deepak fertilisers and petrochemicals corporation limited taloja
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8/11/2019 Deepak Fertilisers and Petrochemicals Corporation Limited Taloja
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CII 13th National award for'Excellence in Energy
Management -2012 '
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Deepak Fertilisers and Petrochemicals Corp. LtdISO 9001:2008, ISO14001:2004, OSHAS 18001:2007 Certified
• Year of establishment : 1979
• Manufacturing Facility : At Taloja, Maharashtra
• Turnover ( 11-12 ) : Rs. 2342.81 Cr
• Products :
ANP ( 24:24:0 )
Isopropyl Alcohol
Weak Nitric Acid ( 59.2% )
Concentrated Nitric Acid ( 98.3% )
Strong Nitric Acid ( 72% )
Ammonium Nitrate
Methanol
Liquid CO2
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Reformation PurificationNH3
Synthesis
Natural Gas
Air
Steam
Methanol AN ANP
MethanolPlant
Purification
Synthesis
Reforming
Compression
Liquid CO2Plant
Purification
Liquefaction
Liq. Co2
WNA Plant Ammonia
Oxidation
Absorbtion
WNA CNA
C.N.A.Plant
AN PlantReactor
Evaporation
PrillingCoating
Reactor
Evaporation
PrillingCoating
Phos Acid
RGP
IPAPlant
ANP Plant
RGPPurification
Reaction
Purification
IPA
Ammonia
Process Flow
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Plants
Plant Original Cap. Current Cap.
Ammonia 272 TPD 380+10 TPD
Methanol 300 TPD 300 TPD
Liquid Carbon dioxide 100 TPD 120 TPD
Isopropyl Alcohol 210 TPD @ BOR 250 TPD @ BOR
Weak nitric Acid 3 X 300 TPD 3 X 300 TPD
Weak nitric Acid 1 X 450 TPD 1 X 450 TPD
Concentrated Nitric Acid 1 X 100 TPD 3 X 120 TPD
Ammonium nitrate melt 520 + 300 TPD 520 + 300 TPD
Ammonium Nitrate Prills 120 TPD 400 TPD
A N P ( Mahadhan Power) 765 TPD 1000 TPD
Steam 2712 TPD 2712 TPD
Captive Power Plant 2 X 4.5 MW2 X 4.5 MW1 X 7.2 MW
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Plant Technologies
Plant Technologies
Ammonia Fish International Engineers
Methanol Davy McKee ( UK )
Isopropyl Alcohol British Petroleum
Weak Nitric Acid One : Weatherly Inc.
One : Uhde Medium Pressure
One : Uhde Dual Pressure
Concentrated Nitric Acid Adolf Plinke
Ammonium Nitrate One : Stamicarbon
One : Grand Paroisse
Ammonium Nitro Phosphate Stamicarbon
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Energy Saving Projects Implemented:
Year
2009-10 8 1157.78 447.33 8437.27 5.30
2010-11 6 1002.21 712.57 11697.36 6.09
2011-12 3 55.17 216.48 14426.71 1.50Total 17 2215.16 1376.38 34561.33 3.98
Schemes
Implemented
Investment Made
(Rs. Lakhs)
Savings Achieve
(Rs. Lakhs/year)
Energy Cost
( Rs. Lakhs/year)
%Savings of
Energy Cost
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Schemes Implemented In 2009-10
Details
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Schemes Implemented In 2010-11
Details
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Schemes Implemented In 2011-12
Details
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Magnetic Resonator on fuel
line of Boiler A & D
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VFD for IPA CT fan motor
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Pump replaced to match with
process requirement
• After
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•100 Nos of 2 x 40 W Ferromagnetic Ballast &
Normal tube light replaced to 1 x 36 W with
Electronic Ballast & High Lux tube light
55 nos ,1 x 125 W HPMV Rusty Lamp Fitting at
ANP plant are replaced to 1 x 70 W New Metal
Halide Fitting.• After
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Energy Management
System in place
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• Initially the technical service department, apart from its routine jobs,
was also looking after the plant performance & energy conservation.
