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The Plant  

MADRAS FERTILIZERS LIMITED is a Central Public Sector Undertaking situated at Manali near Chennai in Tamil Nadu, South India. MFL is an ISO-9001:-2008 and ISO-14001:2004 certified company.

The Plant

MFL consists of production plants, Ammonia, Urea in single streams and NPK in three streams, viz. NPK A Train, B Train and C Train. Utilities Plant is the service plant supplying treated water, cooling water, off-site steam, instrument air, captive power and emergency power. On November 1, 1971, MFL commenced commercial production of Ammonia, Urea and NPK complex. The feedstock for Ammonia is Naphtha and it is being supplied by the neighboring M/s Chennai Petroleum Corporation Limited (CPCL).

The original Ammonia / Urea Plants were of Chemico design with the daily rated capacity of 750 MT (247500 MTPA) and 885 MT (292000 MTPA) respectively. Initially there were only two trains to produce granulated complex fertilizers with a total installed capacity of 360000 MTPA and in September 1976 on more NPK stream, namely C Train, was added raising the installed capacity to 540000 MTPA, all by Hindustan Dorr Oliver.

In 1991, the old Chemico converter of Ammonia Plant was replaced with the latest S 200 Radial Converter.

Revamp

The company, to extend the economic life of the plants by another 15 years and also envisaging improvement in energy consumption, undertook a major Revamp-cum-Modernization and Capacity Enhancement of its plants at a cost of Rs 600 Cr during 1993-1998. Production from the Revamped Plants commenced from March 3, 1998.

Process License and Basic Engineering from M/s Haldor Topsoe, Denmark for Ammonia Plant and from M/s Urea Technologies Inc., U.S.A for Urea Plant was adopted with modern Distributed Control System (DCS). The enhanced production capacities are 1050 MTPD for Ammonia (346500 MTPA) and 1475 MTPD for Urea (486750 MTPD). With respect to NPK, “Pipe-reactor” with Process License & Basic Engineering from M/s Grande Parroise, France was incorporated in NPK B Train. By this and along with higher on-stream efficiency, the installed capacity was raised to 2550 MTPD (840000 MTPD).

Post-revamp

After overcoming initial teething troubles, the Ammonia & Urea Plants reached 87% and 83% capacity utilization levels in 1999-2000. To improve product quality and bring down product temperature before admitting into bagging streams, Prill Tower modification was carried out by Monsanto Enviro-Chem (MECSI), U.S.A. and a fluidized bed cooler (Prills Cooling System – PCS) was put into service.

Urea Plant achieved a record production of 486750 MT in 2011-12 surpassing the previous best of 478834 MT in 2010-11. Specific consumption of feedstock has also come down over the years after process stabilization.

Post Revamp Plant Performance


Description Production Cap.Uti% Feedstock Specific Energy Consumption
Description Ammonia Urea NPK Ammonia Urea NPK Naphtha Ammonia Urea
Unit MT MT MT % % % MT/MT Gcal/MT Gcal/MT
1998-1999 260062 327982 732911 75.1 67.4 87.3 0.826 11.661 9.579
1999-2000 301182 403760 811260 86.9 83.0 96.6 0.783 10.951 8.358
2000-2001 298000 401570 731447 86.0 82.5 87.1 0.791 10.711 8.396
2001-2002 216778 286891 573131 62.6 58.9 68.2 0.818 11.542 9.004
2002-2003 265011 401249 415044 76.5 82.4 49.4 0.797 11.099 8.358
2003-2004 259622 387678 428612 74.9 79.6 51.0 0.778 10.674 8.020
2004-2005 300886 473032 333475 86.8 97.2 39.7 0.757 10.411 7.766
2005-2006 227066 368500 208193 65.5 75.7 24.8 0.761 10.917 8.099
2006-2007  281312 473363 57130 81.2 97.2      6.8 0.764 10.758 7.908
2007-2008  265108 440499 35165 76.5 90.5 4.2 0.751 10.610 7.802
2008-2009  232300 405951 0 67.0 83.4 0.0 0.760 10.865 7.929
2009-2010  258150 436100 7335 74.5 89.6 0.9 0.777 10.789 7.834
2010-2011 280408 478834 40578 80.9 98.4 4.8 0.761 10.334 7.492
2011-2012 283205 486750 35905 81.7 100.0 4.3 0.762 10.369 7.517
2012-2013 260804 435771 100125 75.3 89.5 11.9 0.790 10.908 7.822
2013-2014 285925 486750   44860 82.5 100.0 5.3 0.737 10.085 7.386
2014-2015 196894 328900   74272 56.8 67.6 8.8 0.791 11.283 8.086
2015-2016 236466 407311 34816 68.2 83.7 4.1 0.765 10.456 7.645
2016-2017 275330 468438 48895 79.5 96.2 5.8 0.759 10.191 7.460

 

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