Calcium Thiosulfate Manufacturing Plant Project Report: Key Insights and Outline

Calcium Thiosulfate Manufacturing Plant Project Report by Procurement Resource thoroughly focuses on every detail that encompasses the cost of manufacturing. Our extensive cost model meticulously covers breaking down Calcium Thiosulfate plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimization and helps in identifying effective strategies to reduce the overall Calcium Thiosulfate manufacturing plant cost and the cash cost of manufacturing.

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Calcium thiosulfate is an inorganic compound that is utilised as a liquid fertiliser for agriculture. It provides essential calcium and sulfur to crops. It is used in water treatment as a dechlorination agent and in other industrial processes. The growing focus on sustainable agricultural practices and efficient nutrient management leads to the increasing demand for calcium thiosulfate in speciality chemicals and the agriculture sector.
 

Industrial Applications of Calcium Thiosulfate

Calcium thiosulfate finds its applications as a fertiliser, dechlorinating agent, and complex-forming agent.

• Agriculture: Calcium thiosulfate is utilised as a liquid fertiliser to correct calcium and sulfur deficiencies in soil and plants.
  • Nutrient Supply: It provides calcium that is important for cell wall formation, root development, and nutrient uptake, and thiosulfate sulfur that is required for protein synthesis, chlorophyll production, and healthy crop growth.
  • Soil Amendment: It works as "liquid gypsum" to improve soil structure, porosity, and water infiltration, and helps in leaching harmful soil salts in acidic or sodic soils.
  • Nitrogen Stabiliser: It is used as a nitrogen stabiliser and helps to reduce ammonia volatilisation from surface-applied urea, which improves its efficiency.
• Water Treatment: It is used as a dechlorination agent to remove chlorine from tap water, wastewater, and aquaria. It's a safer and more eco-friendly option compared to some other dechlorinating agents.
• Flue-Gas Desulfurization (FGD): It is used in some advanced FGD processes for removing sulfur dioxide from industrial emissions.
• Ozone and Hydrogen Peroxide Quenching: It is utilised to quench excess ozone or hydrogen peroxide in various industrial processes.
   

Top 5 Industrial Manufacturers of Calcium Thiosulfate

The following calcium thiosulfate includes specialised chemical producers and agricultural input suppliers that focus on producing high-purity calcium thiosulfate.

• Tessenderlo Kerley, Inc.: It is a major global producer of sulfur-based plant nutrients that include various thiosulfates.
• Nutrien Ag Solutions: It is a leading provider of agricultural products and services and provides a range of fertilisers.
• Yara International ASA: It is a global fertiliser company that produces and markets several crop nutrition products that include speciality fertilisers.
• Vizag Chemical: It is a chemical manufacturer and supplier that provides high-quality calcium thiosulfate.
• Peptech Biosciences Limited: It is a biosciences company that manufactures and supplies liquid calcium thiosulfate fertiliser.
   

Feedstock for Calcium Thiosulfate and Its Market Dynamics

The feedstock for calcium thiosulfate production varies depending on the specific manufacturing process chosen.
 

Feedstock for Production from Calcium Chloride:

The major feedstock for this process is calcium chloride and sodium thiosulfate.

• Calcium Chloride: It is commonly produced as a by-product of the Solvay process (soda ash production) or from the neutralisation of hydrochloric acid with calcium carbonate (limestone) or calcium hydroxide. The industrial procurement of calcium chloride is influenced by the demand for soda ash, energy costs for its production, and the availability of natural brines.
• Sodium Thiosulfate: It is produced by reacting sodium sulfite with sulfur, or from by-products of sulfur dioxide scrubbing processes in industrial emissions control. Its costs and availability are affected by sulfur prices, sodium sulfite costs, and the demand from its downstream industries like photography, dechlorination, and gold extraction.
   

Feedstock for Production via Metathesis Reaction:

The primary feedstock for this process is ammonium thiosulfate and either calcium hydroxide or calcium oxide.

• Ammonium Thiosulfate: It is produced by reacting ammonia, sulfur dioxide, and water, often with elemental sulfur. Its price is influenced by sulfur and ammonia prices, and the demand from its primary use as a fertiliser.
• Calcium Hydroxide/ Calcium Oxide: Calcium Hydroxide is produced by reacting calcium oxide (quicklime) with water, while calcium oxide is produced by calcining (heating) limestone (calcium carbonate) at high temperatures. Their prices are mainly influenced by the cost of limestone, energy (for calcination), and demand from construction, steel, and water treatment industries.
   

