ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

SOUTHERN INDUSTRIES CORPORATION LIMITED

Pre-Feasibility Report Energy Reduction and Capacity Expansion by Modernization of Ammonia – urea plants at SPIC Nagar, Tuticorin District-628005,

MARCH 2018

Southern Petrochemical Industries Corporation Limited

1 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

Contents

1 EXECUTIVE SUMMARY ...... 4

2 INTRODUCTION ...... 5

2.1 BRIEF DESCRIPTION OF THE PROJECT ...... 5 2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION ...... 5 2.3 DEMAND SUPPLY GAP ...... 6 2.4 EXPORT POSSIBILITY ...... 6 2.5 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ...... 7

3 PROJECT DESCRIPTION ...... 8

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ...... 8 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT) WITH COORDINATES ...... 8 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ...... 11 3.4 TECHNOLOGY AND PROCESS DESCRIPTION ...... 11 3.4.1 Salient Features of Technology ...... 17 3.5 RAW MATERIALS ...... 19 3.6 ADDITIVES AND CHEMICALS ...... 19 3.7 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT...... 19 3.7.1 Transportation details of Raw Materials ...... 19 3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 20 3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL ...... 20

4 SITE ANALYSIS ...... 22

4.1 CONNECTIVITY ...... 22 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ...... 22 4.3 TOPOGRAPHY (ALONG WITH MAP) ...... 23 4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN...... 25 4.5 EXISTING INFRASTRUCTURE ...... 25 4.6 SOIL CLASSIFICATION ...... 26 4.7 CLIMATIC DATA FROM SECONDARY SOURCES ...... 27 4.7.1 Temperature ...... 27 4.7.2 Wind ...... 27 4.7.3 Rainfall ...... 28 4.7.4 Cloud Cover ...... 28

2 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

4.7.5 Humidity ...... 28 4.8 SOCIAL INFRASTRUCTURE AVAILABLE ...... 28 4.8.1 Assessment of Infrastructure Demand (Physical) ...... 28 4.8.2 Assessment of Infrastructure Demand (Social) ...... 28

5 PLANNING BRIEF ...... 30

5.1 TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ...... 30 5.1.1 Population Projection ...... 30 5.2 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT, ETC) ...... 31 5.2.1 Land Use and Availability ...... 31

6 PROPOSED INFRASTRUCTURE ...... 32

6.1 INDUSTRIAL AREA (PROCESSING AREA) ...... 32 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ...... 32 6.3 GREEN BELT ...... 32 6.4 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...... 32 6.5 SEWAGE SYSTEM ...... 32 6.6 INDUSTRIAL WASTE MANAGEMENT ...... 32 6.7 POWER REQUIREMENT & SUPPLY/ SOURCE ...... 33

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ...... 34

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) ...... 34

8 PROJECT SCHEDULE AND COST ESTIMATE ...... 35

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN) ...... 35 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. 35

9 ANALYSIS OF PROPOSAL ...... 36

3 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

1 EXECUTIVE SUMMARY

S. Item Details No. Energy Reduction and capacity expansion by 1 Name of the Project/s Modernization of Ammonia –Urea plants 2 S. No. in the Schedule 5(a), Chemical Fertilizers Ammonia Proposed capacity / area / length / tonnage to be 547500 MTPA 3 handled/ command area / lease area / no. of wells Urea (Neem Coated) 759200 MTPA to be drilled Carbon Di Oxide 684375 MTPA 4 New / Expansion / Modernization Expansion Ammonia 420000 MTPA 5 Existing Capacity / Area etc. Urea 620400 MTPA Carbon Di Oxide 642000 MTPA 6 Category of Project (A or B) “A” Does it attract the general conditions? If yes, please 7 No specify. Does it attract specific condition? If yes, please 8 No specify SPIC Nagar, Mullakadu Village, Taluka, Location Tuticorin District, Tamilnadu Survey No: 426/2,428,429/3A,431/2, 432/2, Plot Survey / Khasra No. 433,434/2, 435/2A, 436/1, 439 etc 9 Village Mullakadu Tehsil / Taluka / Mandal Thoothukudi District Tuticorin State Tamilnadu Nearest railway station / airport / along with distance 10 Tuticorin (Distance - 10 KM) in km. Nearest town, city, district headquarters along with 11 Tuticorin (Distance -8.0 KM) distances in km 12 Water Requirement No Additional Water Required 13 Power Requirement No Additional Power Required 14 Land Required Existing Premises 15 Hazardous Waste No Additional Waste Will Generate 16 ETP Existing facility will full fill the proposed plant 17 STP Existing facility will full fill the proposed plant 18 Green Belt No additional green belt will have required 19 Employment No additional manpower will be required 20 Project Cost 350 Cr.

4 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

2 INTRODUCTION

2.1 Brief Description of the Project

As the operation profitability depends only on actual energy consumption and payment of all subsidies are energy dependent, it becomes necessary for manufacturers like SPIC to bring down energy norms to best achievable industry levels to continue profitable operation. The capacity wise proposed expansion is listed below.

Existing and Proposed Energy

Item Existing Proposed Energy per MT of Urea 7.184 Gcal / MT < 6.5 Gcal / MT

Existing and Proposed Capacity

Item Existing Proposed Ammonia 420000 MTPA 547500 MTPA ** Urea (Neem Coated) 620400 MTPA 759200 MTPA Carbon Di Oxide 642000 MTPA 684375 MTPA**

** After Natural gas usage, the surplus ammonia and CO2 if any will be sold out

2.2 Need for the project and its importance to region

The ammonia and urea industries represent significant and vital components of the chemical economy. They serve as significant sources of revenue and employment, in particular within countries with large availability of feedstocks such as natural gas and coal. Furthermore, the principal application of ammonia and urea is within the fertilizer sector which is critical to agricultural production and the wider world economy. Global ammonia demand is estimated to be 186 million tons, driven primarily by urea consumption, which in turn is mainly a function of fertilizer demand. In 2016, the consumption of urea globally was an estimated 179 million tons.

Clearly, these are high volume commodity chemicals. Fertilizer demand growth has historically been linked to food consumption through GDP and population growth. This trend is expected to continue, although in recent years this dynamic has begun to change somewhat, due to the strong growth in biofuels production (mainly bioethanol) made from corn and wheat, and biodiesel made from soya, palm and rapeseed oil.

