Presented By:

Indian Farmers Fertiliser Cooperative Ltd.

Phulpur Unit-I

29th – 31st August, 2018

19th National Award for Excellence

in Energy Management - 2018

1

PHULPUR UNIT-I

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 18.5 % to the total ‘N’ and 29.2 % to the total “P2O5”

produced in the Country during the year 2017-18.

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

PHULPUR UNIT-IJourney of 50 Glorious Years

3

PHULPUR UNIT-IIFFCO 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)

123 212

4

PHULPUR UNIT-I

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

5

PHULPUR UNIT-I

in Gcal/MT of Urea

Phulpur-I : Sp. Energy Consumption

6.706.74

6.656.64

6.74

5.88

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

Year

NUP Norm: 7.144(upto March 2018)

0.62

1.264

NUP Norm: 6.5(From April 2018)

Best Ever Yearly Energy

6

PHULPUR UNIT-I

3.853.34

4.323.49

4.29

6.52

5.78

7.58

6.32

7.26

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

Phulpur-I: Production Performance

7

Installed Capacity

Installed Capacity

YEAR

Lakh

sM

T

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2017-18

S.No Energy Saving Schemes Yearly Energy Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

1 Replacement of 2nd Stage Intercooler of Process Air Compressor in Ammonia –I Plant

36342.7 434.94 62.55

2 Installation of Vapor Absorption Machine(VAM ) for CO2 cooling in Urea-I Plant

7486.6 177.8 833.0

3 Installation of VAM for Suction Chilling of Air in Gas Turbine Generator(GTG)

29822 708.3 2817.0

Total (Thermal Energy) 73651.3 1321.04 3712.55

8

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2017-18S.No Energy Saving Schemes Yearly

Energy Saving(KWh)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

4 Installation of 350 KWp Solar Power Panels at different locations in Phulpur- I Plant 116970 7.02 166.08

5 Replacement of 150 Nos 90 W LED Street Light fixture from front side of Plant gate to Gate No 3 in place of 220 W high pressure sodium Fixture

32184 1.93 3.93

6 Replacement of 400 Nos 30 W LED Street Light fixture in Township branch road in place of 120 W high pressure sodium tube

59417 3.57 3.73

7 Replacement of 100 Nos 72 W LED Street Light fixture in Township from Gate no 4 to Gate No 1 in place of 220 W high pressure sodium Fixture

24427 1.47 1.97

8 Replacement of 160 Nos 19 W LED fixture in Bagging Platform in place of 40 W Normal Fluorescent tube light

10827 0.65 2.27

Total (Electrical Energy) 243825 14.64 177.98

9

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2016-17

S.No Energy Saving Schemes Yearly 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 Recovery Process- aMDEAProcess in place of Benfield Process

136851 3969 19004

3 Installation of New Medium Pressure Processcondensate stripper (1104-E)

73442 2130 1032

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

48961 1420 1331

5 Installation of Ammonia recovery section torecover ammonia from off gases of synthesisloop

24481 710 1025

10

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2016-17

S.No Energy Saving Schemes Yearly Energy Saving (Gcal)

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 and Process AirCoil and installation of New VAM Coil inAmmonia Plant

9632 279 1044

9 New Urea Reactor with Casale HighEfficiency Tray in Urea Plant

13959 405 460

10 Installation of Ammonia Preheater in MPSection of Urea-I

6980 202 167

Total (Thermal Energy) 663490 19242 50864

11

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2016-17

S.No Energy Saving Schemes Yearly Energy Saving (KWh)

Monetary Saving

(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 nos CFL fitting

11038 0.66 2.17

Total (Electrical Energy) 273838 16.43 22.61

12

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2015-16

S.No Energy Saving Schemes Yearly Energy Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

1 Revamping of all 336 Nos of Primary Reformer tubes in Ammonia-I plant

20370.3 621 3700

2 Use of Additive in Coal fire Boilers at Power Plant

44621 209.5 56.8

Total (Thermal Energy) 64991.3 830.5 3756.8

13

PHULPUR UNIT-I

Major Energy Saving Schemes Implemented in

2015-16

S.No Energy Saving Schemes Yearly Energy Saving(KWh)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

3 Installation of 50 Nos of Occupancy Sensor in Office Room

82260 4.9 3.7

4 Installation of 6 Nos Solar Light Pipes in Store building.

8550 0.51 1.92

5 Replacement of 20 Nos of 400 Watt Flood Light by 200 Watt Induction Flood Light in Workshop & TG-I Area

12000 0.72 2.56

6 Replacement of 250 Watt HPMV Flood Light by 150 Watt Induction flood light at MatriPark in Ghiyanagar Township

2920 0.18 1.33

7 Replacement of Fluorescent Tube Light with Copper Ballast (53 Watt) & Electronic Ballast (39 Watt) by LED Tube Light (20Watt)

10775 0.6 1.0

Total (Electrical Energy) 116505 6.91 10.51

14

PHULPUR UNIT-I

1. Replacement of 2nd Stage Intercooler of Process Air Compressor in Ammonia –I Plant

Earlier the 2nd Stage intercooler of Process Air

Compressor was leaking frequently. Thereby

the Medium Pressure Steam consumed by

Process Air Compressor Turbine was

increased. But after replacement of old inter

cooler with new one, the leaking problem was

rectified and MS steam consumption in

Process Air Compressor Turbine is reduced.