Dynamics Affecting Raw Materials

The dynamics affecting these raw materials are important for the cash cost of production and overall manufacturing expenses of calcium thiosulfate.

• Commodity Price Instability: The prices of calcium chloride, sodium thiosulfate, ammonium thiosulfate, and calcium hydroxide/oxide are affected by market fluctuations, geopolitical events, and supply-demand imbalances.
• Integrated Production Benefits: The producers that have large-scale industrial processes (like chlor-alkali, sulfur recovery, fertiliser production) have a cost advantage in sourcing raw materials.
• Energy Costs: Production of many raw materials (like sodium hydroxide, calcium oxide, ammonium thiosulfate) is energy-intensive, and their production costs are impacted by fluctuations in energy prices.
• Transportation and Handling Costs: The cost of transporting materials like sodium hydroxide or ammonium thiosulfate that require specialised handling adds to their production cost.
   

Market Drivers for Calcium Thiosulfate

The market for calcium thiosulfate is influenced by several factors:

• Growing Demand for High-Efficiency Fertilisers: The increasing global demand for sustainable and efficient agricultural practices that improve crop yield and quality contributes to its market. Its ability to provide essential calcium and sulfur, improve nutrient uptake, and enhance soil structure makes it a valuable additive in modern agriculture.
• Increasing Awareness of Soil Health: The growing awareness among farmers of the importance of soil health and structure boosts its demand further.
• Demand for Water Treatment Chemicals: The rising concerns for environmental sustainability and strict regulations for water quality drive the demand for effective dechlorination agents in tap water, wastewater, and industrial processes.
• Compatibility with Modern Agricultural Practices: Its liquid form and compatibility with a wide range of other fertilisers and agrochemicals make it an ideal component of integrated nutrient management strategies and precision agriculture.
• Geographical Market Dynamics:
  • North America: This region’s market is driven by the adoption of advanced agricultural practices, large-scale crop production (e.g., corn, wheat), and a well-established agricultural infrastructure.
  • Asia-Pacific (APAC): The market for this region is influenced by a rising population, the need for strong agricultural productivity, and government initiatives promoting sustainable farming.
  • Europe: The market for this region is supported by strict environmental regulations and a growing preference for eco-friendly fertilisers and sustainable agricultural solutions.
     

Capital and Operational Expenses for a Calcium Thiosulfate Plant

Establishing a calcium thiosulfate manufacturing plant involves a significant total capital expenditure (CAPEX) and careful management of ongoing operating expenses (OPEX). A detailed cost model and production cost analysis are crucial for determining economic feasibility and optimising the overall calcium thiosulfate plant cost.
 

CAPEX: Comprehensive Calcium Thiosulfate Plant Capital Cost

The total capital expenditure (CAPEX) for a calcium thiosulfate plant covers all fixed assets required for reaction, purification, and product finishing. The specific equipment will vary depending on the chosen process.

• Site Acquisition and Preparation (5-8% of Total CAPEX):
  • Land Acquisition: Purchasing suitable industrial land, considering access to raw material supply, utilities, and logistics.
  • Site Development: Earthwork, foundations for vessels and tanks, internal roads, drainage systems, and utility connections.
• Raw Material Storage and Handling (10-15% of Total CAPEX):
  • For Calcium Chloride Process: Storage tanks for calcium chloride solution and sodium thiosulfate solution, or silos/hoppers for solid forms with dissolution tanks.
  • For Metathesis Process: Storage tanks for ammonium thiosulfate solution and silos for calcium hydroxide or calcium oxide powder, with slurrying systems.
  • Metering and Pumping Systems: For precise dosing of raw materials into reactors.
• Reaction Section (20-30% of Total CAPEX):
  • Reaction Vessels: Stirred tank reactors made of appropriate corrosion-resistant material (e.g., stainless steel), designed for the specific reaction conditions (temperature, pH). For the ammonium thiosulfate route, reactors must facilitate ammonia removal. These are central to the calcium thiosulfate manufacturing plant cost.
  • Heating/Cooling Systems: Jackets or coils for precise temperature control during the reaction.
  • Agitation Systems: Robust agitators for efficient mixing.
• Separation and Purification Section (25-35% of Total CAPEX):
  • Filtration Units: For removing solid by-products (e.g., sodium chloride if formed in solid form, or insoluble calcium salts) or unreacted materials. This could include plate and frame filters, filter presses, or centrifuges.
  • Evaporation/Concentration: For concentrating the calcium thiosulfate solution, especially if a high-concentration liquid product is desired. This often involves multi-effect evaporators for energy efficiency.
  • Ammonia Removal System (for Metathesis Process): If the metathesis route is used, equipment for efficient ammonia removal (e.g., stripping columns, vacuum evaporation) to achieve high purity and concentration without decomposing thiosulfate. This may include a system for ammonia recovery for recycle or sale.
• Finished Product Storage and Packaging (5-8% of Total CAPEX):
  • Liquid Product: Large storage tanks for liquid calcium thiosulfate solution.
  • Solid Product (if applicable): Dryers (e.g., spray dryers, drum dryers), cooling systems, and bagging machines if a solid crystalline or powdered product is desired.
• Utility Systems (10-15% of Total CAPEX):
  • Steam Generation: Boilers for heating reactors and evaporators.
  • Cooling Water System: Cooling towers and pumps for process cooling.
  • Electrical Distribution: Transformers, switchgear, and cabling throughout the plant.
  • Compressed Air System: For instrumentation and pneumatic actuators.
  • Wastewater Treatment Plant: Facilities for treating aqueous waste streams to meet environmental discharge regulations (e.g., for salts, residual sulfur compounds).
• Automation and Instrumentation (5-10% of Total CAPEX):
  • Distributed Control System (DCS) or PLC-based control systems for precise monitoring and control of temperature, pH, flow, and level.
  • Sensors, analysers, and automated control valves.
• Quality Control Laboratory: Equipment for in-process testing and final product analysis to maintain quality standards.
• Engineering, Procurement, and Construction (EPC) Costs (10-15% of Total CAPEX):
  • Includes detailed process design, material sourcing, civil works, mechanical erection, electrical, and instrumentation installation.