Urea Demand/ Supply Balance –

Urea demand increasing at CAGR of 3 %. Government committed to revive old Fertilizer Units. India’s Urea production to increase in near term by 6.7 Mill MT supported by New Capacity, New Energy norms, lower Natural gas prices. Indian Urea import to reduce from 8.7 Mill MT to 7 Mill MT in 2016-17. Urea Import likely to reduce from current level of 8.7 Mill MT to 3 Mill MT in 2020-21. IFA projects Global Potential Surplus of 18 Mill MT by 2020 excluding recent

5 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

Capacity additions announced by GOI. Global Exportable Surplus to increase due to low Import demand. Lower Urea prices expected due to excess Supply.

Energy Scenario in Fertilizer Industry

Urea Industry is Energy Intensive and controlled fertilizer. To incentivize the Industry, Government introduced various policies based on Energy levels and fixed Energy norms for reducing subsidy. Subsidy outflow to Fertilizer industry is increasing every year and the Government has been keen in reducing the Energy levels by implementing various policies and amendments from time to time. As per the New Urea Policy No. 12012/1/2015-FPP dated 28th March 2018, all Urea fertilizer Industries have been grouped into 3 categories and revised Energy norms with target dates are notified.

2.3 Demand Supply Gap

The gap in demand and supply of Urea is projected to rise to 11 million tons (MT) by the 2016- 17 fiscal, industry body Fertilizer Association of India (FAI) has said. The country produces around 22 MMT of the important nitrogenous fertilizer, while consumption is around 29 MT. The shortfall of 7.8 MMT covered through imports.

"There is an urgent need for construction of new urea projects and modernization of existing urea production plant to fill the projected consumption and production gap of 11 million tons by the year 2016-17,"

The details of demand(requirement), supply(availability) and sales of Chemical Fertilizers in the country during current year 2014-15 (April to February) are as below:

Product Demand (Requirement) Supply (Availability) Sales April’14 to Feb.’15 April’14 to Feb.’15 April’14 to Feb.’15 Urea 296.5 286.79 284.14 DAP 92.88 72.16 67.56 MOP 28.59 28.78 24.98 Complex 94.27 84.54 76.32 Supply of DAP and Complex fertilizers is low because of low sales. In March, 2015 demand (requirement) for Urea, DAP, MOP & NPK is 10.21 LMT, 3.05 LMT, 1.67 LMT and 5.54 LMT respectively and the availability of the fertilizers is expected to be higher than the demand (requirement).

All India Demand Projections of Fertilizer 2015-16 to 2019-20

YEAR Urea DAP NP/NPKs MOP* 2015-16 328.58 122.12 111.42 46.43 2016-17 336.77 124.13 114.2 47.93 2017-18 337.54 127.64 118.41 4934 2018-19 345.36 129.5 123.18 50.48 2019-20 353.07 130.14 127.99 50.86 The gap between demand and indigenous production is fulfilled through import. The cost of imported fertilizers is nearly same as that of domestic production.

2.4 Export Possibility

No

6 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

2.5 Employment Generation (Direct and Indirect) due to the project

It is Energy reduction capacity and expansion by modernization of Urea/Ammonia Plant of existing ammonia manufacturing plant so additional major man power is not required even indirect employment will be generate due to development in nearby area.

Southern Petrochemical Industries Corporation Limited, Tuticorin generate the employment on various levels time to time and give the priority to local persons.

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3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

Proposed Project falls under ‘Section 5(a)’ Manufacturing / Production of Chemical Fertilizers & ‘Category “A”. It does not attract any specific or general condition as per EIA notification dated 14th September 2006 and its amendments.

3.2 Location (map showing general location, specific location and project boundary & project lay out) with coordinates

The existing plant situated on industrial Land in SPIC Nagar, Post Office Muthiahpuram S.O Taluka-Tuticorin, District Tuticorin, State of Tamil Nadu - 628005.

The Plant site is located at about 8.0 km from Municipal Office of Tuticorin City on Thoothukudi- Trichendur Road, Kanyakummari Road.

The proposed site lies between 8°44'16.74"Nlatitude and 78° 8'30.18"Elongitudes and is well connected by Road (NH-7), Rail and Tuticorin port.

Tuticorin city headquarter is located at a distance of 8 KM from the site. Nearest railway station Tuticorin is located at a distance of 10 KM from the site.

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Figure: Location Map of Google Image

ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

Figure: Plant Layout

ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted

No, since this is energy reduction and capacity expansion project in existing plant for Ammonia/UREA (Neem Coated) by modernization on an existing site, with requisite facilities available at site. There is no interlinked project.

The project is not likely to cause any significant impact to the ecology of the area since adequate preventive measures will be adopted to control various pollutants within permissible limits. Green belt development around the area has been and shall be taken up as an effective pollution mitigative technique.

SPIC intends to do energy reduction by modernization improvement revamp of existing Ammonia / UREA (Neem Coated) plants. The revamp is necessitated due to recently announced new urea GOI policy No. 12012/1/2015-FPP dated 28th March 2018 on Urea.

Size or Magnitude of Operation

Southern Petrochemical Industries Corporation Limited, Tuticorin, (SPIC LTD) proposes Energy reduction by modernization of Ammonia – urea plant in SPIC Nagar, District Tuticorin-628005 Tamil Nadu.

There is no additional land is required for the project.

Sl.No Description Existing After Expansion 1 Urea (Neem Coated) 620400 MTPA 759200 MTPA Intermediate 2 Ammonia 420000 MTPA 547500 MTPA ** 3 Carbon Di Oxide 642000 MTPA 684375 MTPA**

** After Natural gas usage, the surplus ammonia and CO2 if any will be sold out

3.4 Technology and Process Description

The existing Ammonia and UREA (Neem Coated) plants are running efficiently but there is still scope for energy improvement to get the maximum production:

AMMONIA PLANT:

Following Improvements are proposed in Ammonia plant for energy reduction:

• At present using 3 Oil fired boilers, which will stop 2 of them.

o SPIC plans to utilize the waste heat generated in the process by production of Steam in the proposed Waste heat recovery Boilers (no

11 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

additional fossil fuel is required) to be installed at Ammonia Converter Exit and HRSG of Gas Turbine. Steam generation from these boilers are adequate for the process by operating only one oil fired Boiler against 3 furnace oil fired boilers used presently

• Inefficient process air compressor & turbine will be changed to gas turbine with new process air compressor.

o For Energy reduction & Capacity Expansion, the available process air compressor & turbine will not be adequate for producing the required Carbon di oxide for producing Urea.

