GREENSTAR FERTILIZERS LIMITED PFR

Pre Feasibility Report

For
Modernization and Capacity enhancement to produce
Multiple grade fertilizers by
M/s. Greenstar Fertilizers Limited in SPIC Nagar,
District Tuticorin, Tamil Nadu

December, 2018

M/s. Greenstar Fertilizers Limited

SPIC Nagar, District Tuticorin,
Tamil Nadu
 GREENSTAR FERTILIZERS LIMITED PFR

CONTENTS
1 EXECUTIVE SUMMARY ................................................................................. 5
1.1 PLANT FEATURES AND PRODUCTION CAPACITY ..................................................... 5
1.2 SUBMISSION............................................................................................. 6

2 INTRODUCTION ........................................................................................... 7
2.1 BRIEF DESCRIPTION OF THE PROJECT ................................................................ 7
2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE REGION ....................................... 10
2.3 DEMAND SUPPLY GAP .................................................................................. 11
2.4 EXPORT POSSIBILITY ................................................................................... 12
2.5 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT........................... 13

3 PROJECT DESCRIPTION ............................................................................. 14

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ............... 14
3.2 LOCATION (MAP SHOWS GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT
LAY OUT) WITH COORDINATES ................................................................................. 14
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,
PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 18
3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 18
3.5 TECHNOLOGY AND PROCESS DESCRIPTION ............................................................ 19
3.5.1 Salient Features of Site ....................................................................... 23
3.6 RAW MATERIALS ....................................................................................... 24
3.7 ADDITIVES AND CHEMICALS ............................................................................ 25
3.8 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF
FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 25
3.8.1 Transportation details of Raw Materials .................................................... 25
3.9 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 25
3.9.1 Fuel ............................................................................................... 26
*330 DAYS PRODUCTION BASIS ............................................................................... 26
3.10 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT
/DISPOSAL ...................................................................................................... 26

4 SITE ANALYSIS ......................................................................................... 27

4.1 CONNECTIVITY ......................................................................................... 27

4.2 LAND FORM, LAND USE AND LAND OOWNERSHIP ...................................................... 27
4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 29
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. ............................................................................................. 31
4.5 EXISTING INFRASTRUCTURE ............................................................................ 31
 GREENSTAR FERTILIZERS LIMITED PFR

4.6 SOIL CLASSIFICATION .................................................................................. 31

4.7 CLIMATIC DATA FROM SECONDARY SOURCES .......................................................... 31
4.7.1 Temperature .................................................................................... 32
4.7.2 Wind Direction Pattern ........................................................................ 32
4.7.3 Rainfall ........................................................................................... 33
4.7.4 Cloud Cover ..................................................................................... 33
4.7.5 Humidity ......................................................................................... 33
4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 33
4.8.1 Assessment of Infrastructure Demand (Physical) ......................................... 33
4.8.2 Assessment of Infrastructure Demand (Social) ........................................... 33

5 PLANNING BRIEF ...................................................................................... 35

5.1 TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ........................ 35

5.1.1 Population Projection .......................................................................... 35
5.2 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT, ETC) .................................... 35
5.2.1 Land Use and Availability ..................................................................... 36

6 PROPOSED INFRASTRUCTURE .................................................................... 37

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 37

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 37
6.3 GREENBELT ............................................................................................. 37
6.4 DRINKING WATER MMANAGEMENT (SOURCE & SUPPLY OF WATER) ................................... 37
6.5 SEWAGE SYSTEM ....................................................................................... 37
6.6 INDUSTRIAL WASTE MANAGEMENT..................................................................... 37
6.7 POWER REQUIREMENT & SUPPLY/SOURCE ............................................................. 37

7 REHABILITATION AND RESETTLEMENTS (R & R) PLAN .................................. 38

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING
HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO BE GIVEN) .................. 38

8 PROJECT SCHEDULE AND COST ESTIMATE.................................................... 39

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE
PROJECT TO BE GIVEN) .........................................................................................
39
8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT.
39

9 ANALYSIS OF PROPOSAL ........................................................................... 40

1
 GREENSTAR FERTILIZERS LIMITED PFR

1 EXECUTIVE SUMMARY
M/s Greenstar Fertilizers Limited proposes to enhance the capacity of their existing
manufacturing units and install new plants at Tuticorin to fulfill the increasing demand of
fertilizers in India.

DAP, Plant: Existing fertilizer plants can produce 606100 MTPA of Di-Ammonium
Phosphate .with growing demand for fertilizers and changing nutrient requirements for
various crops. By the debottlenecking process equipment, the existing capacity will
increase to 900000 MTPA of DAP Plant.

New NPK Plant: New plant of NPK will be installed in the existing vacant land of Green
star Fertilizers Ltd with the capacity of 600000 MTPA. In this plant multiple grades of NPK
/NPS/NP will be produced.

New Triple super phosphate plant: New plant of TSP will be installed in the existing
vacant land of Greenstar Fertilizers Limited with the capacity of 200000 MTPA.

AlF3 Plant : Existing fertilizer plants can produce 10000 MTPA of Aluminium Fluoride .By
the debottlenecking process equipment, the existing capacity will increase to 14000
MTPA of Aluminum Fluoride.

Triple Superphosphate: SSP is a simple fertilizer and it was proposed to produce TSP
in the existing same SSP plant Instead of installing a separate new plant, it has been
proposed to produce Triple Superphosphate by changing the raw material in the existing
Single superphosphate plant itself. By this, both SSP and TSP can be produced and the
capacity will be 115000 MTPA. (No change in capacity)

New Granulation Unit (SSP/TSP/Gypsum):New granulation unit for

SSP/TSP/Gypsum will be installed with the capacity of 200000 MTPA in vacant land of
Fertilizers Ltd.

The proposed capacity enhancement and expansion fall under the category of 5 (a) –
Chemical Fertilizers of the Scheduled list of Projects in the Environment Impact
Assessment (EIA) Notification S.O.-1533, dated: 14-09-2006, which necessitates
obtaining the Environment Clearance from Expert Appraisal Committee, Ministry of
Environment and Forests (MOEF), Government of India.

