18th national award for excellence - …greenbusinesscentre.com... · been replaced with new coils...

Presented By:

Indian Farmers Fertiliser Cooperative Ltd.

Phulpur Unit-I30th August – 1st September, 2017

18th National Award for Excellence

in Energy Management - 2017

Installed/Revamped Annual Capacity (‟000 MT)

IFFCO: At a Glance

Urea : 4242.2

NP/NPK/DAP : 4335.4

Total „N‟ : 2630.7

Total „P2O5‟ : 1719.4

WSFs : 15.0

Zinc Sulphate Monohydrate : 30.0

Contributed about 21% to the total „N‟ and 31.8% to the total “P2O5”

produced in the Country during the year 2016-17.

IFFCO was established as the farmers‟ own initiative in Cooperative Sector on 3rd Nov. 1967

Largest producer of fertilisers in the country.

Nos. of Plant : Five (Kandla, Kalol, Phulpur, Aonla, Paradeep )

2

IFFCO Phulpur Unit-I : Profile

Plant Ammonia Urea

Process Licenser

MW Kellog, U.S.A

SnamprogettiItaly

DailyCapacity(MTPD)

1215 2115

AnnualCapacity(Lakhs MT)

4.0 7.0

Till Date Production(Lakhs MT)

119 205

5

Bagging Plant

COALRLNG

Utility Boiler

HP Steam

Power

Ammonia Plant

RLNG

AmmoniaCO2

Neem Urea

Urea Plant

HP

Steam

RAIL

ROAD

IFFCO Phulpur Unit-I : Production Outline

HP Steam

GTG-HRSG

6

3.853.34

4.32

3.49

4.4

6.52

5.78

7.58

6.32

7.65

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

2013-14 2014-15 2015-16 2016-17 2017-18

Ammonia Urea

Highest Ever Yearly Urea Production

3.11

1.89

ESTIMATED

Actual TillDate

Phulpur-I: Production Performance

7

in Gcal/MT of Urea

Phulpur-I : Sp. Energy Consumption

6.706.74

6.656.64

6.74

5.97

5.855.80

5.7

5.8

5.9

6.0

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

6.9

7.0

7.1

7.2

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 upto

Aug '17

2017-18 upto

March '18

2018-19

Year

0.79

NUP Norm: 6.5(From April 2018)

Best Ever Yearly Energy

8

Major Energy Saving Schemes Implemented in

2016-17

S.No Energy Saving Schemes Energy Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

1 Installation of New Gas Turbine Generator (GTG) - Heat Recovery Steam Generation (HRSG)

251262 7287 23914

2 Modification in CO2 RecoveryProcess- aMDEA Process in placeof Benfield Process

136851 3969 19004

3 Installation of New MediumPressure Process condensatestripper (1104-E)

73442 2130 1032

4 Old Synthesis Gas Converter(105-D) Internal Revamp

48961 1420 1331

5 Installation of Ammonia recoverysection to recover ammonia fromoff gases of synthesis loop

24481 710 1025

9


2016-17


Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

6 Replacement of Old Refrigeration Compressor Turbine with New Turbine in Ammonia Plant

44145 1280 1443.5

7 Replacement of Old Air Compressor Turbine with New Turbine in Ammonia Plant

53777 1560 1443.5

8 Replacement of Mixed Feed andProcess Air Coil and installation ofNew VAM Coil in Ammonia Plant

9632 279 1044

9 New Urea Reactor with CasaleHigh Efficiency Tray in Urea Plant

13959 405 460

10 Installation of Ammonia Preheaterin MP Section of Urea-I

6980 202 167

10


2016-17


Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

11 Installation of CO2 Cooler through VAM in Urea Plant

5584 162 650

Total (Thermal Energy) 669074 19404 51514

S.No Energy Saving Schemes Saving (KWh)

Savings (Rs. Lakh)

Investment

(Rs. Lakh)

12 Replacement of 18 W LED tube light in Township quarter in place of 36 W Fluorescent tube light

262800 15.77 20.44

13 Replacement of 75 Nos 36 W LED Fixtures in place of 36 W 110 nosCFL fitting

11038 0.66 217

Total (Electrical Energy) 273838 16.43 237.44

11

1. Installation of New GTG-HRSG

Key Features

Power Generation: 25 MW

Steam Generation: 60 MTPH

RLNG Saving : 3600 Sm3/Hr

Energy saving : 0.36 GCal/MT of Urea

Monetary saving :Rs. 73 Cr.

