What is a magnesium sulphate project report?
A magnesium sulphate project report is a detailed project report (DPR) for a plant that makes magnesium sulphate heptahydrate, or Epsom salt, usually from calcined magnesite and sulphuric acid. It sets out the process, machinery, raw materials, project cost, means of finance, five-year projections, DSCR and break-even for a lender or investor.
Promoters use a project report on magnesium sulphate to plan capacity and grades and apply for a term loan; banks use it to check repayment.
Also known as: Epsom salt project report, magnesium sulphate heptahydrate plant report, magnesium sulphate business plan, DPR for magnesium sulphate manufacturing.
Magnesium sulphate manufacturing plant cost and profitability
Our sample report models a 25 MT per day plant (8,250 MT a year at full capacity) running 330 days a year. It starts at 60% of capacity and reaches 80% in Year 5, selling at ₹12,400 per MT before GST.
| Land and site development | 39.07 |
|---|---|
| Building and civil works | 81.29 |
| Plant and machinery | 184.46 |
| Other fixed assets | 23.92 |
| Contingencies | 13.29 |
| Preliminary and pre-operative | 8.55 |
| Margin money for working capital | 23.16 |
| Total | 373.74 |
| Promoter's contribution (25%) | 93.44 |
|---|---|
| Term loan from bank (75%) | 280.30 |
| Cash credit limit (separate) | 69.49 |
| Total project cost | 373.74 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. The lowest DSCR in the sample is 1.74, in Year 2. All figures are illustrative.
Magnesium sulphate manufacturing process
A common Indian route makes Epsom salt by dissolving calcined magnesite in sulphuric acid and growing crystals from the clean liquor. The reaction is simple; yield and grade are won or lost in filtration, crystallisation and drying.
- Grinding the magnesite
Caustic calcined magnesite, mostly magnesium oxide, is milled to a fine powder so that it dissolves fully and leaves little unreacted grit.
- Acid digestion
The powder is fed slowly into dilute sulphuric acid in rubber-lined reactors; the reaction gives off heat, and feeding stops when the liquor is close to neutral.
- Filtration
A filter press removes silica, iron and unreacted magnesite, which would otherwise stain the crystals and push water-insoluble matter over the limit.
- Concentration
The clear liquor is evaporated with steam until it is close to saturation at the boiling point.
- Cooling crystallisation
The hot liquor is cooled slowly, so magnesium sulphate comes out as heptahydrate crystals; slow cooling gives larger, free-flowing crystals.
- Centrifuging
Basket centrifuges separate the crystals, and the mother liquor goes back to the reactors so dissolved magnesium sulphate is not lost.
- Drying and packing
Crystals are dried in warm air, kept below about 48°C so they do not lose crystal water, then screened and packed in lined HDPE bags.
Which process route suits a new magnesium sulphate plant?
Four routes are used to make magnesium sulphate. The choice depends on which magnesium source you can buy steadily and close to the plant.
| Calcined magnesite and sulphuric acid | The route used in our sample. Clean reaction and good crystal colour; depends on magnesite from Tamil Nadu or Uttarakhand and on acid prices. |
|---|---|
| Dolomite and sulphuric acid | Cheaper and more widely available rock, but the calcium in dolomite forms gypsum that has to be filtered out and sold or disposed of, and acid use per tonne of product rises. |
| Kieserite dissolution | The mined monohydrate is dissolved and recrystallised as heptahydrate, so there is no acid reaction; the plant depends on imported mineral. |
| Bittern from salt works | Magnesium salts left after common salt is harvested are recovered and converted. Suits units in coastal salt belts; separating other salts adds steps. |
Raw materials for magnesium sulphate
In theory, each tonne of Epsom salt needs about 0.16 tonne of magnesium oxide and 0.40 tonne of sulphuric acid (as 100% acid). Plant figures run higher because calcined magnesite is not pure oxide and some liquor is lost. In our sample, raw materials are 50% of sales.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Caustic calcined magnesite | 46% | 164.70 |
| Sulphuric acid (98%) | 50% | 179.02 |
| Filter aid and process chemicals | 4% | 14.32 |
| Total | 100% | 358.04 |
Sulphuric acid prices move with sulphur and fertiliser demand, so the full report tests a rise in acid cost against profit and DSCR.
