Feature

GSFC Ushers New Era of Growth

Posted on 21 January, 2010 | Tags: Synopsis

A New Chapter Starts in Gujarat
1962 is landmark year in the history of Gujarat when Gujarat State Fertilizers and Chemicals Ltd (GSFC) was set up by the State Government to offer quality products and services to the farmers.  Gujarat ushered a new era of growth when the first prills of fertilizers rolled out of the production unit. The growth story has continued ever since and the company diversified its product portfolio and from 1974 to 1982 set up the manufacturing facilities to produce Caprolactam, Nylon-6, Melamine and Argon gas. The company has evolved into multi location, multi plant, multi product, multi service and multi crore company in the business of manufacturing fertilizers, petrochemicals, polymers and industrial gases.
GSFC has 26 different plants and 25 products with a turnover of Rs 5881 crores in the year 2008-09. Company's manufacturing facilities are spread over 1600 acres of land at four different locations, Fertilizernagar, Sikka, Kosamba and Nandesari. The company has developed excellent marketing network across India independently for fertilizers and petrochemicals. The company has also developed strong base in agro development and services to provide excellent farm advisory services to the farmers in Gujarat and elsewhere. GSFC has a good market presence in export market in products like Caprolactam Melamine and MEK Oxime in the countries of Europe, Asia and Middle East. Today GSFC is the largest producer of Caprolactam and Melamine in the country, which are produced in Baroda.

Core Strength
Competent and motivated personnel are the core strength of the company and GSFC has made significant improvements and progress in all areas of its working. Time and again the employees have taken the challenge to enhance plant performance through efficiency, productivity and economy. Company continues its endeavor to impart appropriate and relevant training to its employees at various levels with a view to equip them to take up the challenges ahead and enhance their performance in the overall interest of the company.
GSFC has in-house research and development capabilities and researchers have developed various market-oriented products such as highly popular water-soluble fertilizers. The company has recently completed sponsored project on development of indigenous de hydro catalyst for dehydrogenation of cyclo-hexanol for caprolactam synthesis at National Chemical laboratories (NCL). The product has been tested on a lab scale reactor and has yielded positive results. Analytical and microbiology teams support the critical R&D projects to improve process efficiency and productivity.
At GSFC, research is an ongoing phenomenon and the company plans to introduce new products, extend support services to the process plants for troubleshooting, upgrading product quality and improving process efficiency.

Performance Unperturbed
Markets have been extremely volatile in the FY 2008-09 as the raw material; fuel and power costs skyrocketed during this period. GSFC exhibited steady performance and surpassed all previous records by achieving the highest ever-net sales, which have gone up to Rs 5880.80 crores in the FY 2008-09. During the first quarter of current year, the company has achieved highest ever production of fertilizers as compared to the corresponding quarters of the last five years.

Expansions and Diversifications
GSFC is pursuing the conversion of Ammonia I plant for production of Methanol based technology from M/S Haldor Topsoe, Denmark and M/S PDIL appointed as consultants to carry out detailed engineering The work relating to the basic engineering has been completed. Detailed engineering and procurement activities for critical and long-term delivery items have been taken up. The mechanical work of project is expected to be completed by end of March 2011.
 To meet the demand of Phosphoric acid at Sikka unit for DAP plant, GSFC has entered into a Joint Venture viz Tunisian Indian Fertilizers (TIFERT). Financial closure for this project has already been achieved and the plant is expected to go on stream during 2011. A 1500 MTPY Urea Phosphate fertilizer has already been commissioned by GSFC to meet the demand of water-soluble fertilizers for micro irrigation system. GSFC has made conscious effort for development of green technology and commissioned 10 MW and 12 MW windmill projects in Kutch to meet the captive power requirements of the company. Encouraged by the performance and incentives available from the Government, GSFC plans to add additional 25 MW capacities to meet future power requirement.
GSFC, GACL and GNFC are embarking on big petrochemical complex in Dahej and formed a Rs 10,000 crore mega joint venture to produce EDC / PVC, Phenol, bis-phenol, polycarbonates and rubber based products. The project will have integration of by-products from GACL and GNFC and will be fully integrated either with the upstream petrochemical projects at Dahej or raw materials available within the country. OPaL, the ONGC and GSPC Joint Venture Company has already set up a cracker in Dahej to produce raw materials such as propylene, ethylene and butadiene with further scope to augment capacities.
GSFC is already a market leader in producing Caprolactam and Melamine, which are produced at Fertilizernagar in Baroda. In order to meet the increasing demand of these products the company may set up mega projects. Adequate quantities of urea are imported into the country, which can support ammonia urea projects in the country. New fertilizer policy of Government and availability of natural gas from the Krishna-Godavri basin would boost the investments to set up ammonia-urea plants with larger capacities. GSFC plans to set up large integrated fertilizer complex, a larger replica of that in Fertilizernagar to manufacture Ammonia, Urea, Caprolactam and Melamine to meet the growing demand. Memorandum of Understanding (MoU) has already been signed with Gujarat Government during Vibrant Gujarat 2009 and land already at Dahej. At present GSFC is carrying out feasibility studies for execution of the project, which involves investment of Rs 7000 crores.

EHS Compliance
Company has taken conscious efforts towards waste minimization, recycling and conservation of natural resources like raw materials water and energy to the maximum possible extent for environment protection. To generate green electricity and mitigate CO2 emissions, GSFC has already commissioned 22 MW windmill in phased manner and has plans to further increase wind power production by adding new projects. Company has adopted Clean Development Mechanism (CDM) to undertake several projects for reduction of emissions, energy conservation and earn carbon credits.
Keeping pace with commitment for good market leaders in the fronts of Environment, Health, Safety (EHS) GSFC has obtained ISO 9001, ISO 14001 and BS OHSAS 18001 and recently received RC Logo in 2008. Preservation and promotion of environment is the fundamental concern for GSFC in the day-to-day business activity. GSFC has already achieved Zero Waste Discharge at the phosphatic group of plants. Two fully-fledged Effluent Treatment Plants (ETP) are installed for treatment of effluents generated from petrochemical plants and treated effluents conforming to Pollution Control Board norms are discharged into the sea. GSFC plans to revamp its Effluent Treatment Plants to enhance their treatment capacity. Various such initiatives have been taken up to reduce its environmental footprint and the company monitors pollutants on a daily basis within as well as outside the factory premises.
The industrial fraternity has recognized the efforts of GSFC and the company was conferred with ICC award for 'Excellence in Management of EHS' in 2007, 'Commendation Certificate' for Scope of Meritorious Award for 'Environment Excellence and Sustainable Development' in 2006-07 and 'Srishti' Good Green Governance Award 2008 from Srishti Publications Pvt Ltd, New Delhi.
Compliance with the highest safety standards of operation has helped the company achieve highest ever accident free million man hours of 13.25 at Baroda unit, 0.88 at Fiber unit, 4.16 at Sikka Unit and 4.25 at polymer unit till date. Earlier in 2004 also GSFC had received Sword of Honor from the British Safety Council.
GSFC has bagged the most coveted 'International Safety Award 2008' from world's renowned Advisory Body, the British Safety Council UK, for the second consecutive year. The company has recently received 'ICC Aditya Birla Award' for the 'Best Responsible Care Committed Company'