Investment :Rs. 239 Cr.

The new GTG is catering the total power demand (24 MW) of the

Phulpur Complex and existing Steam driven Turbo-generators TG-I

and TG-II have been stopped.

The 60 MT HP steam generated from HRSG is being used in

process plants 12

2. Modification in CO2 Recovery Processs

• With modification in CO2 Removal Section from Benfield to aMDEA,

Regeneration Energy of CO2 has reduced from 950 Kcal/NM3 of CO2

to 450 Kcal/Nm3 of CO2.

• Yearly Saving (Gcal) : 136851

• Yearly Saving (Rs. Crore) : 39.69

• Investment (Rs. Crore) : 190

Modification in CO2 Recovery Process

-aMDEA Process

New HP/LP Flash Tower

New CO2 Bulk Absorber

Modified HP Stripper

CO2 Lean Absorber

Old LP Stripper

dismantled

CO2 Strippers

CO2 Absorber

13

3. Installation of New Medium Pressure

Process Condensate Stripper (1104-E)

• In the Low Pressure Steam Process Condensate Stripper, around 8

MT/Hr of LP Steam was being consumed for Stripping.

• In new Medium Pressure Stripper, MP Steam is used as Process

Steam.



• Investment (Rs. Crore) : 10.3

New MP StripperOld LP Stripper

14

4. Synthesis Gas Converter Internal Revamp

New Converter Internals

Ammonia Conversion:Particular Old Converter

105-D(Out)

Before (%) 15.48

After Revamp (%) 17.32

Due to internal revamp, the

conversion efficiency of ammonia in

converter is increased & the recycle

gas flow rate is reduced which

resulted saving of Power in

Synthesis Gas Compressor.




15

5. Installation of Ammonia recovery section

New Ammonia DistillationColumn (1501-E)

• Ammonia recovery section has

been installed to recover ammonia

from off gases of synthesis loop

under Energy Saving Schemes.

• Earlier, Off gases from Synthesis

loop was sent to Primary Reformer

& used as a fuel but after

implementation of this scheme

ammonia in Off gases has been

recovered & thereby reduction in

specific energy consumption.




16

6. Installation of new Refrigeration Compressor

Turbine in place of old Turbine

New Refrig. Compressor Turbine

• Inefficient Old Refrigeration

Compressor Turbine has been

replaced with New efficient

Turbine which has resulted in

reduction in Specific Steam

consumption.




17

7. Installation of new Process Air Compressor

Turbine in place of old Turbine

New Process Air Compressor Turbine

• Inefficient Old Refrigeration

Compressor Turbine has been

replaced with New efficient

Turbine which has resulted in

reduction in Specific Steam

consumption.




18

8. Replacement of Primary Reformer Convection

Section Coils and new VAM Coil

• For higher heat recovery, old Mixed feed & Process Air coil has

been replaced with new coils in convection section of Primary

Reformer. Additional a new VAM Coil has been installed where the

process condensate is heated and this heated Process

condensate is utilized in VAM Machine. .




9. New Urea Reactor High Efficiency Trays

• New Urea Reactor with High

Efficiency Trays (HET) in Urea

Plant has been installed.

• The function of the HET trays is to

increase the CO2 conversion, by

improving the heat and mass

transfer phenomena occurring

inside the reactor.




High Efficiency Trays

20

10. Installation of Ammonia Preheater in Urea

• The exchanger shall result in energy saving by utilizing energy of LP

Decomposer off gas which in existing system is dumped to cooling

water.

• With this modification, heat requirement in form of MS steam in HP

Stripper is reduced.




