Thal unit is a urea manufacturing complex built by RCF (Rashtriya Chemicals & Fertilizers Ltd), a leading Public Sector Undertaking in India, engaged in the production and marketing of fertilizers and industrial chemicals.
The Thal unit primarily manufactures urea and has an installed capacity of 2.0 million MT per annum (mmtpa). The unit also manufactures some industrial products.
The Thal unit is a large producer of Urea along with Industrial Chemicals located 100 kms south of Mumbai spread across 997 acres (including township).
The unit is ISO 14001, OHSAS- 18001 & ISO- 9001 accredited and manufactures Ammonia, Urea, Methylamines, Formic Acid etc.
RCF planned to revamp its Thal (Maharashtra) complex in two phases. The first ended in 1996 and the second in June 1999.
It planned to expand its ammonia plants in three phases. The phase one was completed in 1997. It increased capacity from 1350 MTPD to 1500 MTPD per stream. Completed in 1998, the second phase was for capacity enhancement to 2×1600 MTPD of ammonia.
Commissioning of the third phase of Thal Ammonia revamp scheme was completed in 2013-14 making daily production of Urea cross 6,000 MT. This increased the production of urea from 1.7 million MT to 2.0 million MT per year was completed in 2014.
RCF installed a new process air compressor unit, a new hydrogen recovery unit, a new cooling tower and new pumps in the initial phase, which took 30 months and cost Rs 88 crores. It also converted its steam generation boilers, auxilary boilers and steam superheaters to naphtha/natural gas and replaced reformer tubes, condensate stripper trays and other equipment.
Detailed engineering was done by Projects & Developments India Ltd (PDIL). Process licensor was Haldor Topsoe.
2×1500 MTPD Ammonia Plant Revamp Project (Phase –I ) at Thal
Project Details: Augmentation of capacity of ammonia plant from 1350 MTPD to 1500 MTPD per stream.
The major changes include:
- Installation of additional Process Air Compressor
- Installation of Purge Gas Recovery System
- Modification of Benfield Unit
- Installation of additional offsite facilities
- Also an installation of additional Instrument Air Drying Unit
- Expansion of Electrical/ Instrumentation System
Process Licensor: Haldor Topsoe A/s, Denmark
Prime Consultant: PDIL (Projects & Developments India Ltd)
2×1600 MTPD Ammonia Plants Revamp Project (Phase – II) at Thal
Project Details : Capacity enhancement to 2×1600 MTPD of Ammonia.
The major changes include:
- Replacement of turbine & motor for flue gas blower & combustion air blower
- Detailed Design & Engineering
- Replacement of Secondary Reformer burner assembly
- Replacement of RG & CG WH Boiler along with common steam drum
- Replacement/ addition of separator O/H regenerator, Cells in split steam cooler, Benfield circulation & booster pumps
- Replacement of gas/ gas exchanger
- Modification of syn gas compressor & turbine
- Procurement Services
- Inspection & Expediting of Supplies
- Project Scheduling & Monitoring
- Construction & Erection supervision
- Commissioning assistance
- Performance guarantees
Process Licensor: Haldor Topsoe A/s, Denmark
Prime Consultant: PDIL (Projects & Developments India Ltd)
Hydrogen Recovery Unit And Co2 Recovery Unit
The purpose of the hydrogen recovery unit was to recycle hydrogen which was previously used as fuel. This led to a rise in ammonia production of 4%. Natural gas replaced hydrogen fuel.
The new tubes were made of Manurite 36XM to increase the tube-wall temperature threshold. The thinner tube walls also allow for higher volume of the catalyst and a reduced drop in pressure.
To handle increased load, the CO2-removal unit had to be upgraded. This allowed the absorber with a CO2 slip of less than 800ppm to handle process gases equivalent to 1,500 MTPD. This is opposite to the existing one which used a 1,000 ppm CO2 slip to generate 1,350 MTPD.
Sulzer Industries trays in the condensate stripper process were used as replacements. The downcomer area has been increased by about 9%. This allowed a better coefficient of mass transfer, and increased capacity.
The two existing process-air compressors could manage 2,700 MTPD of ammonia. To produce 3,200 MTPD of ammonia expected from Phase II, a new third air compressor was required.
Further Expansion
The company is planning the third phase of expansion of Thal unit by setting up Ammonia-Urea plants to produce 1.3 million MT urea at an estimated cost of Rs 4000 crore. Bids have already been received. Under the scheme of revival of FCI sick unit at Talcher, RCF in consortium with Coal India is actively pursuing to set up a 1.15-million MT urea manufacturing facility through coal gasification route
Plant Features
- First of it’s kind “Mega Fertilizer Unit” in India using natural gas from Mumbai offshore as raw material.
- This was the largest producer of Urea from single location in Asia (> 1.5 Million MT per annum) when it first started operations.
- First fertilizer unit with DCS (Distributed Control System) in India.
- Advanced control unit and PLC (Programmable Logic Controller) for Electrical Load Management.
- Strong emphasis on Environmental management.
- In-Built Pollution Control and Safety features
- Captive power capacity of 237,600 mwh
Awards Won by Thal Unit
- Heavy Water Plant received National Safety Council, (Maharashtra Chapter) “Certificate of Merit” for Meritorious Performance in Industrial Safety for the year 2017
- FAI award for Excellence in Safety for the year 2017- 18.
- First prize in 12th State Level Award for “State level Excellence in Energy Conservation & Management” for the year 2017-18 from Maharashtra Energy Development Agency (MEDA), Govt. of Maharashtra.
- “Maharashtra Safety Award-2017” for achieving Lowest Accident Frequency Rate and Longest Accident Free Period in Chemicals & Fertilizers Industrial Group Highest Accident Free Days and “Zero Accident Frequency Rate” for the year 2017 from National Safety Council’s.
- Five (5) Star Green rating for air quality for the year 2018-19 by Maharashtra Pollution Control Board for the third consecutive year.
Thal Plant Capacity
| Products | Capacity (MT) |
| Urea | 2,000,000 |
| Ammonia | 1,155,000 |
| Formic Acid | 10,000 |
| DMAc | 5,000 |
| Methyl Amine | 11,000 |
| Argon | 14,000 |
| DMF | 2,500 |