1.1 Plant Features and Production Capacity

Southern Petrochemical Industries Corporation Ltd Tuticorin plant was commissioned in
the year 1975. The industry is spread over 350 Acre, one of the largest manufactures of
the nitrogenous and phosphoric fertilizers was the first non –turnkey venture of its kind in
India.
The company, headquartered in Chennai, was incorporated on 18th December 1969 and
became a joint venture between the M. A. Chidambaram Group and TIDCO (a part of the
Government of Tamil Nadu) in 1975. The government sold its stake in 1992. The
company's biggest client has been the government of Tamil Nadu, which
purchases agro-products for subsidized distribution through its Public Distribution
System.
 GREENSTAR FERTILIZERS LIMITED PFR

Southern Petrochemical Industries Corporation Ltd, Tuticorin transferred Di Ammonium

Phosphate, ALF3 and SSP Units to M/S Green Star Fertilizers Limited, Tuticorin on 24th
October 2011 through Business Transfer Agreement as result of which facility for
manufacturing ammonia & urea alone remains with M/s Southern Petrochemical
Industries Corporation Ltd, Tuticorin.
Greenstar Fertilizers Private Limited, Tuticorin was originally incorporated on 25th August
2010 under Companies Act, 1956. On dated 20th July 2011 Company name was changed
to Green Star Fertilizer Limited.
Greenstar Fertilizers Limited, Tuticorin has DAP plants, with a capacity of 6,06,100 MT
per annum of DAP, 10000 MTPA of AlF3 and 350 MTPD of SSP along with intermediates
and by products.
Existing Plant has sufficient land and other necessary facilities for successful
establishment and operation of plant after enhanced production capacity.

Environment
Company policy and prime aim is to ensure that Environmental Norms are strictly
adhered to.
Some of the key features with respect to effluents and waste disposal in this unit are:
Laboratories and production sites are engineered to be safe working environments in
accordance with local regulations and the company’s high-level operating standards.
Stringent safety procedures, applicable to both internal company and external sub-
contracted employees, are practiced during the sites’ erection stages. Greenstar
Fertilizers Ltd also has made large investments in Automation and in installation and
maintenance of advanced safety equipment and fire protection systems. Plant has also
incorporated online monitoring systems as per the guidelines of CPCB.
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 would also be taking up an
effective pollution mitigative technique, as well as to serve as biological indicators for the
pollutants released from the premises of Greenstar Fertilizers Ltd.
The company proposes to have similar standards at the Expansion of existing plant
which will be planned on same available existing land.

1.2 Submission
In the light of the above, we would like to state that the expansion plant at Tuticorin with
would have in place systems, procedures and hardware to ensure that all guidelines for
protecting the environmental emission norms are followed and its operation has no
adverse impact on environment.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

2 INTRODUCTION

2.1 Brief Description of the Project

Greenstar Fertilizers Limited proposes to enhance the capacity of their existing
manufacturing units and install new plants at Tuticorin to fulfill the increasing demand of
fertilizers in India.

DAP, Plant: Existing fertilizer plants can produce 606100 MTPA of Di-Ammonium
Phosphate with growing demand for fertilizers and changing nutrient requirements for
various crops. By the debottlenecking process equipment, the existing capacity will
increase to 900000 MTPA of DAP Plant.

New NPK Plant: New plant of NPK will be installed in the existing vacant land of
Greenstar Fertilizers Ltd with the capacity of 600000 MTPA. In this plant 10 different
grades of NPK /NPS/NP will be produced.

New Triple super phosphate plant: New plant of TSP will be installed in the existing
vacant land of Greenstar Fertilizers Limited with the capacity of 200000 MTPA.

AlF3 Plant : Existing fertilizer plants can produce 10000 MTPA of Aluminium Fluoride .By
the debottlenecking process equipment, the existing capacity will increase to 14000
MTPA of Aluminum Fluoride.

Triple Superphosphate/SSP: SSP is a simple fertilizer and it was proposed to produce

TSP in the existing same SSP plant Instead of installing a separate new plant, it has been
proposed to produce Triple Superphosphate by modifying the existing Single
superphosphate plant itself. By this, both SSP and TSP can be produced and the capacity
will be 115000 MTPA. (No change in capacity)

New Granulation Unit (SSP/TSP/Gypsum): New granulation unit for

SSP/TSP/Gypsum will be installed with the capacity of 200000 MTPA in vacant land of
Greenstar Fertilizers Ltd.

Greenstar Fertilizers Limited, Tuticorin proposes to enhance the capacity of existing

plants according to below:

• Greenstar Fertilizers Limited, Tuticorin is not acquiring any land for this project.
• The proposed capacity enhancement and expansion fall under the category of 5 (a) –
Chemical fertilizers of the scheduled list of projects in the Environment Impact
Assessment (EIA) Notification S.O.-1533, dated: 14-09-2006, which necessitates
obtaining the Environment Clearance from Expert Appraisal Committee, Ministry of
Environment and Forests (MoEF), Government of India.
• Greenstar Fertilizers Private Limited, Tuticorin was originally incorporated on 25 th
August 2010 under Companies Act, 1956. On dated 20th July 2011 Company name
was changed to Green Star Fertilizer Limited.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

• Southern Petrochemical Industries Corporation Ltd, Tuticorin transferred Di-

Ammonium Phosphate, ALF3 and SSP Units to M/S Green Star Fertilizers Limited,
Tuticorin on 24th October 2011 through Business Transfer Agreement. So now
Greenstar Fertilizers Limited, Tuticorin has ownership of Di-Ammonium Phosphate,
ALF3 and SSP Unit.
• Existing Plant has sufficient land and other necessary facilities for successful
establishment and operation of plant after enhanced production capacity.

Summary of Existing/Proposed Capacity of Plant is given as follows;

S. Product Existing Capacity after Process Remark

No. Capacity Enhancement
(MTPA) (MTPA)
Expansion of Fertilizer Unit of Greenstar Fertilizers Ltd
1. Di- 6,06,100 9,00,000 By the de By the Modification
Ammonium (Grade: 18:46:0 bottlenecking & change in
Phosphate 20:20:0:13) process process equipment
(I+II) equipment, to increase the
increase the production capacity
production in exiting plant.
capacity.