Erection of Ammonia Preheater

21

11. Installation of CO2 Cooler through VAM

• A Vapour Absorption Machine (VAM) is installed to generate chilled

water required for CO2 Gas chiller at the suction of CO2 Compressor

of Urea plant, resulting in saving of steam consumption in CO2

Compressor turbine of Urea plant.

VAM CO2 Cooler

Chilled Water

Return Water


• Yearly Saving (Rs. Crore) : 1..6

• Investment (Rs. Crore) : 6.5 22

Other Energy Saving Schemes

Yearly Savings

Power : 262800 kWh

Saving : Rs. 15.7 Lakh

Investment : Rs. 20.4 Lakh

22

(A) Replacement of 18 W LED tube light

in place of 36 W Fluorescent tube

light

(B) Replacement of 75 Nos 36 W LED

Fixtures for Control rooms in place of

36 W 110 nos CFL fitting

Yearly Savings

Power : 11038 kWh

Saving : Rs. 0.66 Lakh

Investment : Rs. 2.1 Lakh

23

INNOVATIVE SCHEME

• Utilization of waste heat of process condensate from Urea Plants to

generate chilled water through VAM. This chilled water is being used

for suction chilling of GTG Air which has helped to augment GTG

Capacity by 4 MW and running additional motor driven pump instead

of turbine driven pumps.

• Removal of check valve in the low pressure (0.65 kg/cm2g) CO2 gas

line between Ammonia & Urea Plant (HAZOP is essential) which

helped in increment of CO2 Compressor Suction Pressure by 0.04

kg/cm2. This has resulted in HP Steam saving of 1.8 MT/Hr equivalent

to 11120 Gcal / Annum.

• Utilization of excess chilled water available in the complex to reduce

CW temperature at the suction of syn gas cooler by installing spare

plate type exchanger which helped to reduce the syn gas temperature

at suction of compressor by 3 degC.

24

ROADMAP FOR ENERGY CONSERVATION

25

2018-19 2019-20 2020-21

1. Installation of

additional Syn loop waste

heat boiler for additional

process steam

production.

1. No planned Annual

shutdown to avoid

unproductive energy

consumption in the tune

of 0.05 Gcal/MT of Urea

which means special care

to be taken in maintaining

the Cooling water quality

and optimization of

process plants with

minimum variation.

1. Replacement of 40

years old CO2

Compressor Turbine

with highly efficient

Turbine.

2. Replacement of LT

Superheat coil in Primary

Reformer Convection

Section for higher steam

consumption and

bringing down the stack

temperature to around

130 degC.

3. Replacement of

Secondary Reformer Air

Burner for reduced Air

Compressor Discharge

Pressure.

6.57

5.49

7.50

6.18

1.010

0.950

0.9900.979

0.60

0.65

0.70

0.75

0.80

0.85

0.90

0.95

1.00

1.05

1.10

4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

8.5

2013-14 2014-15 2015-16 2016-17

Sp

. C

O2 E

mis

sio

n M

T/M

T

CO

2 E

mis

sio

n in

Lakh

MT

Year

Carbon Foot Print

26

Benchmarking with other Fertilizer Plants

• The fertilizer sector has been divided in the respective Vintage

Groups by Department of Fertilizer based on the year of

commissioning and the original feed stock.

• IFFCO Phupur-I had original technology of the 70‟s and Naphtha as

feed stock.

• Based on the same, our SEC norm shall be less than 6.5 Gcal/MT.

• With SEC of 5.85 Gcal/MT of Urea, IFFCO Phulpur is sitting on top of

the chart.

27

• Product Steward Excellence Certification

by International Fertilizer Association (IFA).

INTERNATIONAL ACCREDITATIONS

28

Installation of Online Environment

Monitoring System

Local display for pH & TAN

Liquid Effluent Monitoring: Monitoring of pH , Ammonical Nitrogen and Flow in pipe line (Reuse of Treated effluent in horticulture & irrigation of farm land within IFFCO’s premises)

Flow Instrument & local display

29

Installation of Online Environment

Monitoring System

Installed Transmitter & Receiver on Boiler Duct and Local Display

PM (Particulate Matter) measurement in Boiler ducts has been completed.

