iffco phulpur project

155

First Prize Fertilizers

INDIAN FARMERS FERTILISER

COOPERATIVE LIMITED

Phulpur Unit-II, Distt. Allahabad (Uttar Pradesh)

Unit Profile

Indian Farmers Fertiliser Cooperative Limited (IFFCO), globally acclaimed cooperative

in fertiliser production and marketing has been striving for socio-economic upliftment

of the rural population of India since inception. To ensure timely availability of

quality fertilizers to the farmers, IFFCO came into being on 3rd November, 1967.

Initially, IFFCO commissioned Kalol and Kandla plants in Gujarat in early 1975.

Due to increasing demand-supply gap of Urea in the country, Govt. of India has

given approval for expansion project at Phulpur site since basic infrastructure facilities

were available at Phulpur. The unit Phulpur-II was commissioned in December

1997 and consists of 1520 MTPD Ammonia Plant based on M/s. HTAS, Denmark

technology and 2620 MTPD Urea Plant based on M/s. Snamprogetti, Italy Technology.

156

Energy Consumption

Ammonia & Urea manufacturing is highly energy intensive and it contributes more

than 80% of the total cost of production Urea. Therefore, a slight change in energy

consumptions affects the cost of production in a big way. Apart from cost of

production reduction in energy saves the valuable fast depleting natural resources

such as Naphtha , Natural Gas, LSHS & Coal. Therefore, the Energy conservation is

a major corporate objective at IFFCO and it is a continuous process at its units.

IFFCO-Phulpur complex has become one of the lowest energy consuming units

amongst fertilizer plants in India. It has substantially reduced its energy consumption

during last three years. The details are highlighted below :

Plant 2006-07 2007-08 2008-09 2009-10 %Reduction

Over 2006-10

Ammonia-II 7.986 7.926 8.116 7.619 4.60

Urea - II 5.792 5.824 5.980 5.658 2.31

All figures are in Million kCal/MT

Performance At A Glance

Pro

du

ctio

n(M

T)

700000

800000

900000

1000000

2006 -07 2007 -08 2008 -09 2009 -10

882600

924223

840584

1000085

YEAR

UREA -II PRODUCTION

400000

500000

600000

2006 -07 2007 -08 2008 -09 2009 -10

506172

519949

475913

583507

YEAR

AMMONIA - II PRODUCTION

Pro

du

ctio

n(M

T)

5.795.82

5.98

5.66

5.50

5.70

5.90

6.10

2006-07 2007-08 2008-09 2009-10

YEAR

UREA- II ENERGY CONSUMPTION

2.2 % reduction over 2006-10

7.997.93

8.12

7.62

7.50

7.70

7.90

8.10

8.30

2006-07 2007-08 2008-09 2009-10

YEAR

AMM - II ENERGY CONSUMPTION

4.6%reduction over 2006 -10

Ov

era

llE

ner

gy

(G

Ca

l/M

T)

Ov

era

llE

ner

gy

(G

Ca

l/M

T)

157

Energy Conservation Commitment, Policy & Set-Up

IFFCO Phulpur Unit is playing a vital role in the national economy by providing

chemical fertiliser Urea to the Indian Farmers for prosperity and growth.

Manufacturing Process of Urea Complex is highly energy intensive and energy

contributes more than 80% of cost of production. Therefore, energy conservation

receives top priority at IFFCO Phulpur. IFFCO Phulpur Unit is committed to produce

good quality product with a mission to reduce the specific energy consumption 1%

every year.

IFFCO Phulpur is the first in fertilizer sector to receive Energy Management

Certification EN -16001.

Energy Conservation Achievements

Phulpur unit has always been a leader in adopting new developments in the field of

fertilizer production and number of modifications / revamp have been carried out

over the years which have resulted in substantial improvement in energy

consumption.