2. New Multi ------------------- 6,00,000 New Plant in New Plant in

Grade NPK (Grade: Existing Existing Premises
/NPS/NP 18:46:0, Vacant Land of Greenstar
Plant 10:26:26, of Greenstar Fertilizers Ltd
14:35:14, Fertilizers Ltd
17:17:17,
28:28:0,
20:20:0:13,
12:36:16,
15:15:15,
16:16:16,
16:20:0:13
3. Single Super 1, 15,000 (350 • Production No Change in For SSP- Sulphuric
Phosphate TPD) of TSP/SSP capacity, Acid will be added
(SSP)/Triple Single Super with Rock
in existing
super Phosphate phosphate
phosphate
SSP plant– /Triple Super TSP-Phosphoric
115000 Phosphate Acid will be added
MTPA (TSP) will be with Rock
produced as phosphate
per market
demand (Few
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

modification &
technology
will be
required in
existing plant)
Granulated ------------------ 2,00,000 New Plant in New Plant in
SSP/TSP/ Vacant Land Existing Premises
Gypsum of Greenstar of Greenstar
Fertilizers Ltd. Fertilizers Ltd
4 New TSP ---------------- 200000 New plant in New Plant in
vacant land of Existing Premises
Greenstar of Greenstar
fertilizers Ltd Fertilizers Ltd
45 Aluminum 10000 14,000 By the de By the modification
Fluoride bottlenecking & change in
(AlF3) process process equipment
equipment, to increase the
increase the production capacity
production in exiting plant.
capacity.
Fertilizers-Intermediate
1. Sulphuric 2,70, 000 2,70, 000 No Change -------------
Acid
2. Phosphoric 1,25,000 1,25,000 No Change Environmental
Acid (Approved) (Approved) clearance obtained
After After from MOEF vide
Revamping- Revamping- F.No.J-
2,16,000 2,16,000 11011/123/2014 –
Environmental Environmental IA-II(I) dated
clearance clearance 30.05.2018 for
obtained from obtained from producing 2,16,000
MOEF vide MOEF vide MTPA .
F.No.J- F.No.J-
11011/123/2014 11011/123/2014
–IA-II(I) dated –IA-II(I) dated
30.05.2018) 30.05.2018)
3. Hydrofluoro 8,800 8,800 No Change ------------
silicic Acid (Approved) (Approved)
After After
Revamping- Revamping-
15,200 15,200
Environmental Environmental
clearance clearance
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

obtained from obtained from

MOEF vide MOEF vide
F.No.J- F.No.J-
11011/123/2014 11011/123/2014
–IA-II(I) dated –IA-II(I) dated
30.05.2018) 30.05.2018)
By Product Details
1. Gypsum 6,25000 6,25000 No Change ------------
(Approved) (Approved)
10,80,000 (After 10,80,000 (After
revamping ) revamping )
Environmental Environmental
Clearance Clearance
F.No.J- F.No.J-
11011/123/2014 11011/123/2014
–IA-II(I) dated –IA-II(I) dated
30.05.2018) 30.05.2018)
2. Silica 4375 6125
Utilities
1. Biomass 5 MTPH 5 MTPH No Change ------------
Boiler
2. CPP 6 MW 6 MW No Change ------------

2.2 Need for the Project and its Importance to the Region

Agriculture is the backbone of Indian Economy. About 70% of the rural households and
8 per cent of urban households are still primarily dependent on agriculture for
employment. The green revolution era resulted in significant increase in the agricultural
yield per unit area. Due to recent industrialization, the economic importance is being
slowly shifted from agricultural to industrial sector. There

Agriculture, along with fisheries and forestry, is one of the largest contributors to the
Gross Domestic Product (GDP). As per estimates by the Central Statistics Office (CSO),
there has been a continuous decline in the share of agriculture and allied sectors
(including agriculture, livestock, forestry and fishery) in the GDP from 16.8 percent in
2007-08 to 13.9% in 2013-14 at 2004-05 prices, same was 15.35 per cent of the Gross
Value Added (GVA) during 2015-16 at 2011-12 prices and now increase to 17.32% in
2016-17.. India is the largest producer, consumer and exporter of spices and spice
products. India's fruit production has grown faster than vegetables, making it the second
largest fruit producer in the world. India's horticulture output, comprising fruits,
vegetables and spices, is estimated to be 283.4 million tonnes (MT) in 2015-16 after the
third advanced estimate. It ranks third in farm and agriculture outputs. Agricultural
export constitutes 10 per cent of the country’s exports and is the fourth-largest principal
exported commodity. The agro industry in India is divided into several sub segments
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

such as canned, dairy, processed, frozen food to fisheries, meat, poultry, and food
grains.

The Indian food industry is poised for huge growth, increasing its contribution to world
food trade every year due to its immense potential for value addition, particularly within
the food processing industry. The Indian food and grocery market is the world’s sixth
largest, with retail contributing 70 per cent of the sales. The Indian food processing
industry accounts for 32 per cent of the country’s total food market, one of the largest
industries in India and is ranked fifth in terms of production, consumption, export and
expected growth.

The projections by working groups for the Twelfth Plan suggest that past growth of these
traditional inputs should be improved upon. However, these working groups also project
lower growth of ‘modern’ inputs than observed during the Eleventh Plan. For example,
2016–17 requirements of chemical fertilizer and farm power are placed at levels that
imply annual growth for both fertilizer’s and ‘modern’ energy at about 4.5 per cent.
These exceed corresponding the Eleventh Plan projections but are much less than the
Eleventh Plan actual. Reduced fertilizer and fuel subsidies would be consistent with the
desired moderation in trend of these inputs. Restraint is also needed on pesticides use
which rose sharply in the Eleventh Plan after years of being subdued.

The government has launched several schemes to increase growth of agriculture sector
and for welfare of the farmers through increase in production and productivity of
agricultural crops and to improve income levels of farmers.

2.3 Demand Supply Gap

Fertilizer production in India is growing at a compounded annual growth rate of 4% from

FY13 onwards and estimation of production to touch 460-470 LMT (Lakh Metric Tonnes)
by 2020. This compares with production of 413.24 LMT in FY17. The Government
declared it would be reviving 5 closed fertilizer plants - 4 of Fertilizer Corporation of India
Limited (FCIL) in Talcher, Ramagundam, Gorakhpur and Sindri and 1 of Hindustan
Fertilizer Corporation Ltd. (HFCL) in Barauni. This is being done by setting up new
ammonia-urea plants with a capacity of 12.7 LMT (Lakh Metric Tonne) per annum.
During the FY 2016-17 India has produced 413.24 LMT of fertilizers. Urea dominates the
total fertilizer production in the country. Government of India is working towards
increasing the production of urea so as to end imports by 2022 and achieve self-
sufficiency in Urea Production. Out of the total fertilizer production India produces only
10%-12% of DAP but due to recent fall of raw material prices in the international
markets, phosphates have become cheaper and its economical to produce the fertilizer
rather than importing the end product. Hence the government is encouraging sprucing
up the production of DAP, which is the second most widely used fertilizer after urea.
Production of Complex Fertilizers includes the various grades of NPK Fertilizers
(Nitrogenous- Phosphorus- Potassic).
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

The Indian product demand forecast till 2020-21 is as follows:

FERTILISER PRODUCT DEMAND FORECASTS TILL 2020-21

(million tonnes)

Year Urea DAP Complex fertilisers

2017-18 33.7 12.7 23.2

2018-2019 34.5 12.9 23.9

2019-2020 35.3 13.0 24.9

2020-2021 41.6 14.7 19.6

The Government is encouraging SSP production as SSP is also considered as a substitute

to diammonium phosphate (DAP), which is largely import based and costlier vis-a-vis to
SSP.

