Project Report Modernization of Ammonia - Urea Plants at SPIC Nagar, Tuticorin District-628005, Tamil Nadu

MODERNIZATION OF AMMONIA AND UREA PLANTS
SOUTHERN PETROCHEMICAL INDUSTRIES

CORPORATION LIMITED
Project Report
Modernization of Ammonia – urea plants at SPIC
Nagar, Tuticorin District-628005, Tamil Nadu
MAY 2019
Southern Petrochemical Industries Corporation Limited
1
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 ............................................................................................................................. 21
3.6 ADDITIVES AND CHEMICALS ............................................................................................................. 21
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. .................................... 21
3.7.1 Transportation details of Raw Materials ........................................................................... 21
3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 22
3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT
/DISPOSAL .................................................................................................................................................. 22
4 SITE ANALYSIS .......................................................................................................................... 24
4.1 CONNECTIVITY ................................................................................................................................ 24

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................................................ 24
4.3 TOPOGRAPHY (ALONG WITH 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. ...................................................................................................................................... 27
4.5 EXISTING INFRASTRUCTURE ............................................................................................................. 27
4.6 SOIL CLASSIFICATION ...................................................................................................................... 28
4.7 CLIMATIC DATA FROM SECONDARY SOURCES ..................................................................................... 29
4.7.1 Temperature ......................................................................................................................... 29
4.7.2 Wind ...................................................................................................................................... 29
4.7.3 Rainfall .................................................................................................................................. 30
4.7.4 Cloud Cover .......................................................................................................................... 30
2
4.7.5 Humidity ................................................................................................................................ 30

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................................................ 30
4.8.1 Assessment of Infrastructure Demand (Physical) ........................................................... 30
4.8.2 Assessment of Infrastructure Demand (Social) .............................................................. 30
5 PLANNING BRIEF ...................................................................................................................... 32
5.1 TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION................................... 32

5.1.1 Population Projection .......................................................................................................... 32
5.2 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT, ETC) ..................................................... 33
5.2.1 Land Use and Availability ....................................................... Error! Bookmark not defined.
6 PROPOSED INFRASTRUCTURE .............................................................................................. 34
6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................................................ 34

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ................................................................................... 34
6.3 GREEN BELT .................................................................................................................................... 34
6.4 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ....................................................... 34
6.5 SEWAGE SYSTEM.............................................................................................................................. 34
6.6 INDUSTRIAL WASTE MANAGEMENT .................................................................................................... 34
6.7 POWER REQUIREMENT & SUPPLY/ SOURCE ........................................................................................ 34
7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................................. 35
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) ......................... 35
8 PROJECT SCHEDULE AND COST ESTIMATE ....................................................................... 36
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE
PROJECT TO BE GIVEN) ................................................................................................................................ 36
8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT.
36
9 ANALYSIS OF PROPOSAL ........................................................................................................ 37
3
1 EXECUTIVE SUMMARY
S.
Item Details
No.
1 Name of the Project/s Modernization of Ammonia –Urea plants
2 S. No. in the Schedule 5(a), Chemical Fertilizers
Proposed capacity / area / length / tonnage to be

Ammonia 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 Modernization
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, Thoothukudi Taluka,
Location
Tuticorin District, Tamilnadu
Survey No: 426/2,427/2,428,429/3A,429/3B,431/2,
Plot Survey / Khasra No.
432/2, 433,434/2, 435/2A, 436/1,438/3 ,439 part
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 be required
19 Employment No additional manpower will be required
20 Project Cost 350 Cr.
4
MODERNIZATION OF AMMONIA – UREA PLANTS PFR
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 Modernization 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
5
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
2.5 Employment Generation (Direct and Indirect) due to the project
It is modernization of Urea/Ammonia Plant of existing ammonia manufacturing plant so

additional major man power is not required .Southern Petrochemical Industries Corporation
Limited, Tuticorin generate the employment on various levels time to time and give the priority
to local persons.
7
MODERNIZATION OF AMMONIA – UREA PLANTS
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.
It is “Modernization of Ammonia – Urea plants with capacity increase” at SPIC Nagar,

Tuticorin based on the EIA notification dated 23rd November 2016 in Section 7for Subsection
ii shall be substituted namely “"7(ii). Prior Environmental Clearance (EC) process for
Expansion or Modernization or Change of product mix in existing projects.
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"N latitude and 78° 8'30.18"E longitudes 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.
8
Figure: Location Map of Google Image

Figure: Plant Layout

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 modernization of existing plant for Ammonia/UREA (Neem Coated) 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 Modernization

