Project Details

Client: Simon India Ltd.
End User: Paradeep Phosphates Ltd.
Location: Paradeep, Odisha, India
PMC: Jacobs
Licensor: MECS
Execution Period: July 2010 (Award Date) – February 2016
Manufacture & Erection: Sparkon Engineers, Pune

Scope of Work

Sparkon’s EPC scope involved the fabrication, supply, and erection of major process equipment designed by DuPont/MECS/Simon India. Key equipment included:

• 5 Nos. SS304H Converters

  • Size: Ø 11,100 mm × 18,300 mm Ht

  • Weight: 230 MT

  • Material: SS 304/304H (min. 0.04% Carbon)

  • Fabricated in segments at Sparkon Pune and assembled at site.

• Drying Tower

  • Size: Ø 6,300 mm × 15,700 mm Ht | Weight: 38 MT

  • Material: SS 316L & SA 36 | Brick-lined vertical cylindrical vessel.

• Final Absorbing Tower

  • Size: Ø 5,800 mm × 16,250 mm Ht | Weight: 40 MT

  • Material: SS 304L & SA 36 | Brick lining completed at site.

• FT/DT Pump Tank

  • Size: Ø 2,130 mm × 5,500 mm | Weight: 12 MT Each

  • Material: SA 36 | Acid-proof brick-lined horizontal vessel.

• Hot Interpass Exchanger

  • Size: Ø 4,420 mm × 10,400 mm Ht | Weight: 50 MT

  • Heat Duty: 4.9 MM Kcal/hr | Heat Transfer Area: 1,633 sq. m

  • Material: SS304 Shell & Tubes.

• Cold Interpass Exchanger

  • Size: Ø 3,810 mm × 15,553 mm Ht | Weight: 135 MT

  • Heat Duty: 11.5 MM Kcal/hr | Heat Transfer Area: 3,246 sq. m

  • Material: CS Shell & Tubes.

• HRS Tower (C)

  • Size: Ø 6,300 mm × 23,200 mm Ht | Weight: 73.5 MT

  • Material: ZECOR + SS304L | Complex fabrication using imported Zecor material.

Erection & Installation Scope

Sparkon executed the erection of over 60 major equipment systems, including process vessels, towers, heat exchangers, filters, burners, and pumps, all supplied by Simon India.

Key installed systems included:

• Steam Coils and Agitators for multiple Sulphur Pits.

• Inlet Air Filters, Compressors, Waste Heat Boilers, and Superheaters.

• Mist Eliminators, Acid Coolers, Circulation & Feed Pumps.

• Catalyst Loading Systems, Deaerators, Sulfur Burners, and Economizers.

• HRS Boilers, Preheaters, Heaters, and multiple Acid Distribution Systems.

Each installation followed strict QA/QC documentation, with complete hydrotesting, insulation, and trial commissioning before handover.

Execution Highlights

• Over 450 MT of structural steelwork fabricated and installed.

• All fabrication completed at Sparkon Pune Workshop, maintaining international quality standards.

• 18–20 months total fabrication & erection duration despite cyclonic interruptions.

• Zero major incidents throughout the project – safety-first execution.

• Successfully handled Zecor material (imported alloy) for HRS towers – a first-of-its-kind challenge in India.

• Delivered fully integrated EPC package covering mechanical, civil, electrical & instrumentation.

Key Achievements

• Completed on schedule despite severe weather delays.

• Fully compliant with ISO 9001:2015 and global QA/QC requirements.

• Achieved seamless coordination between fabrication, logistics, and site execution teams.

• Recognized by Simon India Ltd. and Paradeep Phosphates Ltd. for excellence in fabrication precision, safety, and delivery commitment.