The quantity of Urea imported also has fallen considerably from FY2015-16 by 27% y-o-y
basis in FY 2016-2017. From 26.3% in FY2012-13 import dependence has reduced to
only 18.5% in FY2016-17 vis-à-vis production has increased from 73.7% in FY2012-13 to
81.5% in FY2016-17, indicating that India is moving towards self-sufficiency of Urea
Production. India plans to eliminate imports by 2022.

Among the major states in India, the per-hectare consumption is more than 100 kg in
West Bengal (122 kg), Haryana (167 kg), Punjab (184 kg), Uttar Pradesh and
Uttaranchal (127 kg), Andhra Pradesh (138 kg) and Tamil Nadu (112 kg). It is hence
very vital to increase the fertilizer production in Tamil Nadu and southern states so as to
increase the individual consumption rate and reduce imports by the end of 2020.

Additional Subsidy Disbursement: To reduce the burden of fertiliser subsidy backlogs

during 2016-17, a special banking arrangement (SBA) of Rs 10,000 crore has been
approved by the Cabinet Committee on Economic Affairs (CCEA). The CCEA has also
approved that, in future, the Department of Fertilisers would avail the SBA with the
concurrence of the Department of Expenditure. The government is making available urea
and 21 grades of P&K (phosphate and potassium) fertilisers to farmers at subsidised
prices through fertiliser manufacturers and importers. The government interest liability is
limited to the G-Secs rate.

2.4 Export Possibility

No
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

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

With the expansion of various units in M/s Greenstar Fertilizers Ltd, additional man power
(Approximately 100) is required even indirect employment will be generated which will
aid in development of nearby area.

There were upliftments of Socio-economic standard of local people surrounding the

project site due to proposed project. During the construction phase work will be
generated for skilled, semiskilled and unskilled labors. Technical persons will be recruited
during the operation phase.

Greenstar Fertilizers Limited, Tuticorin generate the employment on various levels time
to time and give the priority to local persons.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

3 PROJECT DESCRIPTION

3.1 Type of Project including Interlinked and Interdependent Projects, if

any
Proposed Expansion 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 amendment on 1st December 2009.

Greenstar Fertilizers Limited, proposes for modernization and capacity enhancement to

produce multiple grade fertilizers of their existing manufacturing units of DAP plant and
new NPK plant, new SSP/TSP/Gypsum granulation plant at Tuticorin to fulfill the fertilizer
demand.

3.2 Location (Map shows 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- Tiruchendur Road, Kanyakumari Road.

The proposed site lies between 08° 44ʾ 28.71” N latitude and 78° 08ʾ 12.74” E
longitudes and is well connected by Road (NH-7), Rail and Tuticorin port.

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

railway station Tuticorin is located at a distance of 10 KM from the site.
MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Figure 1: Project Location on Toposheet

MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Figure 2 : Project Location on Google Image

MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Figure 3: Plant Layout

 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

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 expansion Project on an existing site, with requisite facilities available at
site. There is no interlinked project.

Since the objective is to manufacture Chemical Fertilizer, a lush green & Fertilizer friendly
environment is being selected for installing the plant. The salubrious pollution free
climate of Tamilnadu makes it an ideal location for the health and medical care industry.

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.

Green Star Fertilizers Limited, proposes to enhance the capacity of their existing
manufacturing units of DAP plants, new NPK plant and SSP/TSP/Gypsum granulation
plant at Tuticorin to fulfill the fertilizer demand.

3.4 Size or Magnitude of Operation

S. No. Product Capacity (MTPA)

Existing After Enhancement

Expansion of Fertilizer Unit of Green Star Fertilizers Ltd
1. Di- Ammonium 6,06,100 9,00,000 (Grade: 18:46:0 &
Phosphate (I+II) 20:20:0:13)
2. New multi grade ---------------------- 6,00,000 (Grade: 18:46:0,
NPK Plant 10:26:26,
14:35:14,17:17:17,28:28:0,
20:20:0:13, 12:36:16, 15:15:15,
16:16:16, 16:20:0:13
3. Single Super 1, 15,000 (350 TPD) No Change (TSP will be produced
Phosphate in the same plant with same final
(SSP)/TSP capacity)
Granulated -------------------------- 2,00,000
SSP/TSP/Gypsum
4 New TSP Plant ------ 2,00,000
5. Aluminum 10000 14,000
Fluoride (AlF3)
Fertilizers-Intermediate
1. Sulphuric Acid 2,70, 000 2,70, 000
2. Phosphoric Acid 1,25,000 (Approved) 1,25,000 (Approved)
After Revamping- After Revamping- 2,16,000 MTPA
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

2,16,000 MTPA .Environmental Clearance obtained

.Environmental from MOEF vide F.No.J-
Clearance obtained 11011/123/2014 –IA-II(I) dated
from MOEF vide F.No.J- 30.05.2018
11011/123/2014 –IA-
II(I) dated 30.05.2018
3. Hydrofluoro silicic 8,800 8,800
Acid (Approved) (Approved)
After Revamping- 15200 After Revamping- 15200 MTPA
MTPA .Environmental .Environmental Clearance obtained
Clearance obtained from MOEF vide F.No.J-
from MOEF vide F.No.J- 11011/123/2014 –IA-II(I) dated
11011/123/2014 –IA- 30.05.2018
II(I) dated 30.05.2018
By Product Details
1. Gypsum 6,25000 (Approved) 6,25000 (Approved)
10,80,000 (After 10,80,000 (After revamping)
revamping) Environmental clearance obtained
Environmental clearance from MOEF vide F.No.J-
obtained from MOEF 11011/123/2014 –IA-II(I) dated
vide F.No.J- 30.05.2018
11011/123/2014 –IA-
II(I) dated 30.05.2018
2. Silica 4375 6125
Utilities
1. Biomass Boiler 5 MTPH 5 MTPH
2. CPP 6 MW 6 MW