1 Urea (Neem Coated) 620400 MTPA 759200 MTPA *
Intermediate
2 Ammonia 420000 MTPA 547500 MTPA **
3 Carbon Di Oxide 642000 MTPA 684375 MTPA**
* Because of this modernization, the reliability of the plant and on-stream days will be high
and hence our production capacity will increase from 6.204 Lakh MT(1880MTPD x 330days) to
7.592 Lakh MT (2080 x 365 days)
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.
11
o SPIC plans to utilize the waste heat generated in the process by

production of Steam in the proposed Waste heat recovery Boilers (no
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 & Modernization, 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
12
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)
13
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
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 favoured by high temperature, but the
equilibrium conversion of CO to CO2 is favoured 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
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
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.
SPIC Revamp Approach :
17
SPIC is operating with Naphtha as feedstock and the facility is yet to receive the gas. Our
plant has already obtained Environmental Clearance from Ministry of Environment and Forests
(MoEF) for operating the plant with Dual feedstock mode(Naphtha/natural gas at any
proportion). Generally, the Carbon content in Natural gas is ~87% against ~75% with Natural
gas. Hence, the revamp approach was based on the following main key objectives.
 Reduction of energy to maximum possible extent
 CO2 required for the Urea production is not reduced even operated with 100% Natural
gas(as Co2 generation is less with Natural gas)
 All New equipment is designed for 1500 MTPD
With the above, detailed discussions were carried out with the Technology suppliers/License holders to
identify the best vendor and the following energy conservation offers were received.
M/s M/s Casale M/s KBR M/s Topose

Thyssenkrupp
Energy Reduction Energy Reduction = 0.9 Energy Reduction = 1.77

Could not commit
=0.74 Gcal/MT of Gcal/MT of Urea Gcal/MT of Ammonia is
before placement
Ammonia guaranteed
of order
M/s KBR has offered a guarantee for reduction in energy consumption of 1.77 Gcal/MT and
however as per the detailed working the energy consumption of Ammonia will get reduced
from 9.765 to 7.887 G.Cal/MT.
M/s KBR has completed about 230 Grass Root Ammonia Plants and close to 230 revamp
projects across all countries. Recently M/s KBR has completed commissioning of Ammonia
plant at PT Panca Amara Utama Ammonia Plant in Indonesia and the details are given below.
PT Panca Amara Utama UOM Expected Measured
Ammonia Production MTPD 1900 2045
Ammonia Purity % 99.9 99.95
Gcal/MT of
Net Specific Energy Consumption 6.83 6.794
Ammonia
Co2 Purity % 99 99.570
18
When this energy is still far less than the energy numbers committed to SPIC.
Also, 2 of the Naphtha based plants similar to SPIC – Zuari and Mangalore are also adopted
the technologies of M/s KBR and envisaging substantial reduction in their energy consumption
and the excerpts from their annual report is given below.
 To meet the tightened energy saving norms, Zuari is revamping its Urea unit with an
investment of Rs 13 bn at Goa, making it more energy efficient and increasing
production. Consequently, Urea capacity will increase ~50% from 1,210 MTPD to 2080
MTPD and energy consumption per tonne of Urea will reduce from 6.6 G Cal to 5.39 G
Cal by April 2020, making Zuari amongst the most energy-efficient plants in India.
 MCFL is revamping its Urea unit at an estimated cost Rs. 3.5 bn to be met through
internal accruals and debt. This will reduce energy consumption from 6.65-6.70 G Cal
to 5.25 G cal by April 2020, though capacity will remain unchanged at 1,150 MTPD.
Further, Many of the following Indian plants are already operating with M/s KBR
process
 NFL Nangal,
 IFFCO ,Phulphur-1
 IFFCO –kalol
 Chambal Fertilizers-II.
 Kribhco,Hazhira
And the following plants are on revamp with KBR.
 RCF trombay V
 Mangalore fertizers,
 Zuari fertilizers and
 SPIC
Also, some of the following Urea investments are also with M/s KBR process.
 Matix fertilizers
 Chambal-III stream
Chambal erection is in progress with urea Energy target of 4.9 Gcal/MT of Urea.
19
SPECIALITIES OF REVAMP AT SPIC :
M/s KBR‟s Design of SPIC plants are having various salient features as indicated below.
Only one proprietary Equipment :
Unlike other Technology providers, M/s KBR just have only one proprietary equipment –
Ammonia converter . Catalyst is of client‟s choice as against mandatory to procure catalyst
from the technology supplier like Topsoe.
Revamp Concept :
Our revamp concept is mainly targeted to maximize the steam generation and to reduce the
steam consumption by the equipment.
 Replacement of small turbines to motors always reliable to operate with Steam

