Yara India’s revamped Babrala plant becomes the most sustainable Urea manufacturing plant across India

Date:06-28-2023

Yara India, a subsidiary of Yara International recently overhauled its manufacturing unit in Babrala, Uttar Pradesh in a record time of 35 days, reducing its Specific energy of Urea to below 5 Gcal/MT Urea. After this overhaul, this plant is one of the most sustainable Urea manufacturing plants across India among the same vintage plants and the most sustainable among the manufacturing units under the Yara global network.

This significant achievement marks a milestone since Yara’s acquisition of the plant from Tata Chemicals in 2018. Through diligent efforts, Yara has successfully been able to lower the Specific Energy Consumption from 5.18 GCal/MT Urea to an impressive 4.95 GCal/MT Urea. This remarkable reduction corresponds to a 5% decrease in emissions, which is equivalent to a substantial annual decrease of approx 70,000 TCO2e. By adhering to the principles of the 7Rs of sustainability, the Babrala site has achieved remarkable energy efficiency, specific water consumption, effluent generation, and greenhouse gas emission reduction. These achievements position the Babrala unit as a trailblazer within the urea manufacturing industry in India.

Highlighting its commitment to sustainable land management, Yara India’s Babrala unit has undertaken extensive water conservation projects within and beyond the fence. In the former category, Yara Babrala replaced their old STPs with new MBR-based technology STP and used the treated sewage effluent for high-end application as cooling water makeup. Also, the site developed the infrastructure for rainwater harvesting, having a potential of 1,28,000 KL. In the latter category, over the past two years, the company has successfully covered 350 acres of agricultural land, showcasing its dedication to fostering sustainable agricultural practices of water conservation and ensuring future food production. The company aims to cover 300 acres of land by the end of CY 2023. The site has also rejuvenated four nos. of ponds (approx 15000 sq mtr) in the nearby community for groundwater recharge. The Babrala plant, one of the largest and most sustainable agricultural units in the country, annually produces 1.2 million metric tonnes of urea.

Sanjiv Kanwar, Managing Director, Yara South Asia, said, ″We take immense pride in our newly renovated Babrala plant which now has taken its position among the leading sustainable manufacturing facilities in the country. The unit embodies sustainability, with health, environment, safety, and quality as its key pillars. It has played a pivotal role in driving economic growth by creating employment opportunities through collaborations with local stakeholders and suppliers. We strive to set industry benchmarks by adopting the highest level of environmental responsibility and employing cutting-edge technologies for sustainable operations. Our continuous growth efforts at Babrala align with our global commitment to responsibly nourish the world and safeguard our planet while uplifting the local community towards the nature-positive food future″.

Maya Shanker Prasad, Plant Head, Yara Fertilisers India Pvt. Ltd., said, ″For 28 years, Barbara Plant has played a vital role in our nation’s food security. We have provided crop nutrients that have helped feed people across the country. We are committed to becoming one of the most sustainable plants globally.″

Aligned with Yara India’s core values, the Babrala unit has spearheaded community development initiatives across crucial sectors such as healthcare/sanitation, education, agricultural development, animal husbandry, women empowerment/skill development, and infrastructure enhancement. By integrating sustainable practices throughout its operations, the unit has emerged as a catalyst for positive change within the region.

In line with its mission to create a positive societal impact, Yara India has forged meaningful partnerships with numerous NGOs and government bodies. The company is establishing smart classes in 20 government and government-aided schools, fostering educational advancement in underprivileged communities. Moreover, Yara India has organized residential skill training programs, empowering 390 youth with essential vocational skills in the last two years. The company has also made notable contributions to healthcare, facilitating 270 cataract surgeries, 136 prosthetics for amputees, and implementing projects of various organizations.

The latest infrastructure development at the Babrala unit includes the construction of channels for 33 tube wells through an underground pipeline system, ensuring safe drinking water for the community through RO plants, improvement of 84 cattle sheds covering more than 350 cattle, and providing bench and desk for 300 students of Government Schools.