• To become more focused & proactive, it has been restructured in the
month of June-08 & formed the energy cell named as PI & EnCon,
i.e. Productivity Improvement & Energy Conservation Cell.
• The group has been lead by professional who is in the field of
improvement of plant performance & better management of energy
for more than 15 year and also the BEE's designated Energy Manager.
• The group Head is directly reporting to unit head.
About PI & EnCon Dept.:
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•
This group has two wings , one engineering & one implementation.Each wing has full fledge team of engineers.
• In totality, there are three BEE's Certified Energy Managers.
Company also sponsoring selected candidates for BEE's energy
manager examination on yearly basis.
• Apart from this, we are having nominated as energy managers (14
Nos ) from each stream of plants( like- production-each plant,
maintenance-each stream )
Company has energy policy which reflect
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Company has energy policy which reflect
the top management commitment towards
Energy Conservation.
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Techniques used for energy
conservation:
•We use software like Aspen plus, HTFS etc.
•Daily plant monitoring and carry out internal energy audit of
all plants once in a year
•We also carry out the energy audit from external parties
using recent methodology / technologies.
•We do circulate the knowledge sharing literature , conductseminars related to new developments etc which help for idea
initiation from shop floor person
S F
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Shop Floor
Nominated Energy Manager from
Production & Maintenance ( 15 Nos )
PI & ENCON Department
Energy Conservation
Awareness
Energy Week
Celebration
CirculationLiterature
Seminars
Skills
Internal &
External
Trainings
Interactions
Daily With
Shop floor
personsMonthly with
Nominated
Energy Manager
Motivation &
Recognition
Prizes for
Best Schemes
Display Board with
name of Idea Initiator
Support From
Top Management
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Awareness creation in the employees
& their involvement in energy
conservation program
• Display Boards for Energy Slogans
• Arranging Presentations, lectures, seminars on latest developments
& good practices in industries
• Circulating literature on weekly basis
• Booklet containing relative information of Energy Conservation
along with the case studies.
• Display boards for implemented & under implementation schemes
with idea initiators name & details of schemes
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• Celebration of Energy Week during which different programs
related to EC are arranged.
• Also the prize distribution to idea initiator for implemented
schemes.
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Product wise specific energy consumption for last
four years
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Graphical representation of Sp. Consumption for
energy intensive plants
Ammonia
2008-09 2009-10 2010-11 2011-12
0.83
0.84
0.85
0.86
0.87
0.88
Ammonia ( MTOE / Ton of product )
Ammonia
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IPA
2008-09 2009-10 2010-11 2011-12
0.20
0.25
0.30
0.35
0.40
0.45
IPA ( MTOE / Ton of Product )
Iso Propyl Alcohol
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World wide Benchmarking of Plants
• Ammonia Plant Benchmarking through Plant Survey International ( PSI )
• Net Specific – DFPCL 37.0 GJ / mt at 23 rd rank
- World best 24.7 GJ /mt
- World Avg. 37.4 GJ / mt
The world best plant is hydrogen based.
In 2011-12 , the yearly net specific consumption is Brought down to 35.17 GJ /mt even with converter catalyst at EOR condition which ranked at 15th
• Nitric acid plant Benchmarking through PDC, The Netherlands
• AN plant capacity augmentation and energy conservation through process
licenser M/s Grand Paroisse.
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Future Road Map.....
•
Acid Plants : Incorporation of modified type of cooler condenser torecover the waste heat
• Ammonia Plant : To fire the waste process gas in Boiler , there by
recovering the energy.
• Replace the old energy inefficient pump with efficient one
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Innovative Projects...1
• Innovative change over to total energy integration
strategy
• A back pressure turbo alternator has been installed as
part of the overall steam network to recover energy from
steam as it is let down from 40 to 3.5 bar. This steamturbine along with alternator can produce 3 MW of
electricity.
