pre-feasibility report energy reduction and capacity ... · pre-feasibility report ... final...

ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA

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SOUTHERN PETROCHEMICAL INDUSTRIES

CORPORATION LIMITED

Pre-Feasibility Report

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

MARCH 2018

Southern Petrochemical Industries Corporation Limited


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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


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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.

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9 ANALYSIS OF PROPOSAL ........................................................................................................ 36


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1 EXECUTIVE SUMMARY

S.

No. Item Details

1 Name of the Project/s Energy Reduction and capacity expansion by

Modernization of Ammonia –Urea plants

2 S. No. in the Schedule 5(a), Chemical Fertilizers

3

Proposed capacity / area / length / tonnage to be

handled/ command area / lease area / no. of wells

to be drilled

Ammonia 547500 MTPA

Urea (Neem Coated) 759200 MTPA

Carbon Di Oxide 684375 MTPA

4 New / Expansion / Modernization Expansion

5 Existing Capacity / Area etc.

Ammonia 420000 MTPA

Urea 620400 MTPA

Carbon Di Oxide 642000 MTPA

6 Category of Project (A or B) “A”

7 Does it attract the general conditions? If yes, please

specify. No

8 Does it attract specific condition? If yes, please

specify No

9

Location SPIC Nagar, Mullakadu Village, Thoothukudi Taluka,

Tuticorin District, Tamilnadu

Plot Survey / Khasra No. Survey No: 426/2,428,429/3A,431/2, 432/2,

433,434/2, 435/2A, 436/1, 439 etc

Village Mullakadu

Tehsil / Taluka / Mandal Thoothukudi

District Tuticorin

State Tamilnadu

10 Nearest railway station / airport / along with distance

in km. Tuticorin (Distance - 10 KM)

11 Nearest town, city, district headquarters along with

distances in km Tuticorin (Distance -8.0 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.


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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 – India

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


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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)

April’14 to Feb.’15

Supply (Availability)


Sales


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

http://www.business-standard.com/search?type=news&q=Urea


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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


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Figure: Plant Layout


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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**


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


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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


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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


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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


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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

1 Plant Location Muthiahpuram village, Taluka - Tuticorin, District -

Tuticorin, State- Tamil Nadu Pin Code-628005


PLANTS PFR

18


2 Plant site Latitude and Longitude Latitude 80 45’ North

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

B Predominant wind directions Towards west followed by South-west and North-

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)

12 Water source for the site North main channel of the Tamiraparani river system

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

17

Protected areas as per Wildlife

None in 15-km radius

Protection Act,1972 (Tiger reserve)

Elephant reserve

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

20 Major industries in 15-km radius

1. Green Star Fertilizers Limited

2. Tuticorin Thermal Plant

3. Tuticorin Alkali Chemicals

4. Heavy water plant

5. Ammonia Importation Terminal

6. Indian Oil Corporation

7. SHV LPG India Private Ltd.,


PLANTS PFR

19


8. Bharat Petroleum Industries

9. Sterlite Industries

10. VV Chemicals

21 Socio-economic factors Backward area, now developing with industrial

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**


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


PLANTS PFR

20

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

(Fuel & Feed stock) IOCL & Import By ship and Pipe line from port to plant

Furnace oil IOCL & Import By ship and Pipe line from port to plant

Natural Gas

(Fuel & Feed stock)

ONGC/IOC/ Other sources

By Pipe Line and also transported through Road

tanks as LNG. Further re gasification unit will be

installed inside the plant premises to convert the

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

S.

No. Type of Waste

Hazardous Waste Category

Hazardous

Waste Generation

Treatment / Disposal

1

Industrial Operations

using mineral or Synthetic Oil as lubricant in hydraulic systems or others applications

5.1 Used or Spent Oil

30 KL/Annum Recovery under use authorized recyclers


PLANTS PFR

21

2

Production of

Nitrogenous and complex

fertilizers (LT Vessels Zn & Cu)

18.1 Spent Catalyst 92.2 MT Once in 9

Years IWMA Chennai Or Authorized recyclers

3 Production of

Nitrogenous and complex fertilizers (Co & Mo)

18.1 Spent Catalyst 23.8 MT Once in

28 Years IWMA Chennai Or Authorized recyclers

4

Production of

Nitrogenous and complex fertilizers (ZnO)



5

Production of


fertilizers (Methanator-Nickel)



6

Industrial Operations

using mineral or Synthetic Oil as lubricant

in hydraulic systems or others applications (FO

storage tank Oil residue

from Ammonia & Urea Plant)

5.2 wastes or

residues containing oil

5T/Annum Recovery and reuse

or authorized recyclers.

7

Production of

Nitrogenous and complex fertilizers (Primary and

Secondary Reformer-Nickle)

18.1 Spent Catalyst 25.2 MT Once in 3

Years IWMA Chennai Or Authorized recyclers

8

Production of


fertilizers (HT Vessel – Cu promoted Iron catalyst)



9

Production of

Nitrogenous and complex fertilizers (Convertor-Iron Catalyst)


15 Years

IWMA Chennai Or

Authorized recyclers

ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION AND AUGMENTATION OF

AMMONIA – UREA PLANTS PFR

22

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

1 Existing Site

Southern Petrochemical Industries Corporation

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.

http://en.wikipedia.org/wiki/India

http://en.wikipedia.org/wiki/Tamil_Nadu



23

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 also included 3 Material Storage (Urea Silo) 5992

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 / Instruments shop / Fire / Stores

19102

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.



Figure: Project Site on TOPO Map



25

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



26

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.



27

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

http://tools.wmflabs.org/geohack/geohack.php?pagename=Thoothukudi&params=8.53_N_78.36_E_

http://en.wikipedia.org/wiki/South_India

http://en.wikipedia.org/wiki/Gulf_of_Mannar

http://en.wikipedia.org/wiki/Chennai

http://en.wikipedia.org/wiki/Kanyakumari

http://en.wikipedia.org/wiki/Madurai_district

http://en.wikipedia.org/wiki/Tirunelveli_district

http://en.wikipedia.org/wiki/Ramanathapuram_district

http://en.wikipedia.org/wiki/Tiruchirapalli_district

http://en.wikipedia.org/wiki/Northeast_monsoon

http://en.wikipedia.org/wiki/South-west_monsoon

http://en.wikipedia.org/wiki/South-west_monsoon



28

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



29

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.



30

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%.

http://en.wikipedia.org/wiki/2011_census_of_India

http://en.wikipedia.org/wiki/Demographics_of_India

http://en.wikipedia.org/wiki/Districts_of_India

http://en.wikipedia.org/wiki/Family_planning_in_India

http://en.wikipedia.org/wiki/Sex_ratio

http://en.wikipedia.org/wiki/Women_in_India

http://en.wikipedia.org/wiki/Literacy_in_India



31

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

Building also included

3 Material Storage (Urea Silo) 5992

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 /

Instruments shop / Fire / Stores

19102

15 Area for Installation LNG Handling Unit 19669.36

16 IOCL NG metering Station 7741.8



32

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.



33

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.



34

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



35

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.



36

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.

pre-feasibility report energy reduction and capacity ... · pre-feasibility report ... final...

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