Major Projects Implemented during the Year 2009-2010

1 Higher Load Operation, Maximization of on-stream days & optimization

of Process Parameters

Specific Feed, Fuel and Steam Consumption is monitored on daily basis. Based

on design data corrective measures are taken on day to day basis to run the

plant at optimum efficiency.

Other important parameters like, Turbine & Compressor Efficiency, proper

utilization of Turbine condensate, furnace stack temperature and Turbine exhaust

pressure are monitored to achieve the lowest overall plant energy. Due to

these measures, 5% reduction in the overall energy per MT of Urea has been

realized.

Yearly Saving (MTOE) : 23108.99

Yearly Saving (Rs. Lakhs) : 3471.22

Investment (Rs. Lakhs) : NIL

2 Monitoring & Rectification of steam traps and leakages

Steam traps are installed in the steam lines to remove condensate from the

system. It is required to remove Condensate from the steam system, to avoid

heat loss and hammering in the line.

A survey was conducted to study the faulty traps and it was recommended to

replace those traps with new ones. Accordingly, all the faulty traps were changed.

Overall savings of 2 MT/Hr of HP steam has been realized with this measure.

158



Investment (Rs. Lakhs) : 6.00

3 Absorber temperature improvement in Carbon Dioxide Recovery Plant

(CDR)

Carbon Dioxide Recovery Plant (CDR) has been installed to recover CO2 from

the Flue Gas of Primary Reformer of Ammonia-II Plant. CDR Plant mainly consists

of Wash Column, Absorber and Regenerator. Due to lesser CW supply pressure

to the coolers of Absorber, the design value of top temperature could not be

achieved. Due to higher temperature, low pressure (LP) steam consumption in

the Regenerator was more.

In order to increase the CW flow and bring down the absorber temperature to

design range, CW return line has been connected to the Mist Cooling water

sump. As Mist Cooling sump is located at ground level, due to pressure

differential CW flow increased, resulting in better performance of the Absorber.

Due to lesser temperature, LP steam savings in the regenerator section has

been achieved.




Schematic Dig. of the Scheme

4 Bypass of Adiabatic Pre Reformer

Pre-Reformer was installed by the Process Licensor Haldor Topsoe at the time

of commissioning for the Naphtha feed. Pre-reformer adiabatically breaks the

higher hydrocarbons to lower hydrocarbons. After RLNG Conversion, in-house

study was conducted and it was decided to bypass Adiabatic Pre Reformer.

After by-passing Pre Reformer, pressure drop at the front-end reduced by 1.7

159

5 Installation of Liquid Nitrogen Tank

Syn Gas is highly flammable mixture. Before doing any hot job, purging of Syn

loop is a must. During catalyst loading also N2 atmosphere is a must for Reduced

Fe catalyst. Total time required for purging and catalyst loading with existing

facilities like N2 Blower, Inert Gas Plant was atleast 3 days. Liquid N2 Tank has

been installed for storing the N2 brought through the tankers. With the help of

the stored N2 in the tank, purging and catalyst loading job was completed in

1.5 Days. Thus saving 1.5 Days shutdown time. Steam has been saved, as

steaming of Primary Reformer has been reduced by 1.5 Days.




3 D view of Liquid Nitrogen Tank

kg/cm2. Due to lesser pressure drop, Syn Gas Compressor suction pressure

increased by 1.7 kg/cm2 resulting in lower steam consumption in the Syn

Turbine.




Schematic Dig. of the bypass of Adiabatic Pre Reformer

160

7 Stoppage of Service Water Pump

Water requirement of Phulpur Unit is full-filled by borewell water. Earlier, borewell

water was stored in the raw water storage and water for Softening Plant was

transferred by Service Water Pump.

Now, the feed water for Softening Plant is taken directly from the borewell

header, resulting in stoppage of 122 KW service water pump.

Yearly Saving (Lakh kWh) : 10.69



Sketch before modification Sketch after modification

6 CO2 Ejectors to prevent Seal losses

CO2 compressor is installed in the Urea Plant to compress the CO2 from the

Ammonia Plant from 0.5 kg/cm2 to 160 kg/cm2, before entering Urea Reactor.