The aggregate of these components defines the total capital expenditure (CAPEX), significantly impacting the initial calcium thiosulfate plant capital cost and the viability of the investment cost.
 

OPEX: Detailed Manufacturing Expenses and Production Cost Analysis

Operating expenses (OPEX) are the recurring manufacturing expenses necessary for the continuous production of calcium thiosulfate. These costs are crucial for the production cost analysis and determining the cost per metric ton (USD/MT) of calcium thiosulfate.

• Raw Material Costs (Approx. 50-70% of Total OPEX):
  • For Calcium Chloride Process: Cost of calcium chloride and sodium thiosulfate. Strategic industrial procurement is vital to managing market price fluctuation.
  • For Metathesis Process: Cost of ammonium thiosulfate and calcium hydroxide/oxide. These costs are influenced by the agricultural commodity markets for ammonia/sulfur and energy costs for lime.
  • Process Water: For reaction, dissolution, and washing.
  • Additives/Processing Aids: If any are used to improve filtration or stability.
• Utility Costs (Approx. 15-25% of Total OPEX):
  • Energy: Primarily steam for heating reactors and evaporators/dryers, and electricity for pumps, agitators, and conveying systems. Evaporation/drying (if applicable) and ammonia removal can be major energy consumers, directly impacting operational cash flow.
  • Cooling Water: For process cooling.
• Labour Costs (Approx. 8-15% of Total OPEX):
  • Salaries, wages, and benefits for plant operators, maintenance staff, quality control personnel, and administrative support.
• Maintenance and Repairs (Approx. 3-6% of Fixed Capital):
  • Routine preventative maintenance programs, unscheduled repairs, and replacement of spare parts for reactors, filters, evaporators, and pumps. This includes lifecycle cost analysis for major equipment.
• Waste Management and Environmental Compliance (2-4% of Total OPEX):
  • Costs associated with treating and disposing of aqueous waste streams (e.g., containing sodium chloride from the first process, or residual ammonia from the second process), and any solid residues. Compliance with environmental regulations for sulfur-containing compounds is crucial.
• Depreciation and Amortisation (Approx. 5-10% of Total OPEX):
  • Non-cash expenses that account for the wear and tear of the total capital expenditure (CAPEX) assets over their useful life. These are important for financial reporting and break-even point analysis.
• Indirect Operating Costs (Variable):
  • Insurance premiums, property taxes, general administrative overhead, and expenses for research and development aimed at improving production efficiency metrics or exploring new cost structure optimisation strategies.
• Logistics and Distribution: Costs for transporting raw materials to the plant and finished calcium thiosulfate (often as a liquid bulk product) to customers.

Effective management of these operating expenses (OPEX) through continuous process improvement, efficient industrial procurement of feedstock, and stringent quality control is paramount for ensuring the long-term profitability and competitiveness of calcium thiosulfate manufacturing.
 

