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Urea Plant

The Urea Plant is designed based on the CO2 stripping process, licensed by Stamicarbon b.v., the Netherlands. The Urea plant was revamped in March 2002. This resulted in improvement in the product quality with a marginal increase in production quantity. For better control of the operations, a new Distributed Control System replaced the obsolete pneumatic controls. In 2006, HP Scrubber, the ammonia recovery unit, was replaced with MP Scrubber which can be operated at low pressure and Hydrogen converter was installed to improve the overall process safety.

Di Ammonium Phosphate (DAP) Plant

In March/April 2002, the Plant was modernized by installing a pipe reactor system in the granulator with technology from Incro S.A., Spain. The controls have been upgraded to a Distributed Control System. The advantage from the revamp is the flexibility to produce additional fertilizer grades (i.e., 20:20:00:13 and 16:20:00) apart from DAP of a better quality in terms of size, shape and crushing strength. With the introduction of improved operation and maintenance techniques and the resultant increase in the on stream efficiency of the plant, production of 2,60,000 MT per annum of DAP and complex fertilizers can be achieved.

Ammonia (an intermediate product for urea production) Plant

ICI, U.K, technology utilizing steam naphtha reforming process. The annual production capacity is 217,800 MT.

Ammonium Bi Carbonate (ABC) Plant

The plant is capable of producing 15,000 MT per year of ABC and is based on indigenous technology.

Suphonated Naphthalene Formaldehyde (SNF) Plant

SULPHONATED NAPHTHALENE FORMALDEHYDE (SNF), a speciality basic chemical used in construction industry is manufactured in a state-of-the-art plant adopting modern process technology. It is largely consumed in formulation of Concrete Admixtures which facilitate dispersion of the cement particles and increase the rate of hydration resulting in usage of less water for concrete mixture. The entire manufacturing facility is fully automated to ensure environmentally clean, safe and efficient operation producing consistent quality product.

Sulphuric Acid Plant

The Sulfuric Acid Plant technology is based on double conversion, double absorption contact Sulfuric acid process using powder sulphur as raw material.

Product Handling

There are in all four streams for Urea and three streams for phosphatic fertilizers for bagging and dispatch.

Auxiliary Boiler

The Ammonia and Urea plants are supplemented with an auxiliary boiler of 60 MT/h steam capacity at 75 kg/cm2 pressure and 480℃.

Purge Gas Recovery Unit (PGRU)

The productivity of the Ammonia plant was increased by installing a PGRU of 4,800 NM3/h.

Captive Power Plant (CPP)

To overcome the frequent interruptions in power supply, resulting in equipment failure and wastage of energy during shut down and start-ups of the plants, a Captive Power Plant with eight Wartsila Diesel Engine was commissioned. This has ensured smooth functioning and improved life of all the plants and critical equipment through the steady supply of quality power produced. The power plant meets the total power needs (35 MW) for the entire complex.

Imported Ammonia & Phosphoric Acid Terminal (IAT)

The terminal facilitates direct unloading from a ship. Ammonia is stored in a 10,000 MT atmospheric pressure storage tank. Phosphoric Acid is unloaded into two tanks of 8,000 MT each capacity.

Imported fertilizer handling facility

MCFL has installed Imported Fertilizer handling facility. The fertilizer imported through ships will be brought from the port by trucks/tippers and discharged inside the Bulk Storage Silo or to a receiving Hopper outside the silo for bagging and dispatch. The Silo capacity is 20,000 MT.

Bagging Plant (imported fertilizer)

The material brought from port is transferred to the Bagging plant through bulk handling conveyors of capacity 150 tons per hour. The Bagging plant has two streams of 60 tons per hour capacity each which can either be loaded to wagons or truck.

Water Reservoir

The entire complex requires 2 Million Gallons (MG) per day of clarified water which is supplied by the Mangalore City Corporation from the Netravathi River. In order to overcome the problem of water shortages, especially during summer months, two reservoirs of 6 MG and 18 MG capacity were constructed within the factory premises.

Bulk Storage (Silo)

There are two separate silos to store 30,000 MT and 10,000 MT of Urea and Phosphatic fertilizers respectively.