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By-Products

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.

Applications

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).

Packaging

  • In bulk through tankers of 16 metric tonne solution capacities
  • In bulk through vessel with minimum 10,000 metric tonne solution.

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.

Sulphuric Acid Specification

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

Applications

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.

Packaging

  • In bulk through tankers of 16 metric tonne capacities.
  • In bulk through vessel with minimum 10,000 metric tonne.

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.

Hydrofluorosilicic Acid Specification

Parameters Hydrofluorosilicic Acid Specification
Specific Gravity 1.15 to 1.20
H2SiF6 18 to 24 %
P2O5 200 ppm (max)

Packaging

  • In bulk through tankers of 16 metric tonne capacities.

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
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

Applications

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.

The results of these studies and its sustainable applications are listed below

  • Paver Blocks and Bricks manufacturing process – Replacement of fine aggregate up to 25% (as per CRRI -New Delhi study conducted on copper slag).
  • Concrete Applications – Ferro Sand can replace river sand in fine aggregate up to 50% (as per IIT , Kanpur study report titled “Durability of Cement Concrete using Copper Slag”).
  • Sand / Landfilling – 100% replacement & best alternative option for gravel/ red soil/ river sand. (this is because Copper Slag is non-leachable which is supported by the study conducted by Industrial Toxicology Research Center, CSIR, Lucknow titled “Leachability Test for Slag Sample”).
  • Road Application – Replacement of fine aggregates up to 20% in all layers of the road and embankment construction (Evident from CRRI, New Delhi study titled “Feasibility Study on Use of Copper Slag in Road and Embankment Construction).

Packaging

  • In bulk through trucks of 21 metric tonne capacities
  • In bulk through vessel with minimum 30,000 metric tonne.

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.

Applications

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.

Packaging

  • In bulk through trucks of 21 metric tonne capacities
  • In bulk through vessel with minimum 30,000 metric tonne.
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