best practices in energy efficiency in fertilizer sector€¦ · energy saving scheme ng fuel...

Rashtriya Chemicals and Fertilizers Limited

(A Government of India Undertaking)

Ammonia Plant Rastriya Chemicals & Fertilizers Ltd.1

BEST PRACTICES IN

ENERGY EFFICIENCY IN

FERTILIZER SECTOR

Rastriya Chemicals & Fertilizers Ltd.22

Incorporated in 1978 with the re-organisation of erstwhile FCI

This Organization is a JEWEL called “MINIRATNA”

Consistently PROFIT making

Two UNITS- TROMBAY & THAL

THAL -Capacity to produce 20.00 Lakh MT of UREA

Rashtriya Chemicals and Fertilizers Ltd.


Urea

(20 LMT)

Methyl Amine

(0.11 LMT)

Ammonia

(11.55 LMT)

DMF

(0.025 LMT)

Argon(0.14 LMT)

Thal Unit

DMAc(0.05 LMT)

Formic Acid (0.1 LMT)

RCF, THAL

R.C.F.Thal Unit

FEATURES

1. FIRST of it’s kind “MEGA FERTILIZER UNIT” in INDIA using NATURAL GAS from Mumbai Offshore as Raw Material.

2. When it was established this was the LARGEST producer of UREA FERTILIZER from single location in ASIA (More than 1.5 Million MT in a Year)

3. FIRST FERTILIZER UNIT with DCS in INDIA.

4. ADVANCED CONTROL UNIT and PLC for Electrical Load Management.

5. Strong emphasis on Environmental management.

6. In-Built Pollution Control and Safety features.

Our Achievements: 2014-15

• Highest

• Ammonia Production

13,39,430 MT

• Lowest

• Energy

8.24 Gcal/MT

Our Achievements: 2014-15

• Highest

• Urea Production

21,78,010 MT

• Lowest

• Energy

5.869 Gcal/MT

1000000

1100000

1200000

1300000

1400000

YEAR

1205350 1199070

1339430

Ammonia Production MT

2012-13 . 2013-14 2014-15


AMMONIA PRODUCTION

6

6.5

7

7.5

8

8.5

9

YEAR

8.85 8.594 8.24

Energy in Gcal /MT

2012-13 . 2013-142 2014-15


AMMONIA ENERGY

1500000

1600000

1700000

1800000

1900000

2000000

2100000

2200000

YEAR

1951200

1993800

2178010

Urea Production MT

2012-13 . 2013-14 2014-15


UREA PRODUCTION

5

5.5

6

6.5

7

YEAR

6.22 6.098

5.869

Urea SP.Energy Gcal/MT

2012-13 . 2013-14 2014-15


UREA SP. ENERGY CONS.

1984-85 : Initial set up

Ammonia Plants : 2 x 1350 MTPD

Urea Plants : 3 x 1500 MTPD

Initial Ammonia energy- 9.5 GCal/MT

Initial Urea energy - 7.5 Gcal/MT.

Improvement Schemes at RCF-Thal Unit

1

2011-12 : Ammonia Revamp scheme

Increased Ammonia production capacity to

2 x 1750 =3500 MTPD

Increased Urea production to 6060 MTPD.

Reduction in Ammonia Energy by 0.6 Gcal/MT.

Improvement schemes at RCF-Thal Unit

1

RCF Thal Ammonia & Urea performance

during Commissioning Time and Present

1

Unit Before Present

Ammonia

Production

MTPD 2700 3500

Ammonia Energy Gcal/MT 9.5 8.15

Urea Production MTPD 4500 6060

Urea Energy Gcal/MT 7.5 5.8

ENERGY SAVING SCHEME

Replacement of combustion air pre heater in waste heat section of Primary

Reformer

Before After Gain

Fin type exchanger

Plate type exchanger

Flue gas outlet

temperature 175°C.

Flue gas outlet

temperature 140OC.

