Ammonia IV (A IV) Plant
Commissioned in July 1998, the Ammonia IV plant has a capacity of 1,350 MTD. This plant was established, with an investment of Rs. 1,140 crore, to replace the high energy consuming 450 and 500 MTD Ammonia plants. The Ammonia plant is the mother plant for those fertilizer and industrial products of the company for which Ammonia is required as a basic raw material. Carbon-Dioxide and Argon are gas products that meet captive requirements, with the surplus quantity of these gases being saleable. Oxygen is recovered as co-product for captive utilisation.
Ammonia III (A-III) Plant
Originally owned by Heavy Water project, the Ammonia III plant was bought by GSFC in 2009 and its production was revived to create a standby Synthesis Gas production facility for the Caprolactam plants. The additional Ammonia production of 100 MTD from A IV plant was then available for either sale or transfer to Sikka unit. This plant produces Synthesis Gas at a lower cost.
Di Ammonium Phosphate (DAP) Plant
The DAP plant of 340 MTD capacity was commissioned in May 1967 as a part of GSFC's Phase I. The plant was supplied by Hitachi-Zosen Limited, Japan. GSFC selected M/s TVA & Chemico(USA) process for this plant, based on a worldwide survey of all the available processes during that time. The DAP plant is also designed to produce 800 MTD (Solid route) of APS. A new indigenous process was developed to produce APS by slurry route. After stabilisation of this process since January 2002, GSFC can produce 900 MTD APS on continuous basis by discontinuing production of DAP.
Melamine 1 , 2 and 3 Plants
GSFC has two Melamine plants having rated capacities of 5,000 TPA and 10,000 TPA, which utilise molten urea as a principal raw material sourced from GSFC's own Urea plant. The 5,000 TPA Melamine I plant was commissioned in 1982 and the 10,000 TPA Melamine II plant in 1997. The know-how and technology for this plant was supplied by Agrolinz, Austria.
Though there are other urea producing plants in India, GSFC is the pioneer and only company manufacturing Melamine in the country. GSFC was able to undertake the complex process of producing Melamine because of its technical competency. Melamine has become GSFC's one of the leading industrial products used for the production of laminates, adhesives, surface coating, moulded products and flame retardant products. Melamine is also used for textile and paper treatment and coating, leather tanning, pigment binders and glass fibre binders.
Phosphoric Acid (PA) Plant
The Phosphoric Acid plant of 165 MTD (100% P2O5) capacity is based on Chemico Dihydrate process, used for the first time in the world by GSFC. The plant was supplied by Hitachi-Zosan Limited, Japan. This plant was put up as part of GSFC Phase I and was commissioned in May 1967.
Sulphuric Acid (SA) III and IV Plants
GSFC has two Sulphuric Acid plants of 400 MTD and 1,350 MTD capacities respectively. The 400 MTD SA III plant was supplied and commissioned in 1981 by Simon Carves (India) Ltd. on turnkey basis.
The process know-how is supplied by Monsanto Envirochem, USA. In the year 1990, an additional facility to produce 29% Oleum was also incorporated to meet the requirement for Capro II plant.
The 1,350 MTD SA IV plant was supplied and commissioned in 1993 by M/s Dharamsing Morarji Chemicals Company Ltd. on turnkey basis. The process know-how was supplied by Tim J. Browder, USA.
Urea I and II Plants
The Urea plants of 323 and 800 MTD capacities were commissioned in 1967 and 1969 respectively. They are based on the Mitsui Toatsu Total Recycle-C Process (TRC).
Both these vintage plants, engineered, supplied and commissioned by Toyo Engineering Corporation, Japan, are presently operating well at nameplate capacity, thanks to continual improvements through the replacement or refurbishment of equipment and modifications to achieve energy conservation.
Caprolactam (Capro I and II) Plants
Caprolactam is a blue chip product in GSFC's portfolio. The Capro I plant was part of GSFC's third phase where the company diversified into petrochemicals. Capro II was part of GSFC's 1989-2002 expansion and diversification plan. GSFC's two Caprolactam plants have rated capacities of 20,000 TPA and 50,000 TPA respectively.
GSFC has commissioned a plant to produce 525 MTD of Methanol. The product conforms to US federal norms.
Most of the feedstock for making Methanol, like Synthesis Gases, is available from GSFC's existing plants. Methanol is used in the production of fertilizers, pharmaceuticals and industrial chemicals. Methanol is converted to formaldehyde, used for diverse products like plastics, plywood, paints, explosives, and permanent press textiles.
Ammonium Phosphate Sulphate Plant
GSFC's Ammonium Phosphate Sulphate (APS) plant has a capacity of 2,56,000 TPA. The DAP plant is designed in such a way that APS also can be produced. Sulphuric Acid, Phosphoric Acid and Ammonia are used to produce this product which is a complex fertilizer.
Ammonium Sulphate Plant
GSFC's Ammonium Sulphate plant (NH4)2SO4 (20.6% N) has a capacity of 1,96,000 TPA. Ammonium Sulphate is available as co-product from Caprolactam plants. This product is a slow releasing nitrogenous fertilizer and raw material for various chemicals, dyes and pharmaceuticals.
Nylon-6 (Gujlon) Plant
GSFC has the largest capacity Engineering Plastic Nylon-6 plant in the country with a rated capacity of 7,000 MT. The main raw material for Nylon-6 is Caprolactam which is available from captive capacity.
Gujlon is the registered trade name of Nylon-6 chips manufactured by GSFC.