turbines whenever it warrants,
 Replacement of PAC with HRSG.
 Replacement of the LTS Quench vessel.
 Replacement of the direct contact CO2 Cooler to indirect cooler.
 Replacement of the old and less efficient turbines to motors.
 Replacement of the Syn Gas Turbine.
 Replacement of the Boiler FD fan to turbine to increase the reliability.
 Replacement of the main plant Boiler feed water turbine from Back Pressure to
Condensing Type turbines.
 Replacement of the inefficient fired Heaters with the Waste Heat.
 Generation of more steam from the waste heat in PAC HRSG, Syn Loop and Reformer
and stoppage of 2 FO fired Boilers.
By going through the above points, it is very clear that the revamp concept is targeting to
phase out the old and less efficient equipment along with maximizing the steam internal
generation and avoiding steam generation through boilers. Also, no major change is carried
out with critical catalytic vessels such as Primary reformer, secondary reformer, HT shift
catalyst vessels, LT shift catalyst vessels, absorbers and other compressors such as SGC and
LRC. Some of the equipment like Semi lean pump are being converted to Motor driven
equipment and the standby pump will be retained with steam driven to revert back to original
system at any point of time. Plant is also adopting latest of technologies such as new process
air compressor with Gas turbine and attached HRSG system.
Additionally, converting the direct contact cooler to indirect Contact Cooler will help reducing
CO2 emissions and improving urea production by 15 MTPD. SPIC will be one of the highly
20
benefited company with retaining the energy norms of the policy indicated in 2007 even when
compared with latest generation plants.
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. 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 Modernization

For Ammonia production
Naphtha 298368 0
FO 97356 126911
NG 0 263795.5
For Urea production (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
Details of raw material requirement are 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
Natural Gas ONGC/IOC/ Other sources By Pipe Line „
21
(Fuel & Feed stock)

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 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. Hazardous
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
Production of
Nitrogenous and complex 92.2 MT Once in 9 IWMA Chennai 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
fertilizers (ZnO)
Production of
fertilizers (Methanator-
22
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
fertilizers (HT Vessel – Cu 11 Years Authorized recyclers
promoted Iron catalyst)
Production of
Nitrogenous and complex 122.6 MT Once in IWMA Chennai Or
fertilizers (Convertor-Iron 15 Years Authorized recyclers
Catalyst)
23
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.
Location Distance in KM
No
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
Tuticorin City Government Bus
6 08 KM
Station
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.
24
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.
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
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.
25
Figure: Project Site on TOPO Map

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 471100 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
27
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.
28
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
29
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
30
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.
31
5 PLANNING BRIEF
Southern Petrochemical Industries Corporation Limited, Tuticorin, (SPIC LTD) modernization

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 modernization of ammonia & UREA (Neem Coated) plant 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%.
32
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.
33
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.
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 by modernization 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 modernization of
Ammonia – 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. 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.
37

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MODERNIZATION OF AMMONIA AND UREA PLANTS

SOUTHERN PETROCHEMICAL INDUSTRIES

Southern Petrochemical Industries Corporation Limited

1 EXECUTIVE SUMMARY ............................................................................................................... 4

2.1 BRIEF DESCRIPTION OF THE PROJECT ................................................................................................ 5

3 PROJECT DESCRIPTION ............................................................................................................ 8

4 SITE ANALYSIS .......................................................................................................................... 24

4.1 CONNECTIVITY ................................................................................................................................ 24

4.7.5 Humidity ................................................................................................................................ 30

5 PLANNING BRIEF ...................................................................................................................... 32

5.1 TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION................................... 32

6 PROPOSED INFRASTRUCTURE .............................................................................................. 34

6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................................................ 34

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................................. 35

8 PROJECT SCHEDULE AND COST ESTIMATE ....................................................................... 36

9 ANALYSIS OF PROPOSAL ........................................................................................................ 37

Proposed capacity / area / length / tonnage to be

2.1 Brief Description of the Project

Existing and Proposed Energy

Item Existing Proposed

Existing and Proposed Capacity

Item Existing Proposed

2.2 Need for the project and its importance to region

Urea Demand/ Supply Balance – India

Energy Scenario in Fertilizer Industry

2.3 Demand Supply Gap

The details of demand(requirement), supply(availability) and sales of Chemical Fertilizers in the

Product Demand (Requirement) Supply (Availability) Sales

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

YEAR Urea DAP NP/NPKs MOP*

2.4 Export Possibility

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

It is modernization of Urea/Ammonia Plant of existing ammonia manufacturing plant so

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

It is “Modernization of Ammonia – Urea plants with capacity increase” at SPIC Nagar,

Figure: Location Map of Google Image

Figure: Plant Layout

SPIC intends to do energy reduction by modernization improvement revamp of existing

Size or Magnitude of Operation

There is no additional land is required for the project.

Sl.No Description Existing After Modernization

3.4 Technology and Process Description

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

o For Energy reduction & Modernization, the available process air

12. DM water and BFW system

The reactions in the desulfurization section are as follows:

(1) RSH + H2 à H2S + RH + heat

(3) H2S + ZnO ZnS + H2O + heat

(4) CnHm + nH2O + heat à nCO + ( 2n + m )/2 H2

The convection heat is used for the following services:

Process Air Compression and HRSG

Process air is filtered and compressed in a four-stage centrifugal compressor. Inter-stage

 Process air coil (1577)

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

Carbon Monoxide Shift Conversion

Carbon Dioxide Removal

(7) CO + 3H2 à CH4 + H2O + heat