CO2 from the seals of compressor escapes to the atmosphere. An ejector

system has been installed in the compressor. These ejectors were available in

Urea-II as discarded. The CO2 escaped from the system is trapped by the

ejector and sent back to the compressor suction. Total savings of 300 NM3 of

CO2 has been estimated. Earlier, this amount of CO2 was produced in the

Carbon Dioxide Recovery (CDR) Plant to keep up with the Urea Production.

With this scheme, load of CDR Plant has been reduced. Lower CDR Plant load

resulted in lesser low pressure steam consumed in the regenerator system.





161

8 Stoppage of RO Feed Water Pump

Reverse Osmosis Plant has been installed to treat effluent water. Earlier effluent

water from the plant was stored in a Feed Tank and transferred to the RO feed

with the help of RO Feed water pump.

As a energy saving initiation, effluent water is fed directly to the RO feed. This

has resulted in the stoppage of 45 KW feed water pump.

Yearly Saving (Lakh kWh) : 3.94




9 Installation of Solar Power Pack

A Solar Photo Voltaic Power Plant of 1.5 kW has been installed at R&D building

in plant premises. The power generated is being utilized for fan and lighting

application of the R&D building.

There are total 20 Nos. of Solar Photo Voltaic modules of 75 W each. The

energy generated by these Solar Photo Voltaic modules is stored in rechargeable

batteries and this energy is consumed as per the desired application.

Yearly Saving ( kWh) : 1460



Picture / Sketch of Solar Power Pack

162

10 Installation of Solar Street Lights

6 Nos. of 22 W stand alone Solar Street Lights have been installed in the

premises.

Each system contains, 2 CFL bulbs of 11 W each, Solar Photo Voltaic modules

of 100 W, rechargeable batteries. The energy is saved in the batteries during

day time and consumed during night. The CFL gets ON automatically during

darkness.




Picture of Solar Street Lights

11 Output Voltage Reduction of Lighting Transformer

Power saving by reducing the supply voltage in lighting system has been carried

out by lowering the tap of the lighting transformer. Supply voltage has been

reduced from 414 V (3 phase) to 404 V (3 phase). Total power reduction is

13.9 KW.




164

Environment and Safety

IFFCO Phulpur Unit is totally committed for maintaining an eco-friendly environment.

For controlling air pollution, plants have been provided with Bag Filters, Electro

Static Precipitators, Dust Extraction Systems, etc. A lush green belt with about 3

lakh trees has been developed all around the factory premises which is a natural

means of air purification. To overcome the problem of fly ash disposal, generated

in the Captive Power plant, a dense phase dry fly ash disposal plant has been

installed which directly fills the fly ash in closed tankers for transportation of the

ash to the cement plants manufacturing Portland Pozzolana cement.

Phulpur Unit has always put its best efforts for conserving water. The effluent

generated in the plant is recycled back after purification in Reverse Osmosis Plant.

Even the sewage water generated in the township is reused in the plant after

treatment in sewage treatment plant. The plant is running on zero effluent discharge

and total recycle basis. The present specific water consumption is the lowest among

the fertiliser industry in the country. Plant and its township have ISO 14001

certification which speaks volumes about its environmental commitment.

165

Second Prize Fertilizers

RASHTRIYA CHEMICALS AND

FERTILIZERS LTD.

Trombay Unit, Mumbai (Maharashtra)

Unit Profile

Rashtriya Chemicals and Fertilizers Limited, Trombay, a Govt. of India Undertaking

is one of the largest integrated Fertilizer and Industrial chemicals complexes in the

country. It was incorporated on 6th March'1978 during reorganization of the erstwhile

Fertilizer Corporation of India Ltd. into Hindustan Fertillizer Corporation Ltd., and

National Fertilizers Limited. It has two industrial complexes located at :

Q Trombay in Mumbai

Q Thal in Raigad district of Maharashtra

166

Trombay Unit manufactures a vast range of products ranging from Complex Fertilizers

to Industrial Chemicals. These plants were installed phase wise under various

schemes such as expansion, de-bottlenecking, revamping etc.