Machinery for a magnesium sulphate plant
Everything that touches acid or hot liquor needs rubber lining, FRP or suitable stainless steel. The reactors are the largest single item in the sample.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Ball mill for calcined magnesite | Grinds magnesite to a fine powder | 14.76 |
| Rubber-lined reactors with agitators | Dissolve magnesite in sulphuric acid | 36.89 |
| Filter press | Removes insoluble sludge from the liquor | 16.60 |
| Evaporator for liquor concentration | Brings the liquor close to saturation | 29.51 |
| Cooling crystallisers | Grow heptahydrate crystals | 27.67 |
| Basket centrifuges | Separate crystals from mother liquor | 18.45 |
| Fluid bed dryer | Removes surface moisture at low temperature | 18.45 |
| Acid storage tanks and fume scrubber | Store acid safely and capture fumes | 12.91 |
| Screening and bagging system | Sizes crystals and fills bags | 9.22 |
| Total plant and machinery | 184.46 | |
Costs are the sample report's estimates for a 25 MT per day line. Get current quotations before you finalise.
Utilities and manpower for the plant
Evaporation is the main energy user, so power and fuel are the largest running cost after raw materials in our sample.
| Power and fuel | ₹56.54 lakh in Year 3, or 7.9% of sales, in our sample |
|---|---|
| Steam | From a small boiler for the evaporator and for keeping liquor hot before crystallisation |
| Water | Process water to dilute acid and dissolve magnesite, plus cooling water for the crystallisers |
| Manpower | 14 people in the sample: 2 in management and supervision, 5 skilled operators, 7 semi-skilled and unskilled workers |
| Wages | ₹31.44 lakh in Year 1, rising 5% a year |
Licences and standards for magnesium sulphate
The grade you sell decides the rules. Fertiliser grade falls under the Fertiliser Control Order (FCO); technical grade is sold to a BIS specification or the buyer's own.
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board, covering acid fumes, filter sludge and wash water |
| Fertiliser grade specification | FCO Schedule I: magnesium (as Mg) at least 9.6%, sulphur (as S) at least 12.0%, water-insoluble matter up to 1.0%, lead up to 0.003%, pH of a 5% solution 5.0–8.0 |
| Selling authorisation | Under clause 8 of the FCO, a manufacturer selling fertiliser files a memorandum of intimation (Form A1) with the state's notified authority |
| Technical grade standard | IS 2730:1977, Specification for magnesium sulphate (Epsom salts), used for leather industry grade |
| Factory licence | Under the Factories Act where worker and power thresholds apply; rules vary by state |
Checked against official sources in October 2026. Confirm current requirements with your state agriculture department and pollution board.
Market for magnesium sulphate in India
Fertiliser use drives most demand. Crops on soils short of magnesium and sulphur, such as sugarcane, banana, grapes, vegetables and tea, take it as a soil or spray nutrient. Sales peak before each sowing season.
Technical grade goes to tanneries, textile processors and feed mills. Purified grades sell to pharmaceutical and bath salt makers at a higher price, but they need tighter quality control.
- Fertiliser companies and water soluble fertiliser blenders
- Agri input dealers and distributors in horticulture belts
- Tanneries and textile dyeing units
- Animal feed and premix manufacturers
- Pharmaceutical and bath salt makers
Location matters: Tamil Nadu produced about 71% of India's magnesite in 2021-22, per the Indian Bureau of Mines. A plant near magnesite and acid supply saves freight on both inputs.
Mistakes that weaken a magnesium sulphate project report
- Pricing all output at pharma or bath salt rates
Most tonnage sells as fertiliser grade at bulk prices. A report that assumes retail Epsom salt prices overstates sales and DSCR.
- No margin on the 9.6% magnesium limit
Pure heptahydrate holds only about 9.9% magnesium. Wet crystals or impurities can push fertiliser grade below the FCO minimum, so drying and filtration must be costed properly.