Annual saving comes 36342.7 Gcal per year.

15

2nd Stage Intercooler of Air Compressor

PHULPUR UNIT-I

2.Installation of VAM System for CO2 cooling in Urea-I

Plant:

In Phulpur-I, a Vapour Absorption Machine

(VAM) is installed to generate chilled water

required for suction CO2 chilling of CO2

Compressor in Urea-I Plant. By this

modification, the suction temperature of CO2

at the suction of CO2 Compressor is reduced

to 20 deg C resulting saving of HP Steam

consumption. The heating medium in VAM

machine is waste heat of condensate from

Ammonia-I Plant.

Annual saving comes 7486.6 Gcal per year.

16

VAM for CO2 Cooling

PHULPUR UNIT-I

3. Installation of VAM for Suction Chilling of Air in Gas

Turbine Generator(GTG):

In Phulpur-I, a Vapour Absorption Machine

(VAM) is installed to generate chilled water

required for suction air chilling of Air

Compressor in GT-HRSG. By this modification,

the suction temperature of Air in Air

Compressor is reduced resulting in saving of

Power consumption. The heating medium in

VAM machine is waste heat of condensate

from Urea Plant.

Annual saving comes 29822 Gcal per year.

17

VAM for Suction Chilling of Air in GTG

PHULPUR UNIT-I

4. Installation of 350 KWp Solar Power Panels in Phulpur –I.

350 KWp Solar Power Panels has been installed at different locations such as

Bagging & Material Handling-I, Raw water Pump house, Central canteen and

Raw water storage tank to reduce power consumption. Annual saving comes

116970 KWH in 2017-18.

18Solar Power Panel in Phulpur-I

Solar Power Panels

PHULPUR UNIT-I

5. Replacement 220 W Street Light with 90 W LED:

To reduce the energy consumption, 150 Nos. of 220 W high pressure Sodium

Fixture has been replaced with 90 W LED Street light Fixture from front side

of Plant gate to Gate No 3. Annual saving comes 32184 KWH per year.

19Before After

PHULPUR UNIT-I

6. Replacement of 120 W HP Sodiun Fixture with 30 W LED:

To reduce the energy consumption, 400 Nos. of 120 W High Pressure Sodium

Fixture has been replaced with 400 Nos of 30 W LED Street Light fixtures in

Branch Road of Township. Annual saving comes 59417 KWH per year.

20Before After

PHULPUR UNIT-I

7. Replacement of 220 W HP Sodiun Fixture with LED Street

Light of 72 W :

To reduce the energy consumption, 100 Nos. of 220 W high pressure Sodium

Fixture has been replaced with 72 W LED Street light Fixture in Township from

Gate 4 to Gate No 1 in Township. Annual saving comes 24427 KWH per year.

21Before After

PHULPUR UNIT-I

8. Replacement of 40 W Normal Fluorescent tube light with

19 W LED Fixture:

To reduce the energy consumption, 160 Nos. of 40 W Normal Fluorescent tube

light has been replaced with 19 W LED Fixture in Bagging Platform. Annual

saving comes 10827 KWH per year.

22

Before After

PHULPUR UNIT-I

Solar Power Pack:

585 KWp Solar power pack installed

in plant and is connected to the LT

Grid.

UTILISATIONS OF RENEWABLE ENERGY

SOURCES

23

Solar Water Heaters

6 Nos. Solar Water Heater in Guest House

Bio-Methanation PlantCapacity : 25 m3/day

PHULPUR UNIT-ISolar Power Plant Installation :

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

• Additional Project for installation of 800 KWp(350 KWp + 450KWp) Solar Power Panels comprising of 7 different locations werecommissioned in November 2017.

• Both the Solar Power Units(1385 KWp) are in continuousoperation generating Electric Power in the tune of 439102 KWhand 629067 KWh for both Phulpur-I & II respectively in 2017-18.

• In the Year 2017-18, total Solar Power Generation was 1068.2MWh Unit (Both Phulpur I & 2) which is equivalent to reductionof 747.7 Tonne of CO2 emission.

24

PHULPUR UNIT-I

• Product Steward Excellence Certification by

International Fertilizer Association (IFA).

INTERNATIONAL ACCREDITATIONS

25

PHULPUR UNIT-I

26

INTERNATIONAL CERTIFICATIONS

PHULPUR UNIT-I

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

27

PHULPUR UNIT-IInstallation of Online Environment Monitoring System

Installed Transmitter & Receiver on Boiler Duct and Local Display

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

28

PHULPUR UNIT-I

On-Going Projects: Installation of new Electrostatic

Precipitator in Coal Boilers

• The Coal Based Boilers in Phulpur weredesigned with the emission norm of 250mg/Nm3 based on then prevailingEmission norms of Central PollutionControl Board (CPCB).

• These Electro-static Precipitators(ESP)are very old and their performance hasdeteriorated in due course of time andneeded improvement.

• Boiler No.1 commissioned in Dec. 2017& emission is less than 30 mg/Nm3. Theother Boilers are also being revampedfor emission less than 50 mg/Nm3.