kinds of chemical factory small or big
in size. About 5000-6000 MT Sulphuric acid per year is sold to the Industrial
organization of the country.

PHOSPHORIC ACID (H3PO4):

Annual production: 17884 MT (2006-2007)
Color: Turbid White
USES:
It is an intermediate product and used for manufacture of TSP. Entire quantity
of phosphoric acid produced is used in the process.

TRIPLE SUPER PHOSPHATE-TSP [ 3CaH4(PO4)2 .H2O]:

Moisture: 5% (max)
Total P2O5: 46% (min)
Water soluble P2O5: 40% (min)
Free P2O5: 3% (max)
Physical appearance: Granular
Size: 85% (Between -6 mesh & +16 mesh)

SINGLE SUPER PHOSPHATE-SSP [ CaH4(PO4)2 .H2O]:

Annual production: 55,014 MT (2007-2008)
Moisture: 8% (max)
Total P2O5: 18-20%
Available P2O5: 16% (min)
Free P2O5: 3% (max)
Sulphur: 10% (min)
Calcium: 18% (min)
Physical appearance: Powder.

USES:
Single Super phosphate commonly known as SSP is called mixed fertilizer.
Sulphur has been established as the fourth primary plant nutrient and is
necessary for all kinds of crops. It is also proved that without correction
Sulphur deficiency of the land, the remaining three nutrients (NPK) can only
be utilized by the plants to a limited extent and hence the product quantity but
also improves the product quality in helping to add more vitamin and protein
value. To provide both phosphorus and Sulphur nutrients to the lands, use of
SSP is rapidly increasing. As pre Govt. instruction, SSP is produced in powder
form.
GYPSUM (a by-product):
Chemical formula:
CaSO4.2H2O

Uses of Application:
Gypsum is obtained as a by-product during phosphoric acid manufacturing.
For a long time, use of gypsum except in Cement factories as retarder was not
known. Ultimately with the help of BARC this Sulphur enriched gypsum has
been established as a fertilizer. This gypsum contains 18% Sulphur and 30%
calcium, So, for 20kg Sulphur for a land of one hectre 112kg gypsum is to be
applied.
Annual Production: 41,575 MT

FLOW CHART:
Advantages and Disadvantages:
Advantages:
 TSP is quick in providing plant nutrients and restoring soil fertility.
 TSP improves at increasing the productivity of many crops such.
 TSP is preferred as starter fertilizer for low pH soil.
 TSPCL is the leading gypsum supplier in cement industry.
 H2SO4 another by product used in various chemical industry.

Disadvantages
 The gas evolved SO2 is very much harmful for the entire environment.
 When the gas evolves from the plant, people are affected by this gas
causing breathing problem.
 It also causes acid rain at that area.

Visiting Experience:
We learned about the many elements and equipment utilized, as well as
the various stages of production and the complete process of fertilizer
manufacturing, from raw materials through the final product and the
packaging process, during our visit to the TSP Complex Limited.
Overall, learning about the process of fertilizer manufacture and
distribution was a terrific experience.

Conclusion:
TSPCL plays a very important role in our economy. Its sales revenue was
38135.49 lakhs taka in 2016-17 economy year. And this was
impressively increased. The sales revenue become 43220.33 lakhs taka
in 2018-19 economy year. TSPCL makes a profit of 5458.87 lakhs taka
in last 2017-18 economy year which was very much impressive.
Patenga Sea Beach:
After the learning period at TSP Fertilizer Limited, we went to Patenga Sea Beach
for some refreshment. We arrived at the beach at 4 pm. Stayed there for one hour,
enjoyed the cool breeze of the Bay of Bengal, took photos with our respected
teachers.