- Drying too hot
Above about 48°C the crystals start losing water, turn powdery and cake in the bag. The dryer and its heat source must be sized for low-temperature drying.
- No plan for sludge and liquor
Filter sludge, bleed liquor and acid fumes need treatment and disposal that the pollution board will check. Leaving them out of the cost invites delays.
- Ignoring seasonal sales and dealer credit
Fertiliser buying is seasonal and dealers expect credit. In our sample, trade receivables at 45 days are the largest part of working capital.
How NPCS helps you plan a magnesium sulphate plant
- Route and grade mixChoose between magnesite, dolomite, kieserite or bittern feed, and set the split between fertiliser, technical and purified grades.
- Machinery and suppliersSizing of reactors, evaporator, crystallisers and dryer, with quotations from equipment makers.
- Bank-ready project reportProjections, DSCR, break-even and working capital in the format your lender expects.
- Approvals and layoutPlant layout, acid storage, effluent plan and the FCO and pollution board steps for your state.
NPCS's client list includes 5 magnesium sulphate assignments and 269 in specialty chemicals. The NPCS project team, led by founder Ajay Kumar Gupta, has prepared project reports for chemical plants since 1994.
What's inside the magnesium sulphate sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
19 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Magnesium Sulphate project report: frequently asked questions
What is the cost of a magnesium sulphate manufacturing plant in India?
A 10 MT per day plant needs roughly ₹1.5–3 crore, and a 40–50 MT per day plant about ₹5–8 crore, including land, building and working capital margin. These ranges are indicative. Our sample report models a 25 MT per day plant at ₹373.74 lakh, with ₹184.46 lakh of plant and machinery. Your report prices your own capacity, site and grade mix.
Is magnesium sulphate the same as Epsom salt?
Yes. Epsom salt is the common name for magnesium sulphate heptahydrate, the crystal form with seven molecules of water. The same compound is sold as a fertiliser, a technical chemical for leather and textiles, and a purified grade for pharmaceuticals and bath salts. The grade decides the purity checks, the licences and the price the plant can charge.
Which raw materials are needed to make magnesium sulphate?
The usual Indian route uses caustic calcined magnesite and sulphuric acid, with water and a little filter aid. In our sample report sulphuric acid is 50% of raw material cost and calcined magnesite 46%. Some plants use dolomite, imported kieserite or salt works bittern instead, which changes the process steps and the yield.
Is a magnesium sulphate plant profitable?
In our illustrative sample, a 25 MT per day plant earns a 25% return on investment in Year 3. It breaks even at about 34% of capacity and pays back in about 3.3 years. Real profit depends on the sulphuric acid price, freight on magnesite, the share of higher priced grades in your sales and how fast dealers pay.
Which licence is needed to sell fertiliser grade magnesium sulphate?
Fertiliser grade product must meet the Fertiliser Control Order specification, which sets at least 9.6% magnesium and 12.0% sulphur. A manufacturer selling fertiliser files a memorandum of intimation with the notified authority of the state under the order. Pollution board consent, Udyam and GST registration apply as well. Confirm the current procedure with your state agriculture department.
Is the magnesium sulphate project report PDF free, and can I use it for a bank loan?
The sample PDF is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not taken from a real project, so it should not go to a bank. For a loan, NPCS prepares a report for your capacity, location, grades and lender.
Sources and references
- The Fertiliser (Control) Order, 1985: Schedule I specification for magnesium sulphate and clause 8 authorisationDirectorate of Agriculture and Food Production, Government of Odisha, checked Oct 2026
- IS 2730:1977 Specification for magnesium sulphate (Epsom salts)Bureau of Indian Standards, checked Oct 2026
- IS 257:1950 Magnesium sulphate (Epsom salt), technical (withdrawn, superseded by IS 2730)Bureau of Indian Standards, checked Oct 2026
- Indian Minerals Yearbook 2022, Magnesite (61st edition)Indian Bureau of Mines, Ministry of Mines, checked Oct 2026
- Magnesium sulfate: technical evaluation report (crops)Agricultural Marketing Service, US Department of Agriculture, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.