•
Also we have put additional 7 MW gas based co-generation power plant to improve the energy
integration and power reliance.
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Alternator with Exciter
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Innovative Projects.......2
Modifications in CO2 Removal Section•In June 2009 solvent changeover from @MDEA to @MDEA –
HiCap
•Also the additional LP flash column is added in-between
absorber and stripper
Benefits Envisaged:
• Plant capacity is enhanced from 354 to 380 TPD
• Energy consumption is reduced from 56.1 Mbtu/lbmole to 39.3 Mbtu /lbmole, 31166 to 21833.33 kcal/Kmol i.e. 30 % energy reduction
LP Flash Column in ammonia plant
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LP Flash Column in ammonia plant
CO2 removal section
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Environmental Projects
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Environmental Projects• Scheme for recycling 15 m3/hr water from IPA plant effluent is
successfully implemented in June 2011
• We have successfully implemented the CDM project for two plants of weak
nitric acid. This has substantially reduced the greenhouse gas emission to
atmosphere.
– Also , we are in process of implementing the CDM project for another
three weak nitric acid plants.
• Nox scrubbing scheme is implemented and same is under commissioning ,
this will reduce the Nox emission from acid storage tanks.
• Online ambient air monitoring & online display at main gate
WNA-1 WNA-3 Total
CERs Issued NIL 21448 21448
CERs verified 224678 72336 297014
Deepak CER 224678 93884 318562
B i e t the dified
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Basic concept on the modified
energy plan related to specific
measures
• Design Stage : Each and every modification in DFPCL is
reviewed by energy cell during design stage. Energy cell
evaluate and compare the energy efficiency of equipments
involved in the modification. According to the cost benefit
analysis, recommends the best energy efficient equipment.
• In Operation : Energy cell monitors the energy consumption
of each plant on daily basis. The deviations with respect to
design being addressed with corrective actions. This cell also
carry out complete plant energy audit once in a year. Also thecomplex energy audit is being carried out once after every two
years from external competent agency.
Monitoring & Reporting format
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Monitoring & Reporting format
M i i & R i f
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Monitoring & Reporting format
Future Projects
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Future Projects
• Zero discharge effluent project.
• CDM projects for WNA 3 & 4 plant
• De-Bottlenecking of AN melt plant.
• Replacement of old conventional motors with energy efficient 1 type
motor
• Implementation of recommendation of complex water pump audit.
• IPA & Ammonia Plant waste gases firing in Boiler to eliminate the
flaring
• Complex energy audit from external agency
ISO 9001 ISO 14001 and ISO 18001
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ISO 9001 , ISO 14001 and ISO 18001
audits of Energy Saving Projects
Year No Of NC
Major
No Of
NC
Minor
No Of Corrective
actions
No Of
Preventive
actions
2011 0 0 0 -
2012 0 0 0 -
U f R bl E S
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Use of Renewable Energy Sources
• Company has 8 nos of wind mill of 1.25 MW each , i.e. 10 MW in Dhule
district of Maharashtra.
• Generation Data:
• We have installed the solar water heater for canteen which has stopped
the 6 KW electrical heating system.
Through windmill 2009-10 2010-11 2011-12
Unit generated(Millions
kWh/year)19.285 15.297 16.017
Awards & Accolades:
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Awards & Accolades:
• MEDA State Award for Energy Conservation : 2008-09 ( 2nd ) &
2009-10 ( 1st )
Awards & Accolades:
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Awards & Accolades:
• ICC award for Excellence in Energy Conservation and
Management : 2010
Thank You!!!
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Thank You
Mr.R.S.Sankhe : GM ( PI & ENCON )
Deepak Fertilisers and Petrochemicals Corp. Ltd.
K-1 , Taloja MIDC Industrial area, Raigad – 410208, Maharashtra, India
www.dfpcl.com
Thank You!!!
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