presented by: mr. neeraj rajesh (chief manager- urea), mr ... · mr. neeraj rajesh (chief manager-...
TRANSCRIPT
Presented by:
Mr. Neeraj Rajesh (Chief Manager- Urea),
Mr. J S Garcha (Chief Manager- Ammonia),
Mr. Sunil Kumar (Manager (GE)
Leading producer & marketer of fertiliser in India
No. of plant locations : 5
Installed Annual Production Capacity
• Urea : 4.24 Million MT
• NPK/DAP : 4.34 Million MT
IFFCO in Brief
IFFCO Aonla-II Unit
IFFCO Aonla Unit, located in northern part of India, operates
Two streams of Ammonia (1740 MTPD each) & 4 streams of Urea
(1515 MTPD each) and is based on Natural Gas as feed & fuel.
Last 3 Years Specific Energy Consumption
Year Specific energy consumption
(Gcal/MT Urea)
2015-16 5.308
2016-17 5.360
2017-18 5.224
Specific energy consumption for F.Y. 2016-17 includes
energy losses occurred during implementation of Energy
Saving Schemes (Phase-I) and energy consumed in ongoing
activities of ESP (Phase-II).
Description National
Benchmark
Average
Value (For All
Gas based
Plant)
International
Benchmark
Specific
Energy
Consumption
5.158 5.880 Not Available
IFFCO Aonla-II:
Urea Plant
(year: 2017-18)
5.224 5.224
5.224
Unit : (Gcal/MT of Urea)
Comparison with National & International Benchmark
Advanced Process Design
Complex Integration
Improve Operating Practices
Minor Modifications
Major Modifications
Roadmap to achieve National & International Benchmark
Title of Energy Saving project
implemented
Year of
Impleme
ntation
Total
Annual
Savings
(Rs
Lakhs)
Invest.
Made
(Rs
Lakhs)
Pay
back
(Years)
Provision of additional vent valve
(PIC) in final discharge line of
Process Air Compressor to prevent
compressor from surging
2015-16 189.0 3.0 < 1
Month
Replacement of CFT material spacer
rings and guide rings with PEEK
material rings in High Pressure
Ammonia Pump (P-1C)
2015-16 7.8 2.2 3.0
Replacement of conventional lighting
fixtures with energy efficient lighting
fixtures
2015-16 5.3 26.3 5.0
List of Energy Conservation Projects
Title of Energy Saving project
implemented
Year of
Impleme
ntation
Total
Annual
Savings
(Rs
Lakhs)
Invest.
Made
(Rs
Lakhs)
Pay
back
(Years)
Energy Saving Project (Phase-I) 2016-17 3745 7660 2.1
Utilisation of Flash Steam generated
in Steam Condensate Tank as motive
fluid in booster ejector (EJ-2) in Urea-
II Plant.
2016-17 200 3 < 1
Month
Replacement of conventional lighting
fixtures with energy efficient lighting
fixtures
2016-17 4.9 15.0 3.1
List of Energy Conservation Projects
List of Energy Conservation Projects
Energy Saving Project (Phase-I)
1) Installation of New Ammonia Wash System at 2nd stage discharge
of Synthesis Gas Compressor followed by synthesis loop
modification.
2) Revamp of Synthesis Gas Compressor involving replacement of HP
& LP case internals
3) Replacement of existing CO2 compressors by new higher efficiency
compressors in Urea-II Plant
Title of Energy Saving project
implemented
Year of
Impleme
ntation
Total
Annual
Savings
(Rs
Lakhs)
Invest.
Made
(Rs
Lakhs)
Pay
back
(Years)
Energy Saving Project (Phase-II) 2017-18 7722 26440 3.4
Utilisation of process heat (MV-2 off
gases) for saving of LP steam during
urea melt recovery.
2017-18 130 5 < 1
Month
Replacement of conventional lighting
fixtures with energy efficient lighting
fixtures
2017-18 11.9 23.2 1.9
List of Energy Conservation Projects
List of Energy Conservation Projects
Energy Saving Project (Phase-II)
Replacement of existing GV solution based CO2 removal section by
aMDEA solution based CO2 removal section for less energy
requirement.
Installation of Ammonia Preheaters in 31 & 41 streams of Urea Plant at
upstream of Carbamate Recycle Ejector
Modification in exhaust duct of Gas Turbine Generator (GTG-II).
Utilization of process heat
available in
MP Decomposer Separator
off-gases
for concentrating recovered Urea
Melt in Urea-II Plant
Original System
Urea synthesis of NH3 and CO2 at high pressure & temperature.
Urea formation in High Pressure Synthesis Section is around 60%.
Mixture of urea, ammonia and carbamate solution from HP section is
passed through:
Medium Pressure,
Low Pressure,
Pre-Concentrator,
Vacuum & Evaporation Sections and
Prill Tower to make urea prills
Vacuum & Evaporation Section: (Urea concentration: 80%- 99.97%)
1st stage Vacuum system- 0.3 kg/cm2a ,
2nd stage Vacuum system- 0.03 kg/cm2a
Original System (Contd…)
Original System (Contd…)
Urea Solution Recovery Tank receives around 500 MT Urea solution per
week (of 70% concentration) from following sources:
During weekly preventive maintenance of backend equipments
Urea slurry from urea dissolving tank
During urea melt recovery cycle, this urea solution was concentrated in
1st Stage Evaporator and resulting in additional LP steam consumption
of around 3.0 MT/hr.
Modified System
Vacuum Pre-Concentrator at the upstream of Vacuum & Evaporation
section utilizes process heat of MP Decomposer off-gases to
concentrate Urea solution from 70% to 80%.
