Sulphur Coated Urea Manufacturing Plant Project Report 2025: Cost Analysis, ROI, and Feasibility Insights

Sulphur Coated Urea 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 Sulphur Coated Urea 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 Sulphur Coated Urea manufacturing plant cost and the cash cost of manufacturing.

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Sulphur Coated Urea (SCU) is a type of controlled-release fertiliser. It consists of granules of urea coated with a layer of elemental sulphur and a wax sealant. It appears as a yellowish-white to light yellow solid material in the form of granules. Sulphur-coated urea is an essential fertiliser, which is primarily valued for its properties as a slow-release nitrogen source and a source of sulphur, which enhances crop yield and quality. It is particularly utilised in agriculture, golf courses, professional lawn care and turf, greenhouses, horticulture and nurseries.
 

Applications of Sulphur-Coated Urea

Sulphur-coated urea finds specific applications in the following key industries:

• Agriculture: SCU is widely used as a slow-release fertiliser that is used to provide a steady supply of nitrogen to crops over an extended period. This is crucial for improving crop productivity, reducing nutrient losses, and minimising the environmental impact of fertilisers. It is widely used in cereals, grains, oilseeds, and pulses, thereby contributing to enhanced crop yields and quality.
• Horticulture and Nurseries: The compound is also extensively used in horticulture and nurseries. It is used in greenhouses, ornamental plants, and nurseries to provide a steady supply of nitrogen to the plants, which enhances their growth and improves their quality. 
• Turf and Landscaping: SCU is often used as a key component in fertilisers for golf courses, professional lawn care, and turf. Its slow-release properties ensure a consistent supply of nitrogen, which enhances the green colour and health of the turf. It is also used to improve the overall quality of the soil, which helps to reduce the frequency of application and labour costs.
• Other Industrial Applications: SCU is also used in various industrial processes, including water treatment and as a fire retardant. Its slow-release properties also make it an ideal fertiliser for use in specialised applications, such as for organic or precision farming.
   

Top 7 Manufacturers of Sulphur Coated Urea

The global sulphur-coated urea market is highly competitive, with a mix of national and international players. Leading global manufacturers include:

• Nutrien
• Harrell's
• ICL (Israel Chemicals Ltd.)
• Anhui Moith
• Kingenta
• Stanley Agriculture
• J.R. Simplot
   

Feedstock and Raw Material Dynamics for Sulphur Coated Urea Manufacturing

The primary feedstock materials for industrial Sulphur Coated Urea manufacturing are granular urea, molten sulphur, and wax. A clear view of the raw material chain and influencing factors is essential for gauging the production cost structure of sulphur-coated urea.

• Granular Urea: Urea is a high-nitrogen-content fertiliser that is used as the core of the SCU particle. The global urea market and its prices are influenced by natural gas feedstock costs and demand from the agricultural and chemical industries. Industrial procurement of high-purity granular urea is important, directly impacting the overall manufacturing expenses and the cash cost of production for SCU.
• Molten Sulphur: Molten sulphur is used to coat the urea particles. Sulphur is a byproduct of petroleum refining and natural gas processing. The global sulfur market and its prices are influenced by trade policies, supply chain dynamics, and increased demand from the agricultural (fertiliser) sector. The cost of molten sulphur is a major contributor to the operating expenses and the overall production cost analysis for SCU.
• Wax: Wax is used as a sealant to cover any imperfections in the sulfur layer, which helps to prevent the leaching of urea. The cost of wax is a smaller but necessary input.
   

Market Drivers for Sulphur Coated Urea

The market for sulphur-coated urea is predominantly driven by its demand as a controlled-release fertiliser for enhancing nutrient efficiency in crops.