• In CO2 removal section, indirect cooled heat exchangers will be used and CO2 energy will be reduced. Pressure of CO2 to Urea will be boosted from 0.3 Kscg to 0.6 Kscg.

• In Syn gas section, Syn gas Suction temperature will be reduced through latest technology of Suction chilling

• Old generation low efficiency heat exchangers will be replaced with latest generation-high efficient exchangers.

• Low level heat which was rejected to cooling water is enhanced to higher level heat to improve the captive steam generation.

• low efficiency old generation Syn Gas turbine will be replaced with new efficient turbine.

• High efficient urea reactor with trays will be installed in place of existing reactor

• Converter internal will be modernized for better conversion rate with boiler in the downstream.

Process Description:

1. Feed desulfurization 2. Primary reforming 3. Process air compression and Gas Turbine with HRSG 4. Secondary reforming 5. Carbon monoxide shift conversion 6. Carbon dioxide removal 7. Methanation 8. Compression 9. Ammonia synthesis 10. Ammonia refrigeration 11. Ammonia and hydrogen recovery Degasser

12. DM water and BFW system

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Feed Desulfurization Natural gas for ammonia plant is being supplied through a metering valve maintaining a pressure of 46 kg/cm2a via a pipeline from supplier. Natural gas is pressure controlled and passed through a separator to remove any entrained droplets. Natural gas feed stock contains Sulphur, which is a poison to most catalysts used in the downstream process and must be removed.

The reactions in the desulfurization section are as follows:

(1) RSH + H2 à H2S + RH + heat (2) COS + H2 à CO + H2S + heat In the second step the process gas passes through the bed, containing Zinc Oxide catalyst. The hydrogen sulphide in the gas reacts with and is retained by the ZnO catalyst according to the reaction (3) below and producing an effluent stream containing less than 0.1 ppmv sulphur.

(3) H2S + ZnO ZnS + H2O + heat

Primary Reforming

The desulfurized feed is mixed with HP steam prior to reforming. The process steam is added to achieve a 3.0 steam to carbon molar ratio in the mixed feed gas for Natural Gas Operation. The mixture is preheated to about 490°C in the new mixed feed preheat coil 1537A/B in the convection section of the primary reformer, 1400. The hot mixed feed is distributed to the primary reformer catalyst tubes, which are suspended in the radiant section of the furnace.

The feed gas passes down through the reforming catalyst and is reacted to form hydrogen, carbon monoxide and carbon dioxide. The primary reforming reactions as well as water gas shift reaction will occur on the catalyst and are as follows:

(4) CnHm + nH2O + heat à nCO + ( 2n + m )/2 H2 (5) CH4 + H2O + heat ßà CO + 3 H2 (6) CO + H2O ßà CO2 + H2 + Heat The reforming furnace is designed to attain maximum thermal efficiency (~ 90%) by utilizing process waste gases as part of the fuel, as well as by recovering heat in the convection section from the flue gases. The furnace burners are designed for both Naphtha and Natural gas fuel firing with separate guns. The burners are also designed to utilize process waste gases from the PGHRU and from the Ammonia Absorber-II as fuel. The stack temperature is expected about 135 °C.

The convection heat is used for the following services: • Mixed feed preheater-2 (1537A) • Turbine steam Superheater H.T. Section (1536A) • Mixed feed preheater-1 (1537B) • Turbine steam Superheater L.T. Section (1536A) • Combustion air heater (1511)

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The Flue gas fan (3153) and Combustion air fan (3154) are provided to maintain a negative draft in the reformer radiant box and pull the flue gas to the stack. All fans are operated by back-pressure turbines using HP steam (45 Kg/cm2a) and exhaust to MP steam (12Kg/cm2a).

Process Air Compression and HRSG

New Gas turbine driven air compressor (3120) is considered for process air to the secondary reformer. Gas turbine (3620) exhaust is passed through heat recovery steam generator (HRSG) (3621) where high pressure steam is generated. Process air is also preheated to 480°C in the convection section of HRSG. The flow of process air is controlled by process air control valve at the discharge line near secondary reformer. In case of turndown operation, enough compressed air is vented to maintain the minimum load on the compressors, thereby preventing them from going into surge. The compressor discharge anti-surge valve is located downstream of the process air preheating coil to also protect the coil from overheating during startup and shutdown conditions.

Process air is filtered and compressed in a four-stage centrifugal compressor. Inter-stage cooling and condensate separation is provided. Process air is then heated in the convection section of the HRSG and sent to the secondary reformer. 2000 Nm3/hr of plant air is being supplied from the 4th suction of air compressor.

Air for the gas turbine is filtered and chilled as necessary, passed through mist eliminator and compressed in the axial compressor of the gas turbine. Preheated Natural gas fuel mixes with the air in the gas turbine combustor. The hot gases are expanded to supply the power requirements of the air compressor. The hot gas turbine exhaust (GTE) is ducted to the HRSG.

Chilled water for suction air chiller (1583) is supplied from the chilled water package (VAM machine) (3623). Supplementary firing is provided in the GT exhaust gases going to HRSG. HRSG are having following coils in the convection section before gases vented to stack:

• Process air coil (1577)

• Steam superheat coil (1578): HRSG steam drum steam and Synloop boiler steam are heated to 495°C in this coil.

• Steam generation coil (1579): HRSG steam is generated in this coil

• BFW preheat coil (1580): BFW for HRSG steam drum and ASGU steam drum are preheated in this coil

• Fuel Gas coil (1585): NG fuel for Primary reformer, Gas Turbine and HRSG are preheated in this coil

• The Gas Turbine and Supplementary fuel firing are capable of using either Naphtha or Natural gas as fuel.

Secondary Reforming:

Calculated quantity of preheated Nitrogen required for ammonia synthesis is fixed in Secondary Reformer. Air is added to the hot gas from the primary reformer. The oxygen in the air reacts with part of the gas raising the temperature. The heated mixture then flows through a bed of catalyst and the methane present in the gas from the primary reformer reacts with excess steam to produce further hydrogen, carbon monoxide and carbon di oxide. The methane

14 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS steam reaction is endothermic and therefore the temperature of the gas mixture, after initial sharp increase, falls as the gas pass through the catalyst bed and the reformed gas leaves secondary reformer at 970°C.