3.5 Technology and Process Description

Summary of Modernization of Exiting DAP Plant:
• Slurry Pump replacement
• Scrubber Pump upgradation
• Acid line upgradation on MOC
• Cyclones Upgradation
• Fans Upgradation
• Product Cooling improvisation
• Additional slurry headers
• Higher P2O5 Concentration as input

REACTIONS INVOLVED

NH3 + H3PO4 → NH4H2PO4 ( MAP )

 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

2NH3 + H3PO4 → (NH4) 2HPO4 ( DAP )

In Some grades, Sulfuric acid is required and the following reaction also occurs.
2NH3 + H2SO4 → (NH4) 2 SO4 ( MAP )
Ammonia + Sulphuric acid → Ammonia sulphate ( MAP)

Process:
Phosphoric acid and sulphuric acid are partially neutralized with ammonia in an agitated
Neutralizer Tank. The resultant slurry is then pumped into the rotating drum called the
ammoniator granulator. Also, in DAP-1 train, the feeds are admitted through pipe rectors.
Recycle fines are also added to the drum. Additional ammonia is fed into the bed of
granules through special spargers.

The rolling action promotes the formation of granules while the heat of reaction drives off a
considerable amount of water vapour. The granules are discharged into a rotary, co
current, dryer. The dried granules are then screened. Oversized granules is ground and
recycled along with the fines to the Ammoniator granulator. Product is cooled with air in a
counter current rotary cooling drum. The product is sampled and weighed prior to being
conveyed to storage. Wet scrubber is used to prevent losses of product and raw materials
and to minimize atmospheric pollution.
Wet Section:

A portion of phosphoric acid is used as scrubbing medium into the Scrubbing Tank. The
scrubber solution is circulated by pump to the Fumes & dryer venturi scrubbers and
cyclonic portions. Thus the ammonia and dust coming along with the gas stream are
recovered.
The liquid from Fume Scrubber Tank overflows in the agitated neutralizer. Ammonia is
metered into the Neutralizer to react with the acid. The heat of reaction causes a
considerable evolution of steam from the tank. Neutralizer temperature is controlled by the
addition of process water. Ammonia is supplied to the plant as a liquid and Controls are
provided to supply ammonia at a constant pressure and temperature to enable accurate
control and measurement. The slurry from the Neutralizer is pumped into Granulator by
means of slurry pump. The flow is measured and controlled through a magnetic flow
meter.
Dry Section:

Recycle fines are fed to Granulator by means of Recycle Elevator. Ammonia is fed to
granulator through a sparger beneath the rolling bed of granules. The flow of ammonia is
controlled and measured. Fumes and dust from Granulator are sent to Fume Scrubber to
recover raw materials. The material leaving Granulator flows directly into the rotary dryer.
Heated air is used to reduce the moisture to 1.0 % or lower. Dryer Furnace is fired with
fuel oil. The granules are discharged from Dryer through Lump Crusher and trommel bars
into screen feed elevator by means of Screen Feed Conveyor. The granules are distributed
from the discharge of the elevator over double deck screens by means of screen Feed
Conveyors. Oversize material from the screens is conveyed into oversize mill. Fines and the
material leaving the oversize mill pass through Recycle Conveyor.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Product is conveyed to Cooler. Product may also be recycled. It is discharged to product

elevator, which discharges it into product conveyor. The material is weighed and conveyed
to storage by product conveyors. Dust from various points is recovered using air from dust
fan as collecting medium, through dust cyclone. Dust collected in cyclones is conveyed into
Recycle Conveyor. Dust from Dryer air stream is recovered by dryer cyclones and this is
also conveyed to Recycle Conveyor. The separated air from all the cyclones is taken to dust
scrubber where the decomposed ammonia and dust is recovered by scrubbing with water.
In the existing DAP-2 train, just by changing the proportions of feed flow rates, the
production unit is made capable of producing both DAP and complex fertilizer
(20:20:0:13). All the equipment and the operation remain same and no any change is
expected in the chemical reactions.

ALUMINIUM FLUORIDE PLANT PROCESS

Aluminium Fluoride Plant is designed to produce 10000 Metric Tons per annum of crystal
aluminium fluoride from aluminium hydroxide and hydrofluosilicic acid based on Alusuisse
Process.

Hydrofluosilicic acid is preheated and made to react with dried aluminium hydroxide in
batch reactors to produce soluble form of trihydrate of aluminium fluoride and
precipitates of silica. Silica is separated in belt filters. The trihydrate aluminium fluoride is
sent to crystallizers where aluminium fluoride crystals are formed. These crystals are
separated from mother liquor by belt filters. The crystals contain 10% free moisture that is
removed in a flash drier.

This trihydrate crystal of aluminium fluoride is then sent to calciner. Calciner is a rotary drum
heater burning LSHS where molecular moisture from the crystals is removed by hot flue gas
at 500 0C. The resulting anhydrous aluminium fluoride is cooled and conveyed to storage silo
through a pneumatic conveying system.

TRIPLE SUPER PHOSPHATE (TSP)

The Plant is based on “Conventional Den Process “and is designed to produce fertilizer
grade Triple Super Phosphate.
REACTIONS INVOLVED

CaF2.3 [Ca3 {PO4] 3] + 14H3PO4 + 3 H2O → 10 CaH4 (PO4)2 + 2 HF

PROCESS:

Triple Super Phosphate is manufactured by digesting rock phosphate with phosphoric

acid. Manufacturing process of TSP is same as of Single Super Phosphate (SSP) except
Phosphoric acid used for TSP in place of Sulphuric Acid used for SSP. TSP is considered
as the concentrated form of Single Super Phosphate. To enable the reaction with
Phosphoric acid, the phosphate rock is ground in a ball mill. The ground rock is weighed
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

on a continuous belt weigher and fed into a Mixer where the phosphate rock is mixed
with Phosphoric acid at the required rate.
After a mixing, the reaction mass is discharged from the Mixer onto a continuously moving
enclosed conveyor called den, which has a slow-moving circulating floor. The residence
time in the Den is 40 to 60 minutes. The solidified mass is broken up by a cutter and is
transferred by a conveyer to a storage area for “curing”. Curing takes place for 7 to 10
days approximately, for complete reaction and to attain fertilizer grade.
Waste gases (HF and SiF4 etc) and dust arising due to the reaction of Rock and Phosphoric
acid are treated in the Five-stage Scrubbing Section using water. The Five stage scrubbing
section includes primary and secondary Venturi scrubbers and its cyclone portions along
with duct washing. The scrubbed liquid is recycled back to the Mixer.

