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Acid Plant Database June 13, 2025
Owner | Greenstar Fertilizers Ltd. |
![]() |
Location |
Tuticorin Tamil Nadu India |
|
Background |
Southern Petrochemical
Industries Corporation (SPIC)
www.spic.in
![]() Greenstar has acquired the phosphatics manufacturing assets of SPIC |
|
Website | www.greenstarfertilizers.com | |
Plant | - | |
Coordinates* | 8° 44' 26" N, 78° 8' 21" E | |
Type of Plant | Sulphur Burning | Sulphur Burning |
Gas Source | Elemental Sulphur | Elemental Sulphur |
Plant Capacity |
1975:
470 MTPD 1994: 600 MTPD - SA to DA 2000: 750 MTPD - Booster blower added 2011: 1000 MTPD |
2500 MTPD |
SA/DA |
Originally single absorption 1994 - Retrofitted to DA |
3/1 DA |
Emissions | - | |
Status | Operating | Engineering |
Year Built | 1975 | |
Technology | - | Chemetics (Basic Engineer, Detail Engineering, Proprietary Equipment) |
Contractor | - | |
Remarks | Acid Plant Power Generation: 6 MW (2011) | |
Pictures |
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|
General |
Other Production - Ammonia: 1100 MTPD - Urea: 1600 MTPD - Phosphoric Acid: 165 MTPD - Di-ammonium Phosphate: 1350 MTPD - Aluminum Fluoride: 8 MTPD Power Production: 24 MW combined capacity SPIC commissioned its first sulphuric acid plant in 1975. It had a capacity of 470 MTPD with a Single Contact Single Absorption process. In 1994, the plant was converted to a Double Contact Double Absorption process with a capacity of 600 MTPD. The technology upgrade helped to increase production and to meet the Pollution Control Board's emission standards. To further meet captive consumption needs, a booster blower was installed in the year 2000. This helped to increase production by another 150 MT. In the same year, a steam turbo generator of 6 MW was commissioned to convert steam into power. With allied plants enhancing production, it increased the need for sulphuric acid, which was being procured externally. To increase our share in captive consumption, SPIC’s engineering team has been making several efforts since 2011. We have successfully enhanced production from 600 MTPD to 1,000 MTPD. Some of the major improvements are: - replacement of improved catalyst in all converter beds - IAT & FAT acid distributors with improved MOC and increase in the packing size to bring down the pressure drop - Pressure drop reduction in the furnace, additional air nozzles in the furnace, removal of unwanted dampers and bellows - installation of new higher size super-heater, and upgradation of ducts MOC The production enhancement has helped to substantially reduce costs and dependency while increasing power generation. https://www.youtube.com/watch?v=CXbzB2c8Poo&t=1s |
|
References |
“Life Extension of a Vintage Plant Through Reliability Improvement Systems”,
IFA Technical Conference, |
|
News |
June 13,
2025 - Chemetics has announced its
continued contribution to India's industrial growth with the award of a new
contract from Greenstar Fertilizers Ltd. This marks the fourth
greenfield sulfur-burning sulfuric acid plant the company has supported in
India over the past five years. Under the contract, Worley Chemetics
will deliver basic and detailed engineering, critical plant equipment, and a
low-pressure heat recovery system for a new 2500 tpd sulfur-burning sulfuric
acid facility. The commercial-grade sulfuric acid produced at this site will
support fertilizer production. “We are proud to partner with Greenstar
Fertilizers to bring our advanced technology and expertise to this
significant project. Worley Chemetics proven solutions are designed to
deliver operational efficiency, safety, and long-term value.” The
project will incorporate Worley Chemetics’ proprietary ALPHA® heat
recovery system, along with advanced process equipment including: - Radial flow gas exchangers - Anodically protected strong acid circuit coolers - Radial flow converter - ISO FLOW SWIFT-LOCK™ trough distributors - Anodically protected strong acid piping SARAMET® HT alloy materials used in the ALPHA® system’s equipment, piping, and ducting. This milestone reflects Worley Chemetics’ ongoing commitment to supporting sustainable industrial development through innovative, high-performance technologies. October 22, 2011 - The cash-strapped, debt-burdened Southern Petrochemicals Industries Corporation (Spic) will soon enter into an agreement with Greenstar Fertilizers to sell its phosphatics business, including that of sulphuric acid, phosphoric acid, DAP, NPK, single super phosphate and aluminium fluoride units, situated at Tuticorin district of Tamil Nadu, for an undisclosed sum. Interestingly, Spic group company, Sicagen India, is said to have invested R50 crore into Greenstar Fertilizers for 11% non-convertible redeemable cumulative preference share of R100 each, sources pointed out. Greenstar was incorporated in August 2010 with an aim to distribute imported fertilisers, micro nutrients apart from entering into manufacturing of fertilisers and allied products. It is learnt that Greenstar has offices in Noida and Chennai. Promoters of Spic, including AC Muthiah, Ashwin Muthiah and Sidd Lifesciences (run by Ashwin Muthiah) together hold 48% in Sicagen September 16, 2011 - Cash-strapped Southern Petrochemicals Industries Corporation (Spic) plans to sell its phosphatic (including sulphuric acid, phosphoric acid, DAP, NPK, single super phosphate and aluminium fluoride) business situated at Tuticorin, together with the business undertaking, for a consideration of not less than R300 crore to bring down its liabilities of R3,000 crore. Interestingly, the plant was revived only in October last year after three years of closure owing of huge debt and lack of working capital, among other issues. Asset Reconstruction Company of India (ARCIL) (debt aggregator) has decided to sell the Tuticorin plant business also to raise funds to bring down the overall liability. ACRIL took over the entire debt portion of Spic a few years ago and has been involved in selling several Spic properties, including real estate properties in TN, Mumbai and other places, non-core businesses and its stake in JVs including Spic September 15, 2011 - Southern Petrochemicals Industries Corporation Limited has informed the Exchange that as part of the financial restructuring of the Company the Board of Directors at its meeting held on September 14, 2011 approved the proposal for the sale of the Phosphatic (including Sulphuric Acid, Phosphoric Acid, DAP, NPK, Single Super Phosphate and Aluminium Fluoride) Business of the Company situated at Tuticorin, together with the Business Undertaking, for a consideration of not less than Rs 300 crores, (which price may be adjusted against any secured liabilities that may be transferred along with the Business Undertaking) on the terms and conditions and in the manner as deemed fit by the Board. The above proposal will be subject to the approval of the shareholders by postal ballot and other necessary approvals. |
MTPD - Metric Tonne per Day
STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per
Annum
SA - Single Absorption
DA - Double Absorption
* Coordinates can be used to
locate plant on Google Earth