Carbon Monoxide Shift Conversion

In the shift conversion step, carbon monoxide reacts with steam to form equivalent amounts of hydrogen and carbon dioxide. Before the CO shift conversion reaction, the reformed gas passes through HT shift guard, 1108. It is provided to protect the shift catalyst from potash carryover. It is a packed bed of raschig rings and it collects the solid deposits carried forward from the reforming catalyst and refractory lines. During Natural gas operation, this will remain bypassed. As indicated for primary reforming (reaction no. 6), the shift reaction is reversible and exothermic. The CO shift reaction rate is favored by high temperature, but the equilibrium conversion of CO to CO2 is favored by low temperature. For this reason shift conversion is done in two stages. In the first stage most of the CO is converted to CO2 at high temperature. In the second stage the reaction is performed at a low temperature to bring down the CO concentration to a low level.

Carbon Dioxide Removal

The CO2 contained in the shifted make gas is next reduced to 500 ppmv by washing in a two– stage carbonate based system that utilizes the GV licensed process.

Methanation

The stripped gas from the absorber contains CO and CO2, both of which are poisons to the synthesis catalyst. These components are converted to methane in the Methanator (1112) by the following reactions:

(7) CO + 3H2 à CH4 + H2O + heat

(8) CO2 + 4H2 à CH4 + 2H2O + heat

Compression

The synthesis gas is compressed in the exiting 5 stage (4stage + recycle stage) centrifugal three casing Syngas Compressor. Recovered H2 from existing PGHRU is added in the 1st stage discharge of Syn gas compressor. Provision is available for lining up of syngas from compressor 3rd stage suction to 1104 as recycle H2. The compressor is driven by new SEH-extraction and condensing type steam turbine (3701-001). The syngas compressor speed is controlled to maintain the suction pressure. Interstage coolers and separators are present between each stages of compressor for cooling the synthesis gas going to next stage.

Ammonia Synthesis

In the revamp, the existing basket is being replaced with new configuration of three thermodynamic stage, intercooled design. Due to limitation in the existing convertor (1121) shell design temperature of 130°C, sweep gas arrangement is used to keep the converter shell cool. The syngas from recycle wheel discharged at 205 Kg/cm2(a) is split into two parts.

One part of syngas is passed through annulus space of convertor to keep the shell temperature lower than design of 130°C. Syngas from annulus mixed with the remaining gas of compressor

15 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS and combined gas is sent to Ammonia converter feed / effluent exchanger (1574). Preheated gas from 1574 is sent to inlet of the modified Ammonia synthesis converter (1121). Convertor inlet feed is split into two parts:

(i) Inlet to Ammonia convertor Interchanger-1 (1581) and then 1st bed inlet

(ii) Inlet to Ammonia convertor Interchanger-2 (1582) and then 1st bed inlet

Ammonia Refrigeration

The Loop Refrigeration System is designed to reduce the temperature of the circulating loop gases to -4°C at the entrance for the Ammonia Catch Pot. It is conventional mechanical refrigeration system, using ammonia as the working medium and incorporating two levels of refrigeration.

The Refrigeration Compressor (3104) is a single casing two stage centrifugal machine driven by a condensing steam turbine (3703). The speed of the compressor (and hence capacity of the refrigeration system) is controlled by a pressure signal taken on the L.P. suction of the compressor.

Ammonia and Hydrogen Recovery

The HP purge gas stream from 1525 downstream (from loop) is fed to the Pre-cooler-1 (HEA- 101) and temperature reduced to 5°C. Ammonia is condensed and separated in Ammonia separator (HFA-101). Liquid ammonia from HFA-101 is goes to inlet of 1123. Purge gas from HFA-101 is split into two streams.

1st stream is sent to existing purge recovery unit. The existing PGHRU is a cryogenic based recovery system. H2 is recovered from PGHRU and recycled to Syngas compressor 1st stage discharge. Waste gas from PGHRU is used as fuel in primary reformer (1400). Not all the purge gas from synthesis loop can be sent to PGHRU. Hence, excess purge gas as 2nd stream goes to new Ammonia Absorber-II (1160) which operates at 136 Kg/cm2(a).

Degasser

Process condensate from CO2 removal section, Condensate KOD no.2 (1115), Condensate KOD no.3 (1113) and Absorber inlet KOD (1165) is sent to degasser. LP steam is used for the stripping of dissolved gases such as carbon dioxide, methanol and ammonia from the condensate. Deaerator (1703) steam vent is also mixed in the LP steam. Stripped gas along with steam is vented to atmosphere.

This condensate is pumped by degassed condensate pump (3603-003/004) to the condensate polisher after cooling in 3603-002. It is necessary to cool the condensate to 40ºC to avoid damaging the resin in the polisher.

DM WATER & BFW SYSTEM

DM Water is supplied to Ammonia plant from WTP and flow of water to Deaerator is controlled by level control valve of Deaerator. DM water is joined by steam condensate from various condensing type turbines after cooling in SCC cooler (1588). Condensate from Urea plant is also cooled in Urea condensate cooler (1586) and mixed with DM water stream. This combined feed water called as low-pressure boiler feed water is preheated in 1551 and then in 1513. The

16 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

preheated water at 102°C goes to the Deaerator. LP steam is used for stripping in deaerator. Steam condensate from still reboiler (1534) and from VAM machine is fed to Deaerator directly.

UREA PLANT PROCESS

There is no major modernization in Urea Plant for energy improvement only adding the CO2 Compressor. Urea is synthesized from ammonia and carbon Di-oxide obtained from the Ammonia plant. Carbon di-oxide and Ammonia are separately compressed and allowed to react along with the recycled ammonium carbamate solution. The reaction product which is a mixture of Urea, Ammonium carbamate, excess ammonia and water is further decomposed and separated to obtain Urea solution. The excess ammonia and carbon Di oxide are recycled as ammonium carbamate into the urea reactor along with fresh carbon dioxide and ammonia.

The Urea solution is evaporated under vacuum to obtain Urea crystals which are separated by centrifugation, dried, remelted and prilled.

ENVIRONMENTAL MANAGEMENT There will not be any increase in pollution load due to increase in production. This is achieved by the energy improvement schemes which will be implemented in the plant. The total firing in the primary reformer will be lower resulting in reduction of fuel consumption. All burners were replaced with new burners with lower NOx emissions.