Balance heat available with off-gases has to be extracted by cooling
water in MP condenser, before sending to MP Absorber. Around 6.6
Gcal/hr, process heat was being thrown into cooling water.
To utilize this additional process heat in Pre-concentrator, discharge of
melt recovery pump is connected to the inlet of Pre-Concentrator.
With this modification, process heat of MP Decomposer off-gases is
utilised to concentrate the recovered urea solution and resulting in
saving of LP steam in 1st Stage Evaporator.
Modified System (Contd…)
Benefits
Additional LP steam requirement during melt recovery cycle has
eliminated.
Heat thrown in cooling water is also reduced due to temperature
reduction of MP decomposer off-gases at MP Condenser inlet where
cooling water is used as cooling medium.
Saving & Payback
Energy Saving achieved : 4900 Gcal/annum
Monetary saving : Rs. 130 Lakhs/annum
Investments : Rs. 5.0 Lakhs
Payback Period : Less than a Month
Replication Potential
The modification is innovative in the sense that
energy saving have been achieved by utilizing the
heat available with off-gases which was earlier
dumped in cooling tower.
The modification has high replication potential in any
fertiliser industry where such type of urea recovery
arrangements are in operation.
Solar Water Heating System
Solar Street Light System
Roof Top Solar Photovoltaic Panel at various building
Renewable Energy Sources
Roof Top Solor Power at PH Plant
Particulars Unit FY 2015-16 FY 2016-17 FY 2017-18
Roof Top Solar PV KWH/day - - 378
Solar Water Heating KWH/year 34800 34800 34800
Solar Street Light KWH/year 1100 1100 1100
Utilisation of Renewable Energy
Sources
Utilization of Waste
Waste Utilization
Purge Gas Recovery (PGR) unit to recover Hydrogen and
recycle it back for achieving energy saving.
Carbon Dioxide Recovery Unit
Use of treated effluent water for the irrigation of green belt
Particulars Unit FY 2015-16 FY 2016-17 FY 2017-18
Purge Gas Recovery Gal/year 116879 106757 95740
GHG Inventorization
Particulars Unit CO2 Gen./MT Urea
FY 2015-16 Gal/year 0.486
FY 2016-17
Gal/year
0.478
FY 2017-18
Gal/year
0.490
CO2 generation per MT Urea:
Note: CO2 generation sources includes fuel consumption in
Primary Reformer, GT and HRU in Ammonia Plant and
Purchased Power Used:
Team work,
Employee Involvement
&
Monitoring
Methodology :
1. Estimation of saving in
terms of steam, power,
gas etc.
2. Calculation of saving in
terms of Raw Material,
i.e. natural gas
3. Derive Total energy
Saving based on energy
value of raw material.
4. Total yearly production is
used for calculating
specific energy
consumption.
Energy Monitoring & Methodology
Daily review meeting
chaired by Unit Head
Energy Conservation Cell
Energy monitoring cells for Ammonia, Urea, Product
handling, Offsites and Power plant.
Each cell consists of persons from Technical, respective
Production, Maintenance and Instrumentation sections.
Management Representative – reporting to top
manangement
Energy Manager
Preparation of plant performance and energy reports on
daily, monthly and yearly basis and accordingly corrective
actions are taken.
Energy Efficiency / Awareness Training Program
Steps taken based on the recommendations of energy cell
Monitoring and achieving the most optimum vacuum in
surface condensers.
Based on the performance evaluation, compressors/turbines
are recommended for overhauling.
Trimmed operation of cooling towers to achieve most
optimum cooling water temperature.
Steam lines insulation survey helped in reducing the loss of
heat to atmosphere.
Energy Efficiency / Awareness Training Program
Involvement of plant personnel through Plant Suggestion
Schemes
Employees are motivated through “Innovation &
Creativity Meet” organized at Corporate level.
IFFCO Aonla won Champion – Maximum Participation
Award from INSAAN-NIC for employee involvement in
Suggestion scheme.
Plant personnel are encouraged to give their valuable ideas
on last Friday of each month through ‘Idea Friday’.
Energy Efficiency / Awareness Training Program
Certifications
Energy Saving Project in IFFCO Aonla-II Unit has implemented in two Phases.
ESP Phsae-I (FY 2016-17)
ESP Phase-II (FY 2017-18)
Apart from ESP, Various energy saving schemes are implemented inhouse regularly.
Investment for the ESP and inhouse energy saving modifications are given below for FY 2017-18:
% investment on turnover
% investment for energy
conservation projects on
turnover
12.94%
(Rs. 2137.8
Million)
NSCI Safety Award-2017
(Sarvashreshtha Suraksha
Puraskar) from National
Safety Council of India.
National Energy Conservation
Award-2017 (Second Prize) from Bureau of Energy
Efficiency, Ministry of Power,
Government of India.
Excellent Energy Efficient Unit Award-2017 in
Fertiliser sector from Confederation of Indian
Industry (CII).
Most Innovative Environmental Project Award from
Confederation of Indian Industry (CIl) under CII
Environmental Best Practices Award-2017.
FAI Safety Award-2017 (Runner up) for excellence in
safety from The Fertiliser Association of India.
Uttar Pradesh State Energy Conservation Award-2017
(Second Prize) from Uttar Pradesh New & Renewable
Energy Development Agency (UPNEDA).
Excellence Award for Case Study presented & Best
Suggestor Award from (INSSAN-NIC) in 19th National
Creativity Summit-2017.
7th Annual Greentech HR Award-2017 (Gold Award)
from Greentech Foundation.
Safety Innovation Award in Fertiliser & Chemicals
sector from Institute of Engineers (India).
16th Annual Greentech Safety Award-2017 (Gold
Award) in Fertiliser sector from Greentech
Foundation.