Calcium Thiosulfate Industrial Manufacturing Processes

This report comprises a thorough value chain evaluation for calcium thiosulfate manufacturing and consists of an in-depth production cost analysis revolving around industrial calcium thiosulfate manufacturing. We will examine two distinct processes for its synthesis.
 

Production from Calcium Chloride:

The manufacturing process of calcium thiosulfate involves a reaction between calcium chloride and sodium thiosulfate. In this process, calcium chloride reacts with sodium thiosulfate in a stirred reactor at temperatures of 45–90 degree Celsius. This double displacement reaction results in the formation of calcium thiosulfate and sodium chloride in solution. The final is separated and concentrated to get pure calcium thiosulfate as the final product.
 

Production via Metathesis Reaction:

In this metathesis process, ammonium thiosulfate solution is added to a slurry of calcium hydroxide (or calcium oxide) in a stirred reactor at 25–85 degree Celsius. This reaction leads to the formation of calcium thiosulfate and volatile ammonia (that is efficiently removed by heating, air sparging, or vacuum). The resulting solution is filtered and purified to get pure Calcium Thiosulfate as the final product.
 

Properties of Calcium Thiosulfate

Calcium Thiosulfate (CaS2O3) is an inorganic salt that has a molecular weight of 152.21 g/mol. It has the following physical and chemical properties that make it useful as a source of soluble calcium and thiosulfate sulfur.
 

Physical Properties

• Appearance: Clear, colourless liquid (commercial solution); white crystalline solid when pure.
• Odour: Odourless or mild sulfur smell.
• pH: Neutral to slightly basic (6.5–9.0).
• Freezing Point: ~0 degree Celsius; may crystallise below this.
• Boiling Point: ~100 degree Celsius; decomposes on prolonged heating.
• Density: 1.20–1.33 g/cm³.
• Solubility: Highly water-soluble.
• Flammability: Non-flammable.
   

Chemical Properties

• Formula: CaS2O3 (ionic salt of Ca²⁺ and S2O₃^2-).
• Reactivity: Thiosulfate ion oxidises over time, releasing plant-available sulfur.
• Reducing Agent: Used in dechlorination (reduces Cl² to Cl^-).
• Complexing Ability: Forms complexes with metals.
• Stability: Stable under normal conditions; decomposes with strong acids/oxidisers.
• Nutrient Use: Provides slow-release sulfur and readily available calcium for plants.

Calcium Thiosulfate Manufacturing Plant Report provides you with a detailed assessment of capital investment costs (CAPEX) and operational expenses (OPEX), generally measured as cost per metric ton (USD/MT). This approach ensures that your investment decisions are aligned with the latest industry standards and economic feasibility metrics, enhancing your manufacturing efficiency and financial planning.

Apart from that, this Calcium Thiosulfate manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Calcium Thiosulfate manufacturing plant and its production process(es), and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Calcium Thiosulfate and technology implementation costs. This report also covers operational cash flow, fixed and variable costs, and detailed break-even point analysis, ensuring that your manufacturing process is not only efficient but also economically viable in the competitive market landscape.

In addition to operational insights, the Calcium Thiosulfate manufacturing plant report also comprehensively focuses on lifecycle cost analysis, maintenance costs, and energy consumption costs, which are critical for maintaining long-term sustainability and profitability. Our manufacturing cost analysis extends to include regulatory compliance costs, inventory holding costs, and logistics and distribution costs, providing a holistic view of the potential expenses and savings.

We at Procurement Resource ensure that this report is not only cost-efficient, environmentally sustainable, and aligned with the latest technological advancements but also that you are equipped with all necessary tools to optimize supply chain operations, manage risks effectively, and achieve superior market positioning for Calcium Thiosulfate.
 

Key Insights and Report Highlights

Key Questions Covered in our Calcium Thiosulfate Manufacturing Plant Report

• How can the cost of producing Calcium Thiosulfate be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated Calcium Thiosulfate manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Calcium Thiosulfate manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimize the production process of Calcium Thiosulfate, and what are the associated implementation costs?
• How can operational cash flow be managed, and what strategies are recommended to balance fixed and variable costs during the operational phase of Calcium Thiosulfate manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Calcium Thiosulfate, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Calcium Thiosulfate manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimize the supply chain and manage inventory, ensuring regulatory compliance and minimizing energy consumption costs?
• How can labor efficiency be optimized, and what measures are in place to enhance quality control and minimize material waste?
• What are the logistics and distribution costs, what financial and environmental risks are associated with entering new markets, and how can these be mitigated?
• What are the costs and benefits associated with technology upgrades, modernization, and protecting intellectual property in Calcium Thiosulfate manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Calcium Thiosulfate manufacturing?