In proposed Gas turbine also, new low NOx emissions burners will be installed. All this is possible only because of the improvements going to be achieved with the revamp. The effluent generated in the plant will be treated in the existing effluent treatment facility and there is no additional liquid effluent generation from the plant. The emission of Particulate matter from the urea prill tower would be well within 50 mg/Nm3. Online Analyzer has been installed for better monitoring and control. The Ammonia / Urea revamp project will not have impact on Environment as energy norms will improve further there by reducing the consumption norms on fuel resulting in reduction of emissions.

The proposed project will not have any adverse impact on the existing environment as sufficient pollution control measures are incorporated in the process technology like Ammonia Converter internals modification, new Process air compressor in ammonia and New Urea Reactor in urea plant.

The energy consumption of the plant is substantially reduced from the existing norms of 7.184 Gcal/MT to below 6.5 Gcal/MT.

3.4.1 Salient Features of Technology

Southern Petrochemical Industries Corporation Ltd, Tuticorin has single stream urea plant, with a rated capacity of 6,20,400 MTPA per annum which will be increased by 7,59,200 MTPA. Main raw materials for the production of urea are Ammonia and Carbon Dioxide for which the feed stocks are Natural Gas, Naphtha and fuel oil.

S. No Particulars Details Muthiahpuram village, Taluka - Tuticorin, District - 1 Plant Location Tuticorin, State- Tamil Nadu Pin Code-628005

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S. No Particulars Details Latitude 80 45’ North 2 Plant site Latitude and Longitude Longitude 780 13 East 3 Climatic conditions Arid A Temperature Mean maximum 38.9degC Mean minimum 17.1degC B Mean Annual Rainfall 67 cms C Relative Humidity 55% to 81% D Predominant wind directions January – March N to NNE April – July W to WNW August – September SW October – December NE 4 Climatic conditions at Site Coastal A Temperature 19deg C to 41deg C Towards west followed by South-west and North- B Predominant wind directions East 5 Plant site Elevation above MSL Ave (+) 4.3 meters 6 Plant site Topography Generally flat 7 Present land use at the site Industrial land 8 Nearest highway NH 7A (8 KM from site) 9 Nearest railway station Tuticorin (10 Kms from the site) 10 Nearest Airport Tuticorin (18 Kms from the site) 11 Nearest River Tamiraparani river ( 20 Kms from the site) North main channel of the Tamiraparani river system 12 Water source for the site at Peikula or Srivankundam Pump House 13 Nearest town/City Tuticorin 14 Nearest village Mullakadu 15 Hills/valleys No hills and valleys within 10-km radius 16 Archaeologically important places Marine National park in Gulf of Mannar Protected areas as per Wildlife Protection Act,1972 (Tiger reserve) Elephant reserve 17 None in 15-km radius Biospheres, National parks, Wildlife sanctuaries, community- reserves and conservation reserves) 18 Reserved / Protected Forests None in 15-km radius 19 Defense Installations None in 15-km radius area 1. Green Star Fertilizers Limited 2. Tuticorin Thermal Plant 3. Tuticorin Alkali Chemicals 20 Major industries in 15-km radius 4. Heavy water plant 5. Ammonia Importation Terminal 6. Indian Oil Corporation 7. SHV LPG India Private Ltd.,

18 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

S. No Particulars Details 8. Bharat Industries 9. Sterlite Industries 10. VV Chemicals Backward area, now developing with industrial 21 Socio-economic factors activities and through Port.

3.5 Raw Materials

SPIC is proposing to use the Natural Gas/Naphtha as a feed stock and fuel. Natural gas/Naphtha will be used for the Energy reduction by modernization of Urea/Ammonia Plant and it will depend on the receiving of natural gas from sources. SPIC is having inhouse capacity of ammonia. .. Additionally, they are planning to install re gasification unit inside the plant boundary to convert LNG to NG and stored in 4 X 245KL above ground bullets. LNG will be supplied by the LNG suppliers at out factory by importing through Cochin LNG Terminal (transported from Cochin port through Road tankers).

Till we get natural gas for the complete requirement, Mixed feedstock will be utilized.

Finished product (Urea) is supplying by road and train. Existing plant is connected with Indian Railway network through dedicated railway line.

Details of Raw Materials consumption

Raw Material (MTPA) Existing After Expansion Ammonia Naphtha 298368 0 FO 97356 126911 NG 0 263795.5 UREA (Neem Coated) Ammonia 358591 438818** Carbon di oxide 471504 584584**

** After Natural gas usage, the surplus ammonia and CO2 if any will be sold out

3.6 Additives and Chemicals

No

3.7 Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product.

3.7.1 Transportation details of Raw Materials

Additionally, they are planning to install re gasification unit inside the plant boundary to convert LNG stored in 4 X 245MT above ground bullets to NG. LNG will be supplied by the LNG suppliers at out factory by importing through Cochin LNG Terminal (transported from Cochin

19 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

port through Road tankers).Details of raw material requirement is given in section 3.5 and transportation details are given below.

Details of Raw Material Consumption and Transportation Details Raw Material Source Mode of Transport Naphtha IOCL & Import By ship and Pipe line from port to plant (Fuel & Feed stock) Furnace oil IOCL & Import By ship and Pipe line from port to plant By Pipe Line and also transported through Road tanks as LNG. Further re gasification unit will be ONGC/IOC/ Other sources Natural Gas installed inside the plant premises to convert the (Fuel & Feed stock) LNG to NG. Ammonia Inhouse In SPIC PLANT Carbon di oxide Inhouse IN SPIC PLANT

3.8 Availability of water its source, energy/power requirement and source should be given Water

The present water requirement is 15178 KLD and supplied by Tamil Nadu Water Supply and Drainage Board through dedicated water supply pipe line. There is no additional water requirement for the energy reduction by modernization and augmentation project.

Power

Existing SPIC plant is getting the electrical power from Tamil Nadu Electrical Board and additionally SPIC plant having 18.5 MWH Captive Power Plant also. There is no additional power requirement for modernization project.

Fuel:

Naphtha/NG is used as a fuel in reformer and furnace oil is used as fuel in boilers at present. After receipt of sufficient gas supply both the fuel will be switched over to natural gas.