• Growing Global Demand for Fertilisers: The growing demand for high-value crops and ornamental plants is a major driver of this market. The continuous need for increased agricultural productivity to feed an ever-increasing global population is driving a strong demand for nutrient-rich fertilisers. SCU's slow-release properties ensure a consistent supply of nitrogen to crops, which enhances their growth and improves their quality.
• Increasing Demand for Controlled-Release Fertilisers: The global fertiliser market is witnessing a shift towards controlled-release fertilisers due to their superior performance, which includes reduced nutrient losses and improved nutrient uptake. SCU's slow-release properties ensure that nutrients are released gradually over an extended period, which reduces the frequency of application and labour costs. This is driving its adoption in high-value crops and precision farming.
• Stringent Environmental Regulations: Stringent environmental regulations and the growing global awareness of waste reduction are boosting the demand for sustainable agricultural practices. SCU's slow-release properties help to reduce nitrogen runoff and greenhouse gas emissions, making it an eco-friendly alternative to conventional urea fertilisers.
• Global Industrial Development and Diversification: Sulphur-coated urea is seeing increased demand as farmers and agricultural producers look for controlled-release fertilisers that improve nutrient efficiency and reduce losses. The rising adoption of sustainable farming practices has reinforced the use of SCU in high-value crops. North America drives much of this demand, with the United States focusing heavily on precision agriculture and advanced fertiliser solutions. This global industrial growth directly influences the total capital expenditure (CAPEX) for establishing a new Sulphur Coated Urea plant capital cost.
• Technological Advancements: Technological advancements in fertiliser manufacturing are enhancing SCU production quality and efficiency, with innovations, including advanced coating methods and improved purity levels, yielding more effective products. These advancements are expected to drive the growth of the SCU market.
   

CAPEX and OPEX in Sulphur Coated Urea Manufacturing

Establishing a sulphur-coated urea manufacturing unit demands major CAPEX and ongoing OPEX.
 

CAPEX (Capital Expenditure):

The Sulphur Coated Urea plant capital cost includes investment in coating drums, heated storage tanks, and specialised conveyors for processing urea with molten sulphur. Other major components include:

• Land and Site Preparation: Spending includes buying suitable land and preparing it with foundations and utility access. Special attention is needed for working with molten sulphur and chemicals at high temperatures, which demands solid safety measures and containment.
• Building and Infrastructure: Construction of specialised reaction halls, purification areas, filtration and drying sections, product packaging areas, raw material storage, advanced analytical laboratories, and administrative offices. Buildings must be well-ventilated and designed for chemical resistance and stringent safety.
• Preheating Units: Preheating units to heat the urea granules to a specific temperature (e.g., 60-75 degree Celsius) to improve the adhesion of the coating.
• Rotary Drum: A specialised rotary drum is used to coat the urea particles with molten sulphur and wax. The drum must be designed to withstand high temperatures and a high degree of automation to ensure uniform coating.
• Molten Sulphur and Wax Spray System: A specialised spray system is used to spray molten sulphur and wax onto the urea particles in the rotary drum.
• Cooling System: A cooling system is used to cool the coated urea particles, which helps to solidify the sulfur coating.
• Raw Material Dosing Systems: Automated and sealed dosing systems for precise and safe feeding of urea, molten sulphur, and wax into the rotary drum, ensuring accurate stoichiometry and controlled reactions.
• Filtration and Purification Equipment: Filters (e.g., filter presses, centrifuges) to separate any solid impurities from the crude product. Thorough washing systems are crucial to remove any soluble impurities.
• Drying Equipment: Industrial dryers designed for handling crystalline powders, ensuring low moisture content and product stability.
• Screening and Milling Equipment: Screens to ensure uniform particle size and mills to grind the oversized particles.
• Storage Tanks/Silos: Storage silos for bulk storage of raw materials and the final Sulphur Coated Urea product.
• Pumps and Piping Networks: Networks of chemical-resistant pumps and piping for transferring raw materials, solutions, and slurries throughout the plant.
• Utilities and Support Systems: Installation of robust electrical power distribution, industrial water supply, steam generators (boilers for heating), and compressed air systems.
• Control Systems and Instrumentation: Advanced DCS (Distributed Control Systems) or PLC-based systems with extensive temperature, pressure, pH, flow, and level sensors, and safety interlocks to ensure precise control and safe operation.
• Pollution Control Equipment: Advanced scrubbers for gaseous emissions and efficient effluent treatment plants (ETP) for handling process wastewater are vital for strict environmental compliance, requiring considerable investment that affects the overall Sulphur Coated Urea manufacturing plant cost.
   