New NPK Plant (Process Technology)

The NPK complex manufacturing plant uses liquid anhydrous ammonia concentrate and
week phosphoric acid, potassium chloride and sulphuric acid as main raw materials along
with urea & some other additives as filler material. Occasionally some micronutrients such
(sulphate of magnesium, sulphate of zinc and borax) is added.

The New NPK plant is based on Pipe Reactor Technology and can produce multiple product
grades as listed in FCO. The various grades are as follows.

18:46:0 20:20:0:13 10:26:26 12:36:16 14:35:14

28:28:0 15:15:15 16:16:16 17:17:17 16:20:0:13

Mixed Process (Pipe Reactor) PR+ (Pre Neutralizer) PN:

This technology from INCRO is one of the best process for large DAP/NPK plants, since it
splits the heat between PN and PR, operates at low recycle 4:1 and produces a more
spherical product than any PR only process. It also provides flexibility to produce any NPK
grade, with PR or PR+PN.
Out the technologies mentioned above, Greenstar Fertilizers Ltd has selected Mixed
Process PR+PN technology in view of its advantages over the other technologies for
intended level of production. This technology can provide flexibility of producing various
grades of NPK from the proposed plant as per the marketing scenario.
INCRO’S mixed slurry process (pipe reactor & pre neutralizer) - In this process there is
direct neutralization of phosphoric acid and optionally a lot of sulphuric acid in the PR and
PN (in case of AMS based NPKs). Merits of INCROS Mixed Slurry Process (PN + PR)
Technology.
Production Capacity Increases (Special in PN)
Improved Product Quality (Shape)
Operation and Acid Choice Flexibility (PN+PR OR PR)
Improved on-Stream Factor (2 Reaction Equipment)
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Flexibility to produce other NPK’s (AMS based)

Better Granulation Control (Improved Slurry Feed)
Production Process
There are following major sections of the production process: a) Raw Material Feeds b)
Slurry Preparation and Granulation c) Pre-neutralizer d) Pipe Reactor e) Granulation f)
Drying g) Screening & Crushing h) Final Product Conditioning i) Dust and Fumes Collection
j) Scrubbing a) Raw Material Feeds Phosphoric acid at 50-54% P2O5 strength is pumped
from its storage day tank to the various destinations in the plant, namely the pipe reactor
tank, the granulator pre-scrubber tank, the scrubber tank and occasionally to the pre
neutralizer reactor. Liquid ammonia is pumped from storage to the liquid ammonia heater
and from here to the pipe reactors, to the granulator ammonization system and to the
ammonia separator vessel. Eventually liquid ammonia can also be sent to the pre
neutralizer. These systems are described in detail at a later stage. Sulphuric acid is used for
PH and n/p control and it can be fed to pre neutralizer, to granulator, to granulator pre-
scrubber tank, to the scrubber tank and to the tail gas scrubber.

Production Process
There are following major sections of the production process:
a) Raw Material Feeds
b) Slurry Preparation and Granulation
c) Pre-neutralizer
d) Pipe Reactor
e) Granulation
f) Drying
g) Screening & Crushing
h) Final Product Conditioning
i) Dust and Fumes Collection
j) Scrubbing

3.5.1 Salient Features of Site

S. No. Particulars Details
Muthiahpuram village, Taluka - Tuticorin, District -
1. Plant Location
Tuticorin, State- Tamil Nadu Pin Code-628005
2. Climatic Conditions Arid
a. Temperature
Mean Maximum 38.9 0C
Mean Minimum 17.10 C
b. Mean Annual Rainfall 67 cm
c. Relative Humidity 41% to 77%
d. Predominant Wind Directions January-March : N to NNE
April-July : W to WNW
August-September : SW
October-December : NE
3. Climatic Conditions at Site Coastal
a. Temperature 19 0C to 410C
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

S. No. Particulars Details

b. Predominant Wind Directions Towards west followed by SW and NE
4. Plant Site Elevation above MSL Ave (+) 4.3 Meters
5. Plant Site Topography Generally Flat
6. Present Land use at the Site Industrial Land
7. Nearest Highway NH -7 A (6 km from Site)
8. Nearest Railway Station Tuticorin (8 km from the Site)
9. Nearest Airport Tuticorin (18 km from the Site)
10. Nearest River Tamiraparani river ( 20 km from the Site)
North Main Channel of the Tamiraparani River
11. Water Source for the Site
System at Peikula
12. Nearest Town/City Tuticorin
13. Nearest Village Mullakadu
14. Hills/Valleys No hills and valleys within 10-km radius
Archaeologically Important
15. Marine National park in Gulf of Mannar
Places
Protected areas as per Wildlife
Protection Act, 1972 (Tiger
Reserve)
Elephant Reserve
16. None in 15-km radius
Biospheres, National Parks,
Wildlife Sanctuaries,
Community-Reserves and
Conservation Reserves)
17. Reserved /Protected Forests None in 15-km radius
18. Defense Installations None in 15-km radius area
1. Sterlite Industries
2. Tuticorin Thermal Plant
3. Tuticorin Alkali Chemicals
4. Heavy Water Plant
Major Industries in 15-km
19. 5. Ammonia Importation Terminal
Radius
6. Indian Oil Corporation
7. Super Gas Industries
8. Bharat Petroleum Industries
9.VV Chemicals
Backward area, now developing with industrial
20. Socio-economic factors
activities and through Port
3.6 Raw Materials

‘M/s Greenstar Fertilizers Ltd’ imports all the raw material through ships on V.O.
Chidambaram Port Trust. Existing plant is connected with Indian Railway network
through dedicated railway line.
Details of Raw Material

Aluminium
Product Ammonia PA SA Potash Rock Sulfur FSA
Hydroxide
Existing
DAP 147862 309587 33005 ---- ---- ---- ---- ----
SSP ---- ---- 41400 ---- 66700 ---- ---- ----
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

