Mangalore Chemicals & Fertilizers

Mangalore Chemicals & Fertilizers Limited

Type	Public Limited
Industry	Fertilizers and Chemicals
Founded	1974
Headquarters	Bangalore, India
Key people	Vijay Mallya, Chairman
Products	Fertilizers, Chemicals
Revenue	US$ 0.711 billion (2010-11)
Parent	UB Group
Website	www.mangalorechemicals.com

Mangalore Chemicals & Fertilizers Limited, (BSE 530011) with a turnover Rs. 2,523.83 crores (2010-11), is the only manufacturer of chemical fertilizers in the state of Karnataka, India. It is situated in the port city of Mangalore, opposite to the New Mangalore Port Trust (NMPT) on the other side of the Kochi - Panvel national highway NH 66 (formerly NH 17) and on the banks of the Gurupur river.
The company is a part of the UB group with group shareholding of 30.44%. Dr. Vijay Mallya is the Chairman of the Board of Directors. Mr. Deepak Anand is the current Managing Director of the company. The company's corporate and registered office is located in UB City, Bangalore and its factory unit is in Mangalore.
The company deals with fertilizers like Urea, Diammonium phosphate, granulated fertilizers, liquid fertilizers, soil conditioners, Muriate of potash, soil micronutrients, specility fertilizers, food grade Ammonium bicarbonate, industrial chemicals like Sulphuric acid and Sulphonated granulated fertilizers. The marketing offices of MCF are loacted in Andhra Pradesh, Karnataka, Kerala, Maharastra and Tamil Nadu.
Mangalore Chemicals and Fertilizers Limited is an ISO 14001 and OHSAS 18001 certified company. The ISO 14001 and OHSAS 18001 certificates were received in the year 2003 and 2005 respectively.

Overview of MCF

Mangalore Chemicals and Fertilizers Limited was started in the year 1966 with Dugal Enterprises Private Limited, New Delhi as its first promoters. The company was originally registerd in New Delhi as Malabar Chemicals and Fertilizers Private Limited. The name of the company was changed to its present name in August 1971. Since Dugal Enterprises and International Development and Investment Comapny Limited of Nassau, Bahamas, (IDI) withdrew as promoters in early 1969, it was left to then Government of Mysore to pursue the project. The construction work started with the first pile driven on October 15, 1972 by the then Chief Minister of Mysore, Mr. Devaraj Urs.
In 1990, Government of Karnataka selected the UB group to take over the management of MCF, which was then a potential sick unit, with losses to the tune of about 600 million rupees. Since then the company is being managed by a team of dedicated and highly professionals under the leadership of Dr. Vijay Mallya.

Infrastructure

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 the year 2010, MCF foryaed into the manufacture of suphonated 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 the year 2003, the comapany implemented SAP R3 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 Wartsila Diesel Engine was commissioned in the year 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 Wartsila 18V32 DG sets each of 6MW capacity. The power plant generation voltage is 11,000V at 50Hz. 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

Manufactured products

• Mangala Urea.
• Mangala DAP.
• Mangala Ambica (ABC).
• Mangala 20:20:00:13.
• ChemCF NL - Sulphonated Naphthalene Formaldehyde Liquid.
• ChemCF NP - Sulphonated Naphthalene Formaldehyde Powder.
• Suphuric acid (98%).^[1]

Other products

• Mangala MOP.
• Speciality fertilizers - Mangala Bio20, Mangala 3X, Mangala Calmax, Mangala Sulphomex.
• Fertigation products - Mangala 18:18:18+2MgO+TE, Mangala NPK 19:19:19.
• Soil Conditoners - Mangala Setright for alkaline soil, Mangala Setright for acidic soil.
• Organic products - Mangala Bio Gold, Mangala Gold, Mangala Neem Organic Manure, Mangala Organic Granules, Mangala Megacal.
• Plant Nutrition products - Mangala Tur Special, Mangala GT Booster, Mangala Cotton Special, Mangala Chilli Special.^[2]

Safety, Health, Environment and Pollution Control

The company has obtained Occupational Health and Safety Management System Certification OHSAS 18001 as a part of its commitment to continual improvement. Det Norske Veritas, the certification agency has recertified the company’s OHSAS 18001 system, conforming to the latest 2007 version.
As an ISO 14001 certified Company, the company installed waste water recovery facility to treat, recycle and reuse the entire quantity of sewage and process effluents, thereby achieving zero liquid effluent discharge. It has also implemented a rain water harvesting system and sewage treatment plant at its township. The treated sewage water is used for gardening purpose. Continuing with its green initiative, the company planted an additional 5000 saplings in the green belt area in its factory in Mangalore in the year 2010.

Awards and recognitions

From the year 1996-97, the company’s performance dramatically improved with higher levels of production in all the plants. In fact, the rated capacity of Urea was manufactured for the first time in 1996-97 since commissioning in 1976, a singular achievement.
The company has received the following awards:

• FAI award for 'Improvement in overall performance of a Company’ for three consecutive years 1996-97, 1997-98 and 1998-99.
• Letter of recognition in 1997 from Directorate General of Factory Advisory Services and Labour Institutes (DGFASLI) for maintaining good safety and occupational health standards.
• 'Honest Tax Paying Businessmen’ award from Commercial Taxes Department, Mangalore Division, a unique initiative taken by Government of Karnataka to honour the prompt Tax payers.
• FAI Environmental Protection Award in NP/NPK Fertilizer Plants for the year 2009-2010.
• 'Second Best Safe Industry' award in the large sector in the year 2010, which was instituted by the Directorate of Factories and Boilers, Govt. of Karnataka.

Social Responsibility Initiatives

The company has undertaken its Social Responsibility obligation in its true spirit and has always been actively engaged in the up-liftment/ development of the communities in its operating territory. In this direction, MCF has formulated a comprehensive Corporate Social Responsibility (CSR) policy under which Rural Health and Rural Education have been the areas of specific focus during the year. In line with this philosophy, MCF formulated two schemes viz. Project Eye Care intended to prevent/eradicate eye related ailments in identified rural areas and Mangala Akshara Mitra intended to provide basic facilities and infrastructure to rural schools to promote education and to make schooling a pleasant experience. These schemes were implemented in rural and remote locations in the Company’s operating territory for the benefit of the poor and needy. Under Project Eye Care free eye camps are conducted in which the needy are recommended for eye surgery, to be carried out free of cost by the associated hospital and free spectacles are provided. Under its Mangala Akshara Mitra program, the basic infrastructure that is required, but is lacking in identified schools in remote locations, is provided by the company. Those include, desks, tables, chairs, green boards, racks, cupboards, school bags, lunch plates, water glasses and computers.

References

1. ^ products
2. ^ Other products