The Company has achieved remarkable production performance during the year 2024-25. Day to day plant operations were closely reviewed and plant operations were optimized accordingly, to maximize profit. During the year, strategic optimization of various plant operations had to be done keeping in line with prices of raw materials so as to achieve cost reduction in all aspects.
New Records Established:
During financial year 2025–26, a total of 30 new records were established, of which 20 were in Production and 10 in Filling/Dispatch/Sales. The highest-ever daily production was achieved for Total Urea and Formic Acid. The highestever monthly production was achieved for Ammonia, Total Urea, Technical Grade Urea, Methyl Formate, Formic Acid, Neo Neem Soap, and Hand Wash. The highest-ever yearly production was achieved for Formic Acid, Neo Neem Soap, and Hand Wash.
Ammonia plant scheduled annual shutdown taken from 01/04/2025 to 19/04/2025. During this period, the leaky Ammonia product cooler (E-706) was replaced, and catalyst screening of R-401/402/403 was carried out. Synthesis gas Compressor(C-701) tripped on 17/09/2025 due to low seal oil level and remained under shutdown from 25/09/2025 to 04/10/2025 for seal replacement and inspection. The C-701 BCL barrel underwent replacement of both seal and rotor, while in the 2BCL barrel, seals were replaced. The plant achieved an annual production of 659,169 MT against a budget of 658,630 MT. Record monthly production was achieved consecutively in December (62,991 MT) and January (63,014 MT). Two gasifier operation commenced on 06/11/2025 and has continued thereafter due to the West Asia war crisis.
Ammonia Synthesis Gas Generation Plant (ASGP)was under shut down from 01/04/2025 to 20/04/2025 for annual maintenance. It was again stopped from 25/09/2025 to 04/10/2025 due to maintenance in the Ammonia plant. ASGP achieved an annual production of 360,182 MTs against the budgeted 369,470 MTs. Plant load is restricted as per NG availability in view of West Asia war crisis.NG preheater scheme was implemented in April 2025 for energy savings. Installation of H₂compressor for further energy optimization is currently in progress.
Urea Plant: FY 2025–26 posed significant operational challenges for the Urea plant, primarily due to repeated boiler tripping, leading to multiple shutdowns and load reductions. Despite this, the plant demonstrated strong resilience and achieved seven new performance records. The plant operated above 2,500 MT/day for 279 days and achieved its lowest-ever HPSH equivalent specific steam and power consumption. A high-efficiency condensate pump and a highcapacity MP carbamate pump were commissioned. Safety was enhanced by converting the HP ammonia pump discharge isolation valve to motor-operated valve. The new reactor foundation has been completed, and installation of a VFD for torque converter replacement in the HP ammonia pump is under progress.
Methanol-I, SGGU, and MSUplants remained shut throughout the year due to unfavorable economics.
Methanol-II plant operated from April to November 2024, after which it remained shut due to economic constraints. Methanol requirements for downstream plants were met through market procurement. Excess wet methanol from the Formic Acid (FA) plant was processed in the Methanol Distillation Unit (MDU). PSA continued operation using oilbased gases post Methanol-II shutdown.
Formic Acid plant achieved record-breaking daily, monthly, and annual production, along with the highest annual sales. Separate storage and handling of purchased methanol and reprocessed methanol ensured improved product quality and operational flexibility, leading to periodic operation of the MDU.
50 Annual Report 2025-2026 | 013