Energy Consumption

Year Electrical Energy consumed Thermal energy consumed

Lakhs kWh Lakh SM3

2008-2009 2097.20 1949.17

2009-2010 2713.98 2996.84

Energy Conservation Commitment, Policy & Set-Up

Considerable efforts have been made to reduce energy consumption of age-old

plants making use of latest technology.

An Energy Cell with an Energy Manager and qualified engineers has been set up to

analyze the day to day energy consumption levels in various process plants in the

factory. Energy Conservation Opportunities are identified based on energy audits,

case histories of successful conservation measures implemented by other plants

and through suggestions received from the operating and technical personnel etc.


1. Provision of capacitor banks on 11KV system fed from

Ammonia-1

After provision of capacitor banks on 11 KV system fed the power factor has improved

to the tune of 0.999. Thus reducing the losses in electrical network and saving

almost Rs. 90 Lakhs in electricity bill.

Energy cost savings = Rs. 90.01 Lakhs

Total investment = Rs. 35.00 Lakhs

2. Scheme to use Benfield condensate in place of DM water in

Ammonia-V plant

The above scheme of using Benefield Condensate in place of DM water for purpose

of sealing in Benefield solution pump has lead to saving in electrical power as one

DM water pump (P313) is stopped. The Benefield condensate is connected at

discharge line of DM water pump (P313).



167

3. Conventional 125 Watt HMPV light fittings have been replaced

with 70 Watt Metal halide light fittings

Total 100 no. of Conventional 125 Watt HMPV light fittings have been replaced with

70 Watt Metal halide light fittings leading in electrical energy saving of 0.5 lakh

kWh.



4. Installation of new modified SL Saturator in ANP Plant

The above scheme has lead to savings in steam of 0.5 MT/hr due to stopping of

steam leakage. Thus leading to reduction in fuel consumption.



5. Installation of new AN surface condenser in ANP plant

The above scheme has lead to Saving of electrical energy due to stoppage of 2 no.

Vacuum pump motors (140 kW) which were earlier required to operate with the

old surface condenser.



6. Replacement of 240 Nos of old A/Cs by new energy efficient

A/cs

Replacement of 240 Nos of old A/Cs by new energy efficient A/Cs leading to saving

of electrical energy



7. Installation of Fan less cooling tower in Sulphuric acid plant

Fan less cooling tower is installed in place of two induced draft cooling towers in

Sulphuric acid plant.

Reduction of power consumption:



168

8. Installation of Capacitor Banks in Sulphuric Acid Plant

Installation of Capacitor Banks in Sulphuric Acid Plant has lead to reduction in

electrical energy consumption.



9. Installation of Air Handling Unit for SAP-CNA Control Room

Installation of Air Handling Unit in Sulphuric Acid Plant leading to saving of electrical

energy by stopping Air Conditioners in Control room.



10. Provision VFD for 2 No. of aerator motors in Sewage Treatment

Plant

Installation of VFD in for 2 no. aerator motors leading to saving of electrical energy.

The operation of VFD is linked with online Dissolved Oxygen measurement. By

monitoring the DO value the speed of aerators can be controlled, thus leading to

saving of electricity.



11.Solar water heater for providing 6000 liter per day of hot water

(70 0C) Sewage Treatment Plant

Installation of Solar water heater for providing 6000 liter per day of hot water (70

0C) Sewage Treatment Plant. This has lead to stopping of two electric heaters (24

kW each) and thus reducing power consumption



169

12.Provision of High Capacity C.W. Pump

for Methylamine Plant

Provision of High Capacity C.W. Pump for MAP has

resulted in saving of electrical energy (25 kWh).