OPEX (Operating Expenses):

Operating expenses cover the cost of buying urea and sulphur, utilities for heating and coating, additives, and labour for plant operation and quality management. Its components cover:

• Raw Material Costs: The major cost is tied to sourcing urea, molten sulphur, and wax. Market price movements of these materials directly influence production costs and the per metric ton (USD/MT) cost of the final output.
• Energy Costs: High electricity use for pumps, mixers, dryers, and ventilation, along with fuel or steam for heating and drying, adds significantly to the energy intensity of the process, which is a major factor in the Sulphur Coated Urea production cost analysis.
• Labour Costs: Wages, salaries, benefits, and specialised training costs for a skilled workforce, including operators, quality control staff, and maintenance technicians.
• Utilities: Ongoing costs for process water and compressed air.
• Maintenance and Repairs: Expenses for routine preventative maintenance, periodic inspection and repair of reactors, filters, and dryers.
• Packaging Costs: The recurring expense of purchasing suitable, moisture-proof, and secure packaging materials for the final product (e.g., bags, drums).
• Transportation and Logistics: Costs associated with inward logistics for raw materials and outward logistics for distributing the finished product globally.
• Fixed and Variable Costs: The manufacturing of sulphur-coated urea involves fixed costs, including depreciation of coating equipment, property taxes, and specialised insurance for handling chemicals. Variable costs cover raw urea, sulphur, coating materials, energy used per unit, and direct labour tied to production volumes.
• Quality Control Costs: Significant ongoing expenses for extensive analytical testing of raw materials, in-process samples, and finished products to ensure high purity and compliance with various industrial specifications.
• Waste Disposal Costs: Manufacturing sulphur-coated urea requires considerable spending on the safe and legal disposal of hazardous waste.
   

Manufacturing Process

This report comprises a thorough value chain evaluation for Sulphur Coated Urea manufacturing and consists of an in-depth production cost analysis revolving around industrial Sulphur Coated Urea manufacturing.

• Production from Granular Urea: The production of sulfur-coated urea begins with heating the urea granules so that the coating will stick more effectively. Once warmed, the particles are moved into a rotating drum where molten sulfur is sprayed over them, forming a solid protective layer. Since the sulfur layer can sometimes have tiny cracks or weak spots, a thin layer of wax is added on top to seal these gaps and slow down the release of urea. After coating, the product is cooled to keep the particles from clumping together and then conditioned to stabilise its quality. The complete process results in the formation of sulfur coated urea. The finished material is finally packaged, ready for use as a slow-release fertiliser.
   

Properties of Sulphur Coated Urea

Sulphur Coated Urea (SCU) is a type of controlled-release fertiliser that consists of granules of urea coated with a layer of elemental sulphur and a wax sealant.
 

Physical Properties

• Appearance: Yellowish-white to light yellow solid granules.
• Odour: Faint sulfurous odour.
• Molecular Formula: No specific molecular formula, as it is a mixture of urea, sulphur, and wax. The molecular formula for urea is CH4N2O.
• Molar Mass: No specific molar mass, as it is a mixture of urea, sulphur, and wax. The molar mass for urea is 60.06g/mol.
• Melting Point: The melting point of the urea core is approximately 132−135 degree Celsius. The sulfur coating melts at a higher temperature.
• Boiling Point: No boiling point, as it decomposes before boiling.
• Density: 1.33g/cm3 for urea granules. The bulk density of SCU is approximately 1.2−1.3g/cm3.
• Flash Point: Not applicable, as it is a non-flammable inorganic solid.
   

Chemical Properties

• Slow-Release Fertiliser: The sulfur and wax coating on the urea particles acts as a physical barrier that delays the dissolution of urea, providing a steady supply of nitrogen to crops over an extended period.
• Reactivity: It is a stable compound under normal conditions. It can be degraded by heat, which is why it is stored in a cool, dry place. The sulfur layer is degraded by soil microorganisms, which helps to release the nitrogen.
• Toxicity: It is considered to have low toxicity. However, excessive intake can lead to adverse effects.
• Solubility: It is insoluble in water. The slow-release properties are due to the insolubility of the sulfur coating in water.
• pH: Its 1% aqueous solution is close to neutral (pH 7.0).
• Nutrient Content: It provides a steady supply of both nitrogen and sulfur to the crops.
   

Sulphur Coated Urea 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 Sulphur Coated Urea manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Sulphur Coated Urea 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 Sulphur Coated Urea 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 Sulphur Coated Urea 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 Sulphur Coated Urea.
 

Key Insights and Report Highlights

Key Questions Covered in our Sulphur Coated Urea Manufacturing Plant Report

• How can the cost of producing Sulphur Coated Urea be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated Sulphur Coated Urea manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Sulphur Coated Urea 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 Sulphur Coated Urea, 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 Sulphur Coated Urea manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Sulphur Coated Urea, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Sulphur Coated Urea 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 Sulphur Coated Urea manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Sulphur Coated Urea manufacturing?