Energy savings:

0.05GKcal/MT

16

Modification of NG coil E204A/B in waste heat section of Primary Reformer

S.No Before After Gain

Modification of NG CoilE204A/B(4 inlets)

Modification ofNG Coil

E204A/B(8 inlets)

1 Inlet Pressure 39.8 Kg/cm2

Inlet Pressure 39.8 Kg/cm2

2 Outlet Pressure 37.9

Kg/cm2

Outlet Pressure 39.2 Kg/cm2

3 Diff. press.1.9Kg/cm2

Diff. press. 0.5 Kg/cm2

1.4Kg/cm2

Steam saving 2.52 MT/hr per stream in Synthesis Gas Compressor

17


Energy saving is

0.13 Gcal/MT.

S-50 CONVERTER INSTALLATION FOR L1 &L2

• Increase in ammonia concentration exit the new converter.

• Decrease in loop pressure due to lower circulation rate (from 195-200 kg/cm2 g to 178-180 kg/cm2 g)

• Savings in steam to synthesis gas compressor & refrigeration compressors.

• Additional HP Steam production from loop resulting in lower of energy consumption.



.

Energy Saving

is 0.16

Gcal/MT.

MP Condensate Stripper

Revamp of single stage Benfield CO2 removalsystem to 2 stage GV system in Ammonia - I

Before After Gain

HP Regenerator (single stage)

2 stage GV system HP &

LP regenerator

Steam consumption

32 MT/Hr.

Steam consumption

20 MT/Hr.

LP Steam saving of 12 MT/hr.

To be utilized for

BFW/CT turbines. Energy

savings: 0.15

MKcal/ MT

20


REPLACEMENT OF MP TURBINES WITH LP TURBINES FOR COOLING TOWER AND BFW PUMPS

Energy saving is

0.12 Gcal/MT.

Total MP Steam consumption of 25 MT/hr was saved.


S – 200 BASKET REPLACED WITH S-300 BASKET

SAVING : 0.02

MKCAL/MT


E-1504 water cooler CS tubes replaced with Duplex SS tubes

to improve performance

Energy

saving is

0.03

Gcal/MT.



NG FUEL PREHEATING

Heating of Fuel gas from 300C to 900 C by

MP Stripper outlet condensate which is at

at 1200 C in new Exchanger E 216.

Saving of 0.005 MKcal/MT. of NH3.



NG FUEL PREHEATING



Methanator Heating


Methanator Heating to the required temp.takes

About 6 to 8 hrs.

If Methanator is made ready in advance,process

gas can be lined up directly to the the synthesis

after CO2 Removal section is ready thereby

saving startup time.


Methanator Heating



Provision of CV in NG line to GV absorber for

energy improvement during start up.


Running of small seal water

pump instead of 3.3KV motor

pump during GV startup

Ammonia Plant Rastriya Chemicals & Fertilizers Ltd.

29


Seal water grid modification

Seal water grid modification


30


APC- Advanced process controller for process

Optimization.

• Regular Monitoring of Primary Reformer tube

skin temp. and furnace temp adjustments.

• Flare header/PSV checking with temp. gun.

• Steam traps monitoring.


31


Present Energy reduction plan for Thal

plants

Replacing existing Steam Turbo Generators by

Gas Turbo Generators with HRSG for power &

Steam Production.

• Ammonia Energy will reduce from 8.12 Gcal / MT to 7.7

Gcal / MT.

• Urea Energy will reduce from 5.8 to 5.45 G Cal/MT.

• Total estimated Gas saving - 0.25 MMSCMD

• Total estimated raw water saving – 6400 M3/Day

3


Present Energy reduction plan for Thal

plants

Replacing existing

Steam Turbo

Generators by Gas

Turbo Generators

with HRSG for

power & Steam

Production.

Total estimated Gas

saving-0.25

MMSCMD

best practices in energy efficiency in fertilizer sector€¦ · energy saving scheme ng fuel...

Documents