Earlier two less capacity pumps were operated. These

pumps are now stopped and new high capacity pump

is installed leading to stoppage of two lesser capacity

pumps.




In line with motto of sustainability, The plant is Environment Management System

(EMS) ISO-14001:2004 compliant.

170

Certificate of Merit Fertilizers

GUJARAT STATE FERTILIZERS &

CHEMICALS LIMITED

Vadodara Unit, Distt. Vadodara (Gujarat)

Unit Profile

Gujarat State Fertilizers & Chemicals Ltd. (GSFC), a unit promoted by the

Government of Gujarat is leading manufacturers of fertilizers & chemicals. GSFC is

spread over 648 hectare with 220 (34%) hectare of green belt.

On February 15th 1962, GSFC was incorporated as Joint Sector Company with

determination of the Government of Gujarat to offer quality products and services

to the farmers. The first latency of GSFC's fertilizer rolled out of its production unit

in 1967.

During the years 1974 to 1982 with serene policies of alteration, GSFC turned into

manufacturing of Caprolactam, Nylon-6, Melamine and Argon. Subsequently,

capacities were enhanced in Caprolactam and Melamine. Initially all the power was

drawn from state grid. GSFC installed three nos. of Cogeneration plants in phase

wise manner.

171

Manufacturing facilities / products range

Installed capacity / Actual production / Capacity utilization for the last three years

are presented below:

Product Unit Installed Actual production / (Capacity utilization %)

capacity

2007-08 2008-09 2009-10

Urea MT 367200 277008 280500 326300

(75.44%) (76.39%) (88.86%)

Ammonium MT 196000 292935 265710 271580

sulphate (AS) (149.46%) (135.57%) (138.56%)

Diammonium MT 108000 79300 43770 00

sulphate (DAP)

APS MT 120120 207500 293600

Caprolactam MT 70000 79716 70913 81151

(113.88%) (101.3%) (115.93%)

Melamine MT 15000 14741 13655 13735

(98.27%) (91.03%) (91.57%)

Nylon-6 MT 8000 8638 8751 8688

(107.98%) (109.39%) (108.6%)

MEKO MT 4450 4083 3400 2780

(91.75%) (76.4%) (62.47%)

Energy Consumption

Energy consumption at GSFC is monitored on regular basis during day to day

production meeting, fortnightly Operation division meeting (ODC) and monthly

Technical Monitoring Committee (TMC) meetings.

Consumption of NG, power and LSHS for last three years is as given below:

YEAR NG Power - Power LSHS MT Total

own generation purchased energy

units * 1000 units * 1000 consumed

Gcal

2007-08 153265 169056 424786 4088 3044065

2008-09 145039 162029 392605 5412 2875911

2009-10 551946 140989 446118 6916 3201640

172

Total Energy consumption at GSFC

2000000

2200000

2400000

2600000

2800000

3000000

3200000

3400000

2007-08 2008-09 2009-10

Year

En

erg

y,G

cal

Energy Gcal

Energy Conservation Commitment, Policy and Set-Up

GSFC has energy conservation as major corporate objective. General Manager

(also designated Energy Manager) coordinated the activities of energy conservation

and cost reduction. GSFC has dedicated energy cell comprising members from

Operation, Electrical, Maintenance and Technical Services. Energy conservation

ideas are also received from all employees in form of suggestion through Suggestion

Appraisal Committee. Also a dedicated Energy management team comprising of

16 members is formed to discuss, evaluate and encourage energy conservation

ideas from each plants and departments.

GSFC has also implemented Energy Management system BS - EN-16001 to have

energy conservation approach in systematic, uniform and continuously monitored

parameter by one and all, including higher management. Various energy

conservation schemes are initiated under the Energy management system adopted

and targets set for implementation of the same at faster rate. Special attention is

given for purchase of energy efficient items.