30

Raw Water Consumption

5.0

5.5

6.0

6.5

7.0

7.5

8.0

8.5

9.0

Raw

Wat

er

, M3

/ M

T o

f U

rea

Year

CPCB Benchmark : 12 M3 / MT Urea

National Benchmark (FAI) : 7.3 M3 / MT Urea

Reduction : 47%

31

(A) Solar Street Lights:

40 Nos. 30W LED based Solar

street lights installed in plant

premises and township.

(B) Solar Power Pack:

585 KWp Solar power pack

installed in plant and is

connected to the LT Grid.

Substitution of Conventional Energy withRenewable Energy

(C) Solar Light Pipes:

6 Nos. Solar Light Pipes have

been installed Store Building.

This has reduced the power of

the 36 Tube lights installed in

that area. 32

Substitution of Conventional Energy withRenewable Energy

(D) Solar water Heaters

6 Nos. Water Heater in GuestHouse

(E) Bio-Methanation Plant

Capacity : 25 m3/day

33

Environment & Sustainability

(A) Rain Water Harvesting

Systems

Total 5 Nos. Rain Water

Harvesting systems are

installed in township.Rain Water Harvesting

(B) Installation of Ammonical Nitrogen analyser at Guard Pond

(C) Modification in Neutralization facility of DM Plant and CPU Unit

(D) Installation of new Ammonia sensor near boundary wall

(E) Installation of Vent Silencer in Ammonia-I Plant

34

Solar Power Plant Installation Status:

• Two Units of Solar Power Plant of Capacity 585 KWp (235 KWp +350 KWp) were commissioned in the January and February 2016,respectively.

• Both the Solar Power Units are in continuous operationgenerating Electic Power in the tune of 740 KWh and 1140 KWhon daily basis.

• Additional Project for installation of 800 KWp Solar Power Panelscomprising of 7 different locations is in under progress.

36

Fly Ash Utilised for Brick MakingDry Fly Ash Disposal

Fly Ash Generated in PowerPlant being gainfully utilisedby Cement industries ,for BrickMaking, For Paving &Boundary walls and for Usarland reclamation.

WASTE DISPOSAL

37

Kitchen and Horticulture Waste Bio degradable wastesfrom kitchen and horticulture are converted into verygood manure by vermi composting System. The manure isused in horticulture, green belt area & 150 Acres farmland

Vermi Compost Pits

WASTE DISPOSAL

38

No. of Reports are generated on daily/weekly/monthly/ quarterlyand yearly basis for Reporting & Monitoring the EnergyConsumption:

Daily• Performance Report• Steam Balance Report• Cost report of Ammonia, Urea and Steam & Power

generation Plant

Weekly• Weekly performance Report

Monthly

• Variance report actual vs. targeted as well as last year

• Form ECS/GC 4 to assess profitability

Monitoring & Reporting System

39

Sample Performance Reports

40

Employee Engagement

IFFCO Phulpur Unit encourages its employees through

Suggestion Scheme to give ideas of energy conservation

Approx. 1000 suggestions are received every year from

employees.

Selected suggestion are awarded by the management.

A View of Suggestion Award Ceremony on Republic Day 41

Procurement Process

IFFCO Phulpur has taken care of Energy optimization right from Procurement

process among Vendors / Suppliers / Contractors

The Evaluation of a Bid is done on the basis of Operating Cost

Loading is be done to take care of the Performance and Productivity of

equipment offered.

In case the consumption of utilities are different for different

Bidders. Extra operating cost over the minimum one shall be calculated as

below for loading.

Operating cost = Difference in utilities consumption x Unit cost of

Utility x 8760 x 0.9 x 5.5860 x NWhere:

8760 is number of available hours in a year

0.9 is availability factor

5.5860 is discount factor at an interest rate of 10% per annum for

one year erection/commissioning and ten years operational period.

N is the number of operating equipment items.

42

National Energy Conservation Award- 2016 : 2nd Prize

Awards & Recognition

43

FAI Environment Protection Award : Joint Winner

Awards & Recognition

44

18th national award for excellence - …greenbusinesscentre.com... · been replaced with new coils...

Documents