Manufacturing facilities The company has capacity to manufacture 2,17,800MT of
Ammonia (intermediate product), 3,79,500MT of Urea, 2,55,500MT of Phosphatic fertilizers (DAP & NP 20:20:00:13), 15,330MT of Ammonium bicarbonate (ABC), 33,000MT of Sulphuric acid and 21,450MT of Sulphonated naphthalene
formaldehyde (SNF) annually. The design and engineering of the Ammonia/Urea plants was done by Humphreys & Glasgow Limited, London, a leading international firm in the fertilizer field and their associates, Humphreys & Glasgow Consultants Pvt. Ltd., Mumbai. (The firm is now merged with
Jacobs Engineering, USA). The Phosphatic plant was designed and engineered by
Toyo Engineering Corporation, Japan. Indian firms
PDIL and Furnace Fabrica designed and constructed the ABC and Sulphuric acid plant respectively. In 2010, MCF forayed into the manufacture of sulphonated naphthalene formaldehyde (SNF). SNF is a speciality basic chemical used in construction industry. It is largely consumed in formulation of concrete admixtures which facilitate dispersion of the cement particles and increases the rate of hydration resulting in usage of less water for concrete mixture. In 2003, the company implemented
SAP R/3 for its entire operation.
Utilities • Cooling water system – 16,600 m3/h circulation rate. • Water De-mineralizing plant – 120 m3/h capacity. • Nitrogen plant – 650 Nm3/h of gaseous nitrogen and equivalent 50 Nm3/h of liquid nitrogen. • Instrument Air Compressor with Instrument Air drier – 1,500 Nm3/h capacity. • Product Handling – There are 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 °C. • Purge Gas Recovery Unit (PGRU) – The productivity of the Ammonia plant was increased by installing a PGRU in May 1984 of 4,800 Nm3/h capacity. • Captive Power Plant – To overcome the frequent interruptions in power supply, resulting in equipment failure and wastage of energy during shut down and start ups of the process plants, a Captive Power Plant with
Wärtsilä Diesel Engine was commissioned in 1985. This has ensured smooth functioning and improved life of all the plants and critical equipment through the steady supply of quality power captively produced. The 48MW captive power plant complex consists of 8 units of Wärtsilä 18V32 DG sets each of 6MW capacity. The power plant generation voltage is 11,000V at 50 Hz. The power plant meets the total power requirement of the entire complex. • Imported Ammonia & Phosphoric Acid Terminal – The terminal facilitates direct unloading of ammonia and phosphoric acid from a ship. Ammonia is stored in a 10,000MT atmospheric pressure storage tank and
Phosphoric acid is stored in two tanks each of 8,000MT capacity. • Water Reservoir – The entire complex requires 2 Million Gallons (MG) per day of clarified water which is supplied by
Mangalore City Corporation from
Netravathi river. In order to overcome the problem of water shortages, especially during summer, two reservoirs of 6MG and 18MG capacity were constructed within the factory premises. • Bulk Storage (Silo)- There are two separate silos to store 30,000MT and 10,000MT of Urea and Phosphatic fertilizers respectively. ==Products==