GSFC implemented following schemes at Vadodara unit.

1. Installation of small capacity Make up water pump at Co-Generation -III plant.

Due to low load operation requirement, make up water pump was operating

at low capacity. Small capacity, low head pump installed in place of high

capacity, high head pump to reduce power consumption by 2.4 lacs

173

equivalent to Rs. 6.03 lacs/Yr. Cost of installation of small capacity small head

pump is Rs. 3.17 lacs/Yr with payback period of about 7 months.

2. Power saving by stopping continuous operation of high capacity Caustic pump

(P-1046) in Capro-II plant. A high capacity caustic pump common for

continuous and occasional consumers is provided which runs on continuous

basis. Small capacity pump for continuous supply to consumers, installed. It

resulted in to stoppage of higher capacity pump except for occasional running.

It resulted in to annual power saving by 0.48 lacs units/Yr, equivalent to Rs.

1.81 lacs/Yr. Cost of installation of small capacity pump is Rs. 1.65 lacs/Yr

with payback period of less than a year.

174

3. Changing of CT fan blade from Aluminium to FRP-Hollow blades at Ammonia

storage plant. Existing Aluminium blades replaced by hollow FRP blades to

reduce power consumption. It resulted in to annual power saving by 0.32 lacs

units/Yr, equivalent to Rs. 1.21 lacs/Yr. Cost of installation of is Rs. 1.0 lacs/Yr

with payback period of 10 months.

Savings and payback period for Energy conservation schemes atGSFC.

0

2

4

6

8

10

12

1 2 3

NO. of SchemesEletricity conservation, Lacs/kWh Savings, Rs. (lacs/Yr)

Cost of Implementation, Rs. (lacs) Payback period, months

175


176

Certificate of Merit Fertilizers

INDIAN FARMERS FERTILISER

COOPERATIVE LIMITED - PARADEEP UNIT

Distt. Jagatsinghpur (Orissa)

Unit Profile

Indian Farmers Fertiliser Cooperative Limited (IFFCO) took over OCFL's Phosphatic

Fertiliser Complex at Paradeep in October 2005

The plant consists of two streams of Sulphuric Acid Plant, one stream of Phosphoric

Acid plant and three streams of Complex fertilizer plant. In addition to these various

offsite and utilities facilities are also present inside the complex to fulfill various

requirements.

177

Energy Consumption

Production Performance

During the financial year 2009-10, IFFCO Paradeep unit have produced 15.00 lakhs

metric tonnes (MT) of complex fertilisers, 14.28 lakhs MT of Sulphuric Acid and

4.62 lakh MT of Phosphoric Acid (as 100% P2O5).

0

0.2

0.4

0.6

0.8

1

1.2

Sp

.C

on

s.

(Gc

al/

MT

)

2006-07 2007-08 2008-09 2009-10

Year

Specific consumption of Energy

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

1.000

Sp

.C

on

s.(

MW

H/M

T)

2006-07 2007-08 2008-09 2009-10

Year

Specific consumption of Power

178

Energy Conservation: Commitment, Policy & Set-Up

179


1. Replacement of cooling tower fan blades: The cooling tower blades of

Energy Center cooling tower & Sulphuric Acid Plant (SAP) cooling tower were

replaced with energy efficient FRP hollow blades as an energy savings scheme

measure. The modification led to savings of 15kWh per fan.

Investment in SAP cooling tower : Rs. 21,00,000 /-

Savings in energy due to replacement SAP cooling tower blades with hollow

FRP blades :Rs.246600/year

Investment in TG cooling tower : Rs. 30,00,000 /-Savings in energy due to

replacement TG cooling tower blades with hollow FRP blades : Rs.65,26,000

per year

2. Trimming of filter water pumps: The filter water pumps are used to pump

process water to different plants inside the complex. Each of the three pumps

was designed to give a flow of 1800 m3

/hr at a discharge pressure of 6.9 kg/

cm2

. After an in-house study as per the requirement of the plant it was observed

that the impeller of one pump can be trimmed for lower flow without any

change in the discharge pressure. The impeller dia. of the pump was trimmed

form 520 mm to 490 mm. After the trimming the performance of the pump

was observed and tabulated below.

