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Concept Note on Capacity Enhancement by Setting up New 1650 Npk Plant at Fact, Kochi

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Concept Note on Capacity Enhancement by Setting up New 1650 Npk Plant at Fact, Kochi CONCEPT NOTE ON CAPACITY ENHANCEMENT BY SETTING UP NEW 1650 NPK PLANT AT FACT, KOCHI. SUBMITTED TO MINISTRY OF ENVIRONMENT AND FOREST AND CLIMATE CHANGE (MoEF & CC) GOVERNMENT OF INDIA OCTOBER 2019 PREPARED BY FACT ENGINEERING AND DESIGN ORGANISATION A Division of The Fertilisers And Chemicals Travancore Ltd., (A Government Of India Enterprise), Udyogamandal– 683501, Kochi, India CONCEPT NOTE ON SETTING-UP NEW 1650 MTPD NP PLANT PAGE 1 OF 7 1.0 INTRODUCTION: The Fertilisers And Chemicals Travancore Limited (FACT) is one of leading fertiliser manufacturer in India. FACT is having two manufacturing divisions, FACT Udyogamandal Complex (FACT-UC) and FACT Cochin Division (FACT-CD) located at Kochi, Kerala State. Main products of FACT and their installed capacities are a. Factamfos 20:20:0:13 -- 6,33,500 MT b. Ammonium Sulphate -- 2,25,000 MT c. Caprolactam -- 50,000 MT FACT as part of its vision plan earlier proposed 1,000 MT NP plant for enhancing the capacity of complex fertiliser from 2,000 to 3,000 MTPD. The Ministry of Environment, Forest and Climate Change accorded environmental clearance to FACT for earlier proposal of 1,000 MTPD complex fertilizer plant along with 5,000 MT ammonia storage at FACT – CD vide F.No. J-11011/177/11-IA II (I) dated 4th February 2015. FACT now intends to go for 1,650 MTPD NPK plant capable of producing complex fertiliser NP 20:20:0:13 by installing a new fertiliser plant in Cochin Division located at Ambalamedu in Ernakulam District, Kerala State, instead of earlier proposal of 1,000 MTPD, at the same location thereby enhancing the total production capacity to 3,650 MTPD of complex fertiliser. FACT has assigned the Project Management Consultant (PMC) works to its own engineering division – The FACT Engineering and Design Organisation (FEDO). 2.0 EXISTING FACILITIES: The brief description of existing facilities at FACT - CD is given below: a. 1 x 1,000 MTPD Sulphuric Acid Plant b. 1 x 360 MTPD Phosphoric Acid Plant c. 2 x 1,000 MTPD Complex fertiliser plant producing NP-20:20:0:13 based on conventional slurry granulation process d. Offsite Facilities & e. Material Handling Facility at Willingdon Island (WI), Cochin Port FACT ENGINEERING AND DESIGN ORGANISATION A Division of The Fertilisers And Chemicals Travancore Ltd., (A Government Of India Enterprise), Udyogamandal– 683501, Kochi, India CONCEPT NOTE ON SETTING-UP NEW 1650 MTPD NP PLANT PAGE 2 OF 7 The offsite facilities includes raw material unloading & storage, 5,000 MT ammonia storage, sulphuric acid & phosphoric acid storage, bulk storage, bagging plant with railway siding facility, water treatment plant and ETP. The material handling facilities at Willington Island (WI) include storage and handling (i.e, ship unloading/loading) for rock phosphate, sulphur, phosphoric acid and sulphuric acid. And 1x10,000 MT ammonia storage and handling facility. 3.0 BACKGROUND OF PROJECT PROPOSAL: The brief summary of the project proposal is given below: FACT, as part of its vision plan has proposed to go for capacity enhancement of its complex fertiliser production at its Cochin Division (FACT - CD) located at Ambalamedu in Kochi, Kerala State, South India. Accordingly, FACT had proposed a new 1,000 MTPD NP plant adopting conventional slurry granulation process for producing only a single grade product i.e., NP-20:20:0:13. 1) Vision plan outlining projects was presented to FACT’s Board of Directors in its Meeting held on 26th June 2009 2) DPR for 1000 MTPD NP plant was prepared by FEDO and was approved in-principle by the Board in its 436th meeting dated 06th January 2011 3) FEDO then submitted the DPR to MoEF & CC (formerly MoEF) in February 2011 (TOR is enclosed as Annexure -1) 4) Public hearing was conducted in presence of district administration & KSPCB on 7th February 2013 5) Then presented to Expert Appraisal Committee (Industry) at New Delhi on 28th April 2014 6) Environmental Clearance (EC) was obtained on 4th February 2015 (EC is enclosed as Annexure - 2) But, then due to financial constrains the project didn't take-off. Recently, in 2019 the Department of Fertilizers (DoF) has approved the land monetization proposal of FACT which will enable us to proceed with the implementation of vision plan. Considering the favourable financial condition and in order to realize higher turnover, FACT Management now intends to go for a new 1,650 MTPD NPK plant using latest pipe reactor technology enabling to produce NP-20:20:0:13. FACT ENGINEERING AND DESIGN ORGANISATION A Division of The Fertilisers And Chemicals Travancore Ltd., (A Government Of India Enterprise), Udyogamandal– 683501, Kochi, India CONCEPT NOTE ON SETTING-UP NEW 1650 MTPD NP PLANT PAGE 3 OF 7 Also in the original proposal, EC was obtained for an additional 5,000 MT ammonia storage tank. Now it is planned to enhance the ammonia storage tank capacity to 10,000 MT at the same location. 4.0 CONCEPT NOTE: This concept note aims to give a brief outlook of the comparison of 1,000 MTPD NP plant using conventional slurry granulation process, for which the environmental clearance was obtained with the proposed 1,650 MTPD NPK plant based on pipe reactor technology at the same location. It describes the project objective, pipe reactor technologies, project facilities, manpower requirement, comparison of the pollution load, mode and stages of implementation of project. 5.0 PROJECT OBJECTIVE: Capacity enhancement of complex fertilizer plant NP 20:20:0:13 from 2,000 MTPD to 3,650 MTPD instead of 3,000 MTPD compliance to the earlier environmental clearance by installing additional NPK plant which is capable of producing NP-20:20:0:13. premier product of FACT, traded under the name Factamfos. The annual production envisaged from the new 1650 MTPD NPK plant with pipe reactor technology will be 5,11,500 MTPA of NP-20:20:0:13. The 1,650 MTPD NPK plant with pipe reactor technology have the advantage of low recycle ratio around 3-4:1 against conventional process and thereby increase in production, low fuel requirement and achieving better pollution standards than conventional process. Sustained operation of NPK production can be ensured with assured supply of outsourced inputs like ammonia, phosphoric acid, sulphuric acid and sustained operation of existing ammonia plant at FACT-UC, sulphuric acid plant and phosphoric acid plant of FACT-CD. 6.0 TECHNOLOGY PROVIDERS/PROCESS LICENSORS The following process licensors have technology for pipe reactor. 1) Incro SA, Spain 2) Espindesa, Spain 3) La Grande Paroisse, France FACT ENGINEERING AND DESIGN ORGANISATION A Division of The Fertilisers And Chemicals Travancore Ltd., (A Government Of India Enterprise), Udyogamandal– 683501, Kochi, India CONCEPT NOTE ON SETTING-UP NEW 1650 MTPD NP PLANT PAGE 4 OF 7 4) thyssenkurrup Industrial Solutions. 5) Stamicarbon, Netherlands 6) Incitec, Australia The above mentioned process licensors offer different pipe reactor configurations and in the below table these licensors are brought under three categories based on the process and pipe reactor configuration offered worldwide: PROCESS TECHNOLOGY PROVIDERS System with pipe reactor in granulator only M/s. Stamicarbon (without pre- neutralizer). M/s. spindesa M/s. Incitec System with two pipe reactors, one in granulator and one in dryer (without pre- M/s. La Grande Paroisse neutralizer). Mixed system consisting of both pre- M/s. La Grande Paroisse. neutralizer and pipe reactor installed either M/s. thyssenkrupp Industrial Solutions in granulator or in dryer. M/s. Incro 7.0 PROJECT COST AND FACILTIES The Capital investment for this brownfield project, NPK plant with pipe reactor technology and the ammonia storage of 10,000 MT (Battery Limit) at FACT Cochin division is estimated to be approximately Rs. 480 crores. The capital cost required for the proposal shall be meet from the revenue obtained from land monetization. The time schedule for the completion of the project is 24 months. Being the brownfield Project existing facilities available at the unit shall serve the allied facilities required for the project. FACT ENGINEERING AND DESIGN ORGANISATION A Division of The Fertilisers And Chemicals Travancore Ltd., (A Government Of India Enterprise), Udyogamandal– 683501, Kochi, India CONCEPT NOTE ON SETTING-UP NEW 1650 MTPD NP PLANT PAGE 5 OF 7 8.0 SITE SELECTION: FACT-Cochin Division located at Ambalamedu, Puthencruz Village of Ernakulum District in India about 120 acres of land available for expansion project in CD-Phase II plants. Suitable locations are identified, scrutinized in detail and a final recommendation is arrived for locating the plant envisaged under the Cochin Phase-II for earlier proposed 1,000 MTPD NP plant. For the proposed new 1,650 MTPD NPK plant the same location is recommended in consideration of the proximity to the existing plants in Phase-II area. The complex fertilizer plant requires around 4000 sq.m area. The proposed location envisaged for the new project is east of existing bulk storage, considering the handling facilities for raw material /intermediate chemicals and product. An artificial reservoir with an earthen dam has been built to meet the water requirements of plants and township. The reservoir is supplied with water from the Periyar Valley Irrigation Project. This reservoir can meet the water requirement of the proposed plant. The ammonia requirement for production of complex fertilizers is envisaged though imports and for this a 10,000 MT capacity ammonia storage was established at Cochin Port from where ammonia is transported and stored in a site storage of 5,000 MT capacity for eventual consumption in the complex fertilizer plant. The location east to the existing 5,000 MT is envisaged for the proposed ammonia storage of 10,000 MT at the same site.
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