Mangalore Chemicals & Fertilizers
Encyclopedia
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.
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.
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
Other products
, 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.
The company has received the following awards:
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.
Turnover
-Business:*Turnover is sometimes a synonym for revenue , especially in European and South African usage.Services sold by a company during a particular period of time....
Rs. 2,523.83 crores (2010-11), is the only manufacturer of chemical fertilizers in the state of Karnataka
Karnataka
Karnataka , the land of the Kannadigas, is a state in South West India. It was created on 1 November 1956, with the passing of the States Reorganisation Act and this day is annually celebrated as Karnataka Rajyotsava...
, India
India
India , officially the Republic of India , is a country in South Asia. It is the seventh-largest country by geographical area, the second-most populous country with over 1.2 billion people, and the most populous democracy in the world...
. It is situated in the port city of Mangalore
Mangalore
Mangalore is the chief port city of the Indian state of Karnataka. It is located about west of the state capital, Bangalore. Mangalore lies between the Arabian Sea and the Western Ghat mountain ranges, and is the administrative headquarters of the Dakshina Kannada district in south western...
, 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
Bangalore
Bengaluru , formerly called Bengaluru is the capital of the Indian state of Karnataka. Bangalore is nicknamed the Garden City and was once called a pensioner's paradise. Located on the Deccan Plateau in the south-eastern part of Karnataka, Bangalore is India's third most populous city and...
and its factory unit is in Mangalore.
The company deals with fertilizers like Urea
Urea
Urea or carbamide is an organic compound with the chemical formula CO2. The molecule has two —NH2 groups joined by a carbonyl functional group....
, Diammonium phosphate
Diammonium phosphate
Diammonium phosphate is one of a series of water-soluble ammonium phosphate salts which can be produced when ammonia reacts with phosphoric acid...
, granulated fertilizers, liquid fertilizers, soil conditioners, Muriate of potash, soil micronutrients, specility fertilizers, food grade Ammonium bicarbonate
Ammonium bicarbonate
Ammonium bicarbonate, a compound with formulaNH4, also called bicarbonate of ammonia, ammonium hydrogen carbonate, hartshorn, AmBic or powdered baking ammonia, is the bicarbonate salt of ammonia....
, industrial chemicals like Sulphuric acid and Sulphonated granulated fertilizers. The marketing offices of MCF are loacted in Andhra Pradesh
Andhra Pradesh
Andhra Pradesh , is one of the 28 states of India, situated on the southeastern coast of India. It is India's fourth largest state by area and fifth largest by population. Its capital and largest city by population is Hyderabad.The total GDP of Andhra Pradesh is $100 billion and is ranked third...
, Karnataka
Karnataka
Karnataka , the land of the Kannadigas, is a state in South West India. It was created on 1 November 1956, with the passing of the States Reorganisation Act and this day is annually celebrated as Karnataka Rajyotsava...
, Kerala
Kerala
or Keralam is an Indian state located on the Malabar coast of south-west India. It was created on 1 November 1956 by the States Reorganisation Act by combining various Malayalam speaking regions....
, Maharastra and Tamil Nadu
Tamil Nadu
Tamil Nadu is one of the 28 states of India. Its capital and largest city is Chennai. Tamil Nadu lies in the southernmost part of the Indian Peninsula and is bordered by the union territory of Pondicherry, and the states of Kerala, Karnataka, and Andhra Pradesh...
.
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 facilitiesThe company has capacity to manufacture 2,17,800MT of Ammonia
Ammonia
Ammonia is a compound of nitrogen and hydrogen with the formula . It is a colourless gas with a characteristic pungent odour. Ammonia contributes significantly to the nutritional needs of terrestrial organisms by serving as a precursor to food and fertilizers. Ammonia, either directly or...
(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 WartsilaWärtsiläWärtsilä is a Finnish corporation which manufactures and services power sources and other equipment in the marine and energy markets. The core products of Wärtsilä include large combustion engines...
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 acidPhosphoric acidPhosphoric acid, also known as orthophosphoric acid or phosphoric acid, is a mineral acid having the chemical formula H3PO4. Orthophosphoric acid molecules can combine with themselves to form a variety of compounds which are also referred to as phosphoric acids, but in a more general way...
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 CorporationMangalore City Corporation-History:Mangalore came under Municipal administration following enactment of the Madras Town Improvement Act 1865 and the thereafter the establishment of the Municipal Council on 23 May 1866. Prior to the introduction of the local self-government system, the district collector was in charge of the...
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%).
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.
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 VeritasDet Norske Veritas
Stiftelsen Det Norske Veritas is a classification society organized as a foundation, with the objective of "Safeguarding life, property, and the environment". The organization's history goes back to 1864, when the foundation was established in Norway to inspect and evaluate the technical condition...
, 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.