3. Use of Liquid ammonia instead of vapor ammonia: In the DAP/NP plant it

was designed to use vapor Ammonia to react with Phosphoric acid to produce

the complex fertiliser (DAP/NP). So steam was used to vaporize liquid ammonia

as the ammonia is received and stored in the liquid state. After an in-house

study it was considered to use liquid ammonia in place of vapor ammonia

which saves energy in terms of steam being used for vaporization.

Description Before trimming After Trimming

Dia. of the Impeller 520 mm 490 mm

Flow of the pump 1800 m3

/hr 1500 m3

/hr

Discharge Pressure 6.9 kg/cm2

6.9 kg/cm2

Current 42 amp 36 amp

Power consumption 411 kW 338 kW

Savings - 73 Kw

Monetary Savings - 17.96 Lakh rupees

Investment - NIL

180

A. Savings of energy in DAP/NP plant due to liquid ammonia feeding

I. Energy savings from Steam pre-heater

Consumption of steam in Preheater = 2360 kg/hr

2.360 MT/hr

Heat content of the LP steam = 661.300 Kcal/kg

Energy savings per hour = 1.561 Gcal

Total energy savings for 2009-10 for three trains = 29462.291 Gcal

(considering stream hours for three trains 18878 Hrs)

II. Energy savings from ammonia vaporiser

Steam requirement during the start up = 10.250 MT/startup

Heat requirement per startup = 6.778 Gcal

Assuming one startup each day (330 days) 2236.847 Gcal

energy savings for three trains due to ammonia vaporiser = 6710.542 Gcal

Total savings per year (I + II) = 36172.832 Gcal

Steam savings per year = 44879.444 MT

(converting to HP steam, 805.9 Kcal/kg)

Price of steam per MT = 500.00 INR

Total savings per year = 22439722 INR

Coal savings per year = 13598.472 MT

(considering sp. Cons. Of 0.3030 per MT of steam)

B. Investment: Rs. 30,00,000 /-

C. Payback period: 0.133 Yrs

4. Reduction of MP steam pressure in DAP/NP Complex fertiliser Plant:

2 MT of Medium Pressure steam at 15 kg/cm2

g was being used in combustion

chamber of Dryer for atomization of furnace oil, flushing of slurry pumps and

slurry lines. After an in-house study it was observed that MP steam at 10 kg/

cm2

g can be used for the above purpose. Accordingly the pressure was reduced

as per requirement and the savings are as following.

181

A. Investment: NIL

B. Savings due to reduction of pressure in MP steam

Quantity of MP steam used in DAP = 2 TPH

Enthalpy of steam at 15kg/cm2g, 220 OC = 679.9 Kcal/kg

Enthalpy of steam at 10kg/cm2g, 200 OC = 674.1 Kcal/kg

Savings in energy per hour = 11600 Kcal/Hr

Savings in energy per year = 218984800 Kcal/Yr

Enthalpy of HP steam (61 Kg/cm2g, 480 OC) = 805.4 Kcal/kg

Savings in terms of HP steam per year = 272 MT

Cost of HP steam = 500 INR

Monetary savings = 135948 INR

Coal savings per year = 82 MT

Energy savings in Coal Handling Plant (CHP): In the old CHP total eleven nos.

of conveyors were present for conveying coal inside the plant. When it was planned

to construct the new present CHP it was considered to reduce the no. of the belts

which in turn reduces the energy consumption as the no of drives were reduced.

iffco phulpur project

Documents

energy intensive

lowest energy

energy conservationreceives

energy consumption4

energy consumption2

energy consumptionduring

unit phulpur

iffcophulpur complex