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal

Details of hazardous waste generated, quantity and mode of disposal is as given below .

Hazardous wastes are disposing through authorized parties. Recyclable waste is recycling through register recyclers.

Hazardous Waste Generation and disposal Details Hazardous S. Hazardous Waste Treatment / Type of Waste Waste No. Category Disposal Generation Industrial Operations using mineral or 5.1 Used or Spent Recovery under use 1 Synthetic Oil as lubricant 30 KL/Annum Oil authorized recyclers in hydraulic systems or others applications

20 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS

Production of Nitrogenous and complex 92.2 MT Once in 9 IWMA Or 2 18.1 Spent Catalyst fertilizers (LT Vessels Zn Years Authorized recyclers & Cu) Production of 23.8 MT Once in IWMA Chennai Or 3 Nitrogenous and complex 18.1 Spent Catalyst 28 Years Authorized recyclers fertilizers (Co & Mo) Production of 19.5 MT Once in IWMA Chennai Or 4 Nitrogenous and complex 18.1 Spent Catalyst 13 Years Authorized recyclers fertilizers (ZnO) Production of Nitrogenous and complex 25.2 MT Once in IWMA Chennai Or 5 18.1 Spent Catalyst fertilizers (Methanator- 10 Years Authorized recyclers Nickel) Industrial Operations using mineral or Synthetic Oil as lubricant 5.2 wastes or Recovery and reuse in hydraulic systems or 6 residues containing 5T/Annum or authorized others applications (FO oil recyclers. storage tank Oil residue from Ammonia & Urea Plant) Production of Nitrogenous and complex 25.2 MT Once in 3 IWMA Chennai Or 7 fertilizers (Primary and 18.1 Spent Catalyst Years Authorized recyclers Secondary Reformer- Nickle) Production of Nitrogenous and complex 98.6 MT Once in IWMA Chennai Or 8 18.1 Spent Catalyst fertilizers (HT Vessel – Cu 11 Years Authorized recyclers promoted Iron catalyst) Production of Nitrogenous and complex 122.6 MT Once in IWMA Chennai Or 9 18.1 Spent Catalyst fertilizers (Convertor-Iron 15 Years Authorized recyclers Catalyst)

21 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

4 SITE ANALYSIS

4.1 Connectivity

Existing site has very good connectivity by Indian Railway, Port, Roads and Air Port. Plant is located on Tiruchendur - Tuticorin State highway. Existing plant is connected with National Highway No-7 through Tiruchendur- Tuticorin State highway.

Tuticorin railway station is nearest railway station and located at a distance of 10 km from existing plant. Tuticorin City (District Head Quarter) is located at a distance of 8 km.

Tuticorin City bus station is located at a distance of 8 km. Tuticorin airport is located 18 KM from existing plant.

V.O. Chidambaram Port Trust, formerly Tuticorin Port Trust is located 10 KM from existing plant. V.O. Chidambaram Port Trus is one of the 12 major ports in India it is second-largest port in Tamil Nadu and fourth-largest container terminal in India. V.O. Chidambaram Port is an artificial port. This is the third international port in Tamil Nadu and its second all-weather port.

V.O Chidambaram Port is connected with existing plant via railway line, Naphtha and Furnace Oil Pipe line.

S. No Location Distance in KM Southern Petrochemical Industries Corporation 1 Existing Site Limited, SPIC Nagar, Tuticorin(TN), Pin Code- 628005 2 Tehsil Tuticorin 3 District Tuticorin 4 State Tamil Nadu 5 Railway Station Tuticorin City 10 KM 6 Tuticorin City Government Bus Station 08 KM 7 Tuticorin Air Port 18 KM 8 National Highway -07 06 KM 9 V.O. Chidambaram Port Trust 10 KM

Dedicated existing railway lines (Broad Gauge) are connected existing plant to Indian Railway Network at Melavittan railway station for dispatch the fertilizers and V.O Chidambaram Port trust.

4.2 Land Form, Land Use and Land ownership

Southern Petrochemical Industries Corporation Limited, Tuticorin is not acquiring any land for this project. The existing UREA plant of Southern Petrochemical Industries Corporation Limited, Tuticorin make a boundary wall with three industrial units in three directions and in north direction with Harbor Construction Road.

Existing Plant is situated on industrial land declared by Tahsildar Tuticorin in year 1968. Existing land is using as Industrial land since 1972. Southern Petrochemical Industries Corporation Limited, Tuticorin is having full ownership of this land.

North: Harbor Construction road is lying adjacent to the boundary wall of existing plant.

22 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

East: Tuticorin Alkali Chemicals and Fertilizer Ltd, Tuticorin make boundary wall with existing plant.

South: Heavy Water Plant (Under Ministry of Atomic Energy, GOI) make boundary wall with existing plant.

West: Green star fertilizer Limited, Tuticorin make boundary wall with existing plant

Land Area Break-Up

S.No Description Area in Sq.M~ Remark Total Area 1 Total SPIC Factory Area 461341 Road Area 2 Road 97997 Green Belt Area 1 Green Belt Area 147836 Area Split-up details as per the requirement 1 Process Area 63924 Process Area Building 3 Material Storage (Urea Silo) 5992 also included 4 Utility Area - WTP / CPP / OSB / MSS 24398 5 Bagging Plant & Bagged Storage 1111 6 IETP Area 16694 7 Tank Farm Area 29134 9 Railway Siding Area 13212 10 Parking Area 660 11 Water Reservoir 5453 12 Stores Open Yard 8416 13 Workshop / Canteen / QCL / Inspection / 19102 Instruments shop / Fire / Stores 15 Area for Installation LNG Handling Unit 19669.36 16 IOCL NG metering Station 7741.8

4.3 Topography (along with map)

Thoothukudi District carved out of the erstwhile Tirunelveli District on 20.10.1986 has certain rare features. The mixed landscape of the sea and the ‘their (waste) lands has imbibed some special traits in the character of the sons of the soil. Valour and devotion with burning patriotism are the watchwords of the people here. The story of our country'’ freedom struggle cannot be complete without mentioning the supreme sacrifices of the illustrious sons of the district like V.O.Chidambaram Pillai who brought the first swadeshi ship “Galia” to the Tuticorin port and Veerapandi Kattabomman who waged a war against the British.