AlF3 ---- ---- ---- ---- ---- ---- 11500 11000

SA ---- ---- ---- ---- ---- 89640 ---- ----
PA ---- ---- 381250 ---- 431250 ---- ---- ----
Total 147862 309587 455655 0 497950 89640 11500 11000
Proposed
DAP 201600 422100 45000 ---- ---- ---- ---- ----
NPK 208200 281400 265200 273600 ---- ---- ---- ----
SSP ---- ---- 41400 ---- 66700 ---- ---- ----
TSP ---- 146000 ---- ---- 84000 ---- ---- ----
AlF3 ---- ---- ---- ---- ---- ---- 16100 15400
SA ---- ---- ---- ---- ---- 89640 ---- ----
PA ---- ---- 381250 ---- 431250 ---- ---- ----
Total 409800 849500 732850 273600 581950 89640 16100 15400

3.7 Additives and Chemicals

No

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

3.8.1 Transportation details of Raw Materials

Existing and proposed quantity of raw material consumption is given in Section 3.6.
Details of raw material transportation is given below table

Details of Raw Material Transportation Details

Raw Material Source Mode of Transport

Ammonia Import Thru Pipeline

Phosphoric acid Inhouse + Import By Ship & Road (Purchased Quantity)
Potash Import By Ship & Road
Rock Phosphate Import By Ship & Road
Aluminium Hydroxide Inhouse + Import By Road tanker
Sulphuric acid Inhouse + Import By Ship & Road (Purchased Quantity)
Sulphur Import By Ship & Road

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

Water

The existing water requirement for Greenstar Fertilizers Ltd is approximately. 4046 KLD
and for expansion project additionally 500 KLD water will be required.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Existing Greenstar plant is taking raw water and treated effluent from integrated effluent
treatment plant of Southern Petrochemical Industries Corporation Limited Tuticorin.
Excess water is available with Southern Petrochemical Industries Corporation Limited
Tuticorin.
Power

Additionally, 5.0 MW power will be required for expansion project. Existing Greenstar
plant is getting the electrical power from Tamil Nadu Electrical Board and cogeneration
plant with capacity of 6.0 MW is also available.

3.9.1 Fuel

Existing Green Star plant is utilizing Furnace oil as fuel for its DAP/NPK/TSP plants.
Furnace oil is procured through roads from nearby manufacturers/Suppliers. It is
proposed to utilize Furnace oil for the new NPK and existing DAP plant until Natural gas
is available at ease.

Quantity
S.
Product Fuel (MT/Annum) Total Source
No.
Exiting Proposed
Expansion of Fertilizer Unit of Greenstar Fertilizers Ltd
Di-Ammonium
1 FO
Phosphate 4670 7650 12320
Purchase from
New multi grade NPK
2 FO NA 8400 8400 open Market
Plant
3 Granulated SSP/TSP FO 3564 3564
*330 Days Production Basis
3.10 Quantity of waste to be generated (liquid and solid) and scheme for their
management /disposal

Solid Waste Generation and Management

Around 1080000 MT Gypsum (after revamp) generated from phosphoric acid plant. It will
be sold to Cement and Cement Sheet Manufacturing Industries and also as fertilizer

Hazardous Waste Generation and Management

Existing Sulphuric acid plant is generating the approximately 05 Mᶟ/Year of V2O5 Spent
Catalyst, 30 KL/Year Used Oil.

Generated Hazardous wastes will be recycle by authorized recyclers or dispose through

authorized disposal site.
Hazardous Waste Generation and disposal Details
Hazardous Waste Hazardous Waste Treatment /
S/N Type of Waste
Category Generation Disposal
TSDF Site
From Sulphuric Acid
1 V2O5 Spent Catalyst 18.1 /authorized
Plant
recyclers
Compressors/ Registered
2 Used Oil 5.1
Hydraulic System Recyclers
4
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

4 SITE ANALYSIS

4.1 Connectivity

Proposed 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 (NH-7) through Tiruchendur-Tuticorin State
Highway.
Tuticorin railway station is nearest railway station and located at a distance of 10km from
existing plant. Tuticorin City (District Head Quarter) is located at a distance of 10km.
Tuticorin City bus station is located at a distance of 8 km. Tuticorin air port is located
18km from existing plant.

V.O. Chidambaram Port Trust, formerly Tuticorin Port Trust is located 10KM from existing
plant. V.O. Chidambaram Port Trust 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, km

Green Star Fertilizers Limited Muthiahpuram
1. Existing Site Tuticorin, Tamil Nadu
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 Oownership

Greenstar Fertilizers Limited proposes to enhance the capacity of their existing

manufacturing units of DAP plant, new NPK plant, new TSP and SSP/TSP granulation plant
at Tuticorin to fulfill the fertilizer demand.
Greenstar Fertilizers Limited, Tuticorin is not acquiring any land for this project.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Existing Plant is situated on industrial land declared by Tehsildar Tuticorin in year 1968.
Existing land is using as Industrial land since 1972. Greenstar fertilizers Limited, Tuticorin is
having full ownership of this land.
North: Harbor Construction road is lying adjacent to the boundary wall of existing plant.
East: Southern Petrochemical Industries Corporation Ltd, Tuticorin make boundary wall
with existing plant.

South: Heavy Water Plant (Under Ministry of Atomic Energy, GOI) and Gypsum Dyke
West: SPIC Nagar Township, Tuticorin make Boundary wall with existing Plant
It is capacity enhancement of existing DAP plant, Installation of New NPK, GSSP/TSP
Plants.
Land use pattern

DESCRIPTION Sq.M Total

Process area Plant area 19200

DAP I Silo 3360

DAP II Silo 3360
RP Silo & 6770
Unloading
Buildings Bagging Plant 15288 39523
& Bagged Storage

Technical office / Training Centre / PH&D / 9245

Stores / Others
SSP silo 1500
Sulphur storage 5600
yard
Storage / other Stores open yard 10574
29118
Yards Sand blasting yard 890
Open yard 4018
Scarp yard 8036
Other land Open area 258600

Including proposed project area and

Total Vacant land 28258
remaining vacant area

Proposed project area in M2

New Multi Grade NPK Plant 4100

Product Silo 6300
Raw Material Silo 720
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Granulated SSP/TSP/Gypsum
1300
Plant
Raw Material Silo 375
Product Silo 450
TSP Raw material Silo 372
New TSP plant 1092
Product TSP Silo 480
Total Area 15189