The climate is hot and dry. The district has a coastal line of 135Kms. And territorial waters covering thousands of hectares. The district particularly in and around Tuticorin is the major salt producer in the state and contributes 30% of the total salt production of Tamil Nadu.

Agriculture is the main occupation on which 70% of the people depend. But the recent boom in the industrial sector has put the district prominently in the country’s industrial map. Heavy industries like Sterlite, SPIC, TAC, HWP and Thermal Power Plant promise hope for a bright future. Hundreds of ancillary units have also sprung up. Textile units and match industries crowd the Kovilpatti belt. The fast growing Tuticorin Port in the changing economic scenario has added pep to the development of the district.

23 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

Figure: Project Site on TOPO Map

ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.

Land use pattern: The project site area is almost flat land with Industrial use.

Distance of Project Site from Sensitive Areas Area Distance in km Direction Western Ghat 100 KM North -West Bandipur National Park 360 KM North -West

Distance of Project site from Water Bodies Water body Distance in km Direction Thamiraparani river 20 KM South Bay of Bengal 2.5 KM East

4.5 Existing Infrastructure

The existing site having below infrastructure:

S. No Existing Infrastructure Capacity

1 Land 461341 sqm 2 CPP 18.5 MW 3 DG Set 1X1100 KVA, 2X830 KVA, 1X500 KVA 4 FO Storage 2X3800 KL 5 Naphtha Storage Facility 2 X 8750 KL+ 2 X 6150 KL 6 Ammonia 3000 T 7 Bagging Plant 2500 Ton/day 8 Integrated Effluent Treatment Plant 150 m3/hr 9 Urea Silo 25000 Ton 10 Water storage reservior 150 MG 11 Railway loading shed 150 Tons/hr 12 Offsite boiler 2 X 85 TPH 13 Auxiliary Boiler (I & II) 90 TPH (Each) 14 Auxiliary Boiler (III) (For CPP) 120 TPH

25 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

4.6 Soil classification

The district is covered by Black Cotton soil in the west with isolated red soil patches in high ground. The sandy soil is present in the coastal tract. Alluvial soil is restricted to river flood plain and coastal part. Alkaline and saline soils are also noticed at places.

26 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

4.7 Climatic data from secondary sources

The general agro-climatic zone of the study area is flat.

Information presented in subsequent paragraphs is from the most recently published Long Term Climatological Tables for the nearest observatory, Tuticorin by the Indian Meteorological Department (IMD).

Thoothukudi is located at 8.53°N 78.36°E. Thoothukudi is located in South India, on the Bay of Bengal, about 540 km (340 mi) south of Chennai and 125 km (78 mi) north of Kanyakumari. The hinterland of the port of the city is connected to the districts of Madurai, Tirunelveli, Ramanathapuram and Tiruchirapalli. The city mostly has a flat terrain and roughly divided into two by the Buckle channel. Being in coastal region, the soil is mostly clay sandy and the water table varies between 1 m (3.3 ft) to 4 m (13 ft) below ground level. The city has loose soil with thorny shrubs in the north and salt pans in the south. The city experiences tropical climatic conditions characterized with immensely hot summer, gentle winter and frequent rain showers. Summer extends between March and June when the climate is very humid. Tuticorin registers the maximum temperature of 39 °C (102 °F) and the minimum temperature of 32 °C (90 °F). The city receives adequate rainfall during the months of October and November. The city receives around 444 mm (17.5 in) rainfall from the Northeast monsoon, 117.7 mm (4.63 in) during summer, 74.6 mm (2.94 in) during winter and 63.1 mm (2.48 in) during the South-west monsoon season. The coolest month is January and the hottest months are from May to June. The city has a very high humidity being in the coastal sector.

Tuticorin has a monsoon influenced humid subtropical climate characterized by very hot summers and cool winters. Summers last from early April to late June during and are extremely hot with temperatures reaching 43°C. The monsoon arrives in June and continues till the middle of September. The winter season start from October to the middle of March and temperature fall down up to 20°C. Rainfall is about 80 cm to 100 cm per annum, which is suitable for growing crops. Most of rainfall is received during the monsoon.

4.7.1 Temperature

The period from March to May is one of continuous increase in temperatures. May is generally the hottest month with a mean daily maximum temperature of about 41.1 °C and mean daily minimum of about 21.1 °C.

January is generally the coldest month with the mean daily maximum temperature of about 28.6 °C and mean daily minimum of about 21.3°C.

4.7.2 Wind Predominant First Second Third Month Morning Evening Morning Evening Morning Evening January N E NW NE NE N February N E NW NE NE SE March N E NE SE NW S April NW S N SE W E May W S SW W NW SE June W W SW SW S S

27 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

Predominant First Second Third Month Morning Evening Morning Evening Morning Evening July W W SW SE/S/SW NW NW August W W NW S SW SE September W S SW SE NW W October W S NW SE SW W November N NE NE E NW SE December N NE NE SE NW N

4.7.3 Rainfall

The total rainfall in year is observed to be 640.7 mm. Distribution of rainfall by season is 69.0 mm in winter (January, February, March), 80.6 mm in summer (April, May, June), 35.8 mm in monsoons (July, August, September) and 455.3 mm in Post monsoon (October, November and December)

4.7.4 Cloud Cover

The area remains cloudy between July - December, which is the active period of the monsoon season. Generally cloud cover ranges from 0 Oktas during this Post monsoon season.

4.7.5 Humidity

The humidity remains relatively high all year round generally it remains between 55 – 81 %

4.8 Social infrastructure available

4.8.1 Assessment of Infrastructure Demand (Physical)

Existing Urea Plant was commissioned in 1974-75. Today, all basic infrastructures has been developed for smoothly running of industry at this location. Existing Site has well connectivity by road & Indian Railways. Existing Site is 08 away from National Highway and connected with Indian Railway network by dedicated railway track at Melavittan Railway Station.

A 230 KVA Auto Substation of Tamil Nadu Electric Board is located at a distance of 300 meter from boundary wall of existing plant .Water is supplying by Tamil Nadu Water Supply and Drainage Board through dedicated water supply pipe line.

4.8.2 Assessment of Infrastructure Demand (Social)

Existing plant having more than 450 employees, those are living in SPIC Nagar Township. Nearby area is well developed and needful facilities are available in short distance like School, Hospitals and Parks etc.

There are numerous Educational Institutions, Polytechnic Colleges, Schools in and around Tuticorin giving Quality Education.

The Agricultural College and Research Institute, Killikulam was established in 1984 – 85 as the third constituent College of Tamil Nadu Agricultural University. At the beginning, the College started functioning in rented building of MDT Hindu College, Pettai in Tirunelveli. Subsequently, after the acquisition of lands and buildings from the State Seed Farm, Killikulam, a part of the

28 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS educational activities was shifted to Killikulam during 1986–'87. Consequent on the completion of hostel buildings, entire academic activities were shifted to Killikulam campus from 01.11.1989.The institution was upgraded as Agricultural College and Research Institute in 1989. The college was also upgraded as a Post-graduate teaching institute from November 1990. The first batch of B.Sc. (Ag.), graduates passed out in 1988. The institution was made into a co-education institution from 1990–'91.

V.O.C College is one of the few Colleges in Tamil Nadu offering course in Geology.

29 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

5 PLANNING BRIEF

Southern Petrochemical Industries Corporation Limited, Tuticorin, (SPIC LTD) proposes Energy reduction capacity expansion by modernization and augmentation of Ammonia/UREA (Neem Coated) Plant at SPIC Nagar, District Tuticorin-628005 Tamil Nadu. The production capacity of UREA (Neem Coated) plant will be increase by 6,20,400 MTPA to 759200 MTPA after modernization.

Southern Petrochemical Industries Corporation Limited, Tuticorin is not acquiring any land for this project.

The major raw material is Natural Gas/Ammonia/ Carbon Di Oxide. Natural gas is available in Ramanathapuram field. Existing plant has been submitted the application to Petroleum and Natural Gas Regulatory Board for authorization of laying, building and operating the pipe line from Ramanathapuram field to SPIC Nagar.

It is Energy reduction capacity expansion by modernization and augmentation of ammonia & UREA (Neem Coated) plant along with installation of LNG terminal for re gasification and following facilities are available inside the plant premises and no any further major requirement for production of UREA (Neem Coated) in existing plant.

• Land • Ammonia Plant • Urea Plant • CPP • Naphtha Storage Tanks • Electrical Sub Station • Water Supply • Integrated Effluent Treatment Plant • Water storage reserve • Bagging Plant • Railway loading shed • Urea Silo

5.1 Town and Country Planning/Development Authority Classification

5.1.1 Population Projection

According to the 2011 census Thoothukudi district has a population of 1,750,176. This gives it a ranking of 277th in India (out of a total of 640). The district has a population density of 378 inhabitants per square kilometer (980 /sq mi). Its population growth rate over the decade 2001–2011 was 9.14%. Thoothukudi has a sex ratio of 1024 females for every 1000 males, and a literacy rate of 86.52%.

30 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

5.2 Land Use Planning (Breakup along With Green Belt, Etc)

The proposed modernization of UREA (Neem Coated)/Ammonia Plant will be developed within the existing plant premises.

5.2.1 Land Use and Availability S.No Description Area in Sq.M~ Remark Total Area 1 Total SPIC Factory Area 461341 Road Area 2 Road 97997 Green Belt Area 1 Green Belt Area 147836 Area Split-up details as per the requirement 1 Process Area 63924 Process Area 3 Material Storage (Urea Silo) 5992 Building also 4 Utility Area - WTP / CPP / OSB / MSS 24398 included 5 Bagging Plant & Bagged Storage 1111 6 IETP Area 16694 7 Tank Farm Area 29134 9 Railway Siding Area 13212 10 Parking Area 660 11 Water Reservoir 5453 12 Stores Open Yard 8416 13 Workshop / Canteen / QCL / Inspection / 19102 Instruments shop / Fire / Stores 15 Area for Installation LNG Handling Unit 19669.36 16 IOCL NG metering Station 7741.8

31 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

Not applicable

6.2 Residential Area (non-processing area)

Not applicable

6.3 Green belt

Greenbelt area of about 147836 Sq.Mt which constitutes more than ~32% of the factory Area..

6.4 Drinking water management (source & supply of water)

Existing plant is taking water from Thamiraparani River (20 KM from the existing plant).

6.5 Sewage system

Southern Petrochemical Industries Corporation Limited, Tuticorin has combined STP (700 KLD) in township for treatment of sewage. Treated water is used in green belt development.

6.6 Industrial waste management

There is no additional waste water will be generated from proposed project. So, no load will be increased on existing ETP Plant.

32 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

6.7 Power requirement & supply/ source

Existing Site has 110 KVA Electrical Sub Station connected with 230 KVA Auto Substation of Tamil Nadu Electric Board.

Existing Site has 18.5 MWH Captive Power Plant and 3260 KVA Diesel fired D.G set as standby power supply units. These D.G Sets will be operated only when there is a normal supply failure. HSD is used for power generation in D.G Sets.

There is no additional power required for proposed of plant.

33 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given)

Not Applicable

34 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given)

It is estimated that the project can be fully implemented in by 2020 with concurrent sanction of funds. Complete Energy reduction capacity expansion by modernization and augmentation of existing Ammonia/UREA (Neem Coated) project will be implemented and commissioned in 2020.

This is a tentative schedule in which flexibility can be exercised depending upon the market demand and fund availability.

8.2 Estimated project cost along with analysis in terms of economic viability of the project.

Cost of Estimates of the proposed modernization project is 350 Cr. (INR) for the energy reduction and capacity expansion by modernization and augmentation of Ammonia – urea of UREA (Neem Coated) only. Project work will start after getting the environmental clearance.

35 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF PFR AMMONIA – UREA PLANTS

9 ANALYSIS OF PROPOSAL

Any Industrialization will benefit the local population in a number of ways. Already more than 500 local persons are getting the benefits directly or indirectly from existing UREA Plant. Southern Petrochemical Industries Corporation Limited, Tuticorin shall prefer to recruit new appointees from nearby locality, subject to availability.

Southern Petrochemical Industries Corporation Limited, Tuticorin has proposed to give preference to local people for requirement in semi-skilled and unskilled category. Approximately 500 persons would be given direct and indirect employment in operation stage. Transport and other infrastructural facilities such as market centers, business establishment, recreation etc in the area will be improved.

Employment potential both direct and indirect coupled with business opportunity and strong social commitment of the company in the form of different social work would result in enhancement in the status and standard of living of the local population resulting in positive impact.

Tribal population is not living in 15 km radius of proposed site.

36