187855
Greenbelt(M2)
562554
TOTAL AREA (M2)
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.
 MODERNIZATION AND CAPACITY ENHANCEMENT TO PRODUCE MULTIPLE GRADE
FERTILIZERS BY M/S. GREENSTAR FERTILIZERS LIMITED IN SPIC NAGAR, DISTRICT
TUTICORIN, TAMIL NADU PFR

Figure: Topomap of Project Location

 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

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.
4.5 Existing Infrastructure

The existing site having below infrastructure:

S. No. Existing Infrastructure Capacity

1. Land 562554 SQM
2. Sulphuric Plant 270000 MTA
3. Phosphoric Plant 125000/216000 MTA (EC cleared)
4. DAP 606100 MTA
5. DG Set 2250KVA
6. Phosphoric Acid Storage Facility 4 x 618 M3 + 2 x 5000 M3
7. Rock Phosphate Silo 30000 MT
8. Sulphuric Acid Storage Facility 3 X 1800 MT
9. Sulphur Silo 25000 MT
10. Bagging Plant facilities Storage + Railway siding + Road dispatch
11. DAP Silo 10000 MT
12. Complex Silo 10000 MT
13. SSP Plant 350 TPD
14. SSP Silo 3500 MT
15. Biomass Boiler 5 TPH
16. AlF3 Plant 10000 MT
Co-Generation Plant
17. 6.0 MW
(Waste Heat Recovery from SA Plant)

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 few places.

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 Gulf of Mannar, about 540 km (340 mi) south of Chennai and 125 km (78 mi) north
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

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 0.5°C. Rainfall is about 80cm 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 Direction Pattern

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
July W W SW SE/S/SW NW NW
August W W NW S SW SE
September W S SW SE NW W
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening
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 during the period of July to 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 DAP Plant was commissioned in 1994. Today, all basic infrastructures have been
developed for smoothly running of industry at this location. Existing Site have well
connectivity by road & Indian Railways. Existing Site is 06km away from the National
Highway No. 7 (NH-7) and connected with Indian Railway network by dedicated railway
track at Meelavittan 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 requirement will bet met from M/s.
SPIC Limited.

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.
There are numerous Educational Institutions, Polytechnic Colleges, and Schools in &
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.
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

Subsequently, after the acquisition of lands and buildings from the State Seed Farm,
Killikulam, a part of the 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.
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

5 PLANNING BRIEF

Greenstar Fertilizers Limited, proposes to enhance the capacity of their existing DAP
manufacturing units and install new plants at Tuticorin to fulfill the increasing demand of
fertilizers in India.
The proposed expansion fall under the category of 5(a)/Chemical Fertilizers of the
scheduled list of projects in the Environment Impact Assessment (EIA) Notification S.O.
1533, dated: 14-09-2006 which necessitates obtaining the Environment Clearance from
Expert Appraisal Committee, Ministry of Environment and Forests (MoEF), Government of
India.
It is expansion of existing plant and following facilities are available inside the plant
premises.

• Land
• Sulphuric Acid Plant
• Phosphoric Acid Plant
• Cogen Unit
• Storage Tanks
• Electrical Sub-station
• Water Supply
• Bagging Plant
• Railway Loading Shed

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 2001–11 was 9.14%. Thoothukudi has a sex ratio of
1024 females for every 1000 males, and a literacy rate of 86.52%.

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

The proposed expansion will be developed within the existing plant premises.
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

5.2.1 Land Use and Availability

DESCRIPTION Sq.M Total

Process area Plant area 19200

DAP I Silo 3360

DAP II Silo 3360
RP Silo & 6770
Unloading
Buildings Bagging Plant 15288 39523
& Bagged Storage

Technical office / Training Centre / PH&D / 9245

Stores / Others
SSP silo 1500
Sulphur storage 5600
yard
Storage / other Stores open yard 10574
29118
Yards Sand blasting yard 890
Open yard 4018
Scarp yard 8036
Other land Open area 258600

Including proposed project area and

Total Vacant land 28258
remaining vacant area

Proposed project area in M2

New Multi Grade NPK Plant 4100

Product Silo 6300
Raw Material Silo 720
Granulated SSP/TSP/Gypsum
1300
Plant
Raw Material Silo 375
Product Silo 450
TSP Raw material Silo 372
New TSP plant 1092
Product TSP Silo 480
Total Area 15189

187855
Greenbelt(M2)
562554
TOTAL AREA (M2)
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

In proposed project, there will be increase in the production capacity of DAP and
installation of new NPK plant along with new granulation unit of SSP/TSP/Gypsum.

6.2 Residential Area (non-processing area)

Residential area is already developed.

6.3 Greenbelt

Existing plant has already developed the greenbelt on 187855 sq. m area. Greenbelt
density will be improved in the available land in future.

6.4 Drinking Water Mmanagement (source & supply of water)

Existing plant is taking fresh water from SPIC. Also, Existing plant is taking treated
effluent from Integrated Effluent Treatment Plant of Southern Petrochemical Industries
Corporation Limited Tuticorin.

6.5 Sewage System

Greenstar Fertilizers Limited, Tuticorin is sending the sewage to common STP provided in
township. Treated water is used for greenbelt development.

6.6 Industrial Waste Management

Generated waste has been categorized in below categories

• Domestic Waste
• Solid Waste (Non hazardous)
• Hazardous Waste
o Domestic waste generated from canteen is being used in bio gassifier for fuel.
o Solid waste (Gypsum) is selling to Cement Industries.
o Hazardous waste is sending to authorized recyclers.
Waste Water

• Industrial Waste Water

o Waste water completely reused in process.

6.7 Power Requirement & Supply/Source

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

This Power supply is managed with the existing facility itself. The source of power supply
is Tamil Nadu Electricity Board (TNEB) and partly from Captive power unit.
 EXPANSION OF EXISTING PLANT BY M/S. GREENSTAR FERTILIZERS LIMITED IN
SPIC NAGAR, DISTRICT TUTICORIN, TAMIL NADU PFR

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 laborers (a
brief outline to be given)
Not Applicable
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 expansion 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 expansion project is 200 Cr. (INR). Project activities
will start after the environmental clearance.
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 DAP,
Plant. Greenstar Fertilizers Limited, Tuticorin shall prefer to recruit new appointees from
nearby locality, subject to availability.

Greenstar Fertilizers Limited, Tuticorin has proposed to give preference to local people
for requirement in semi-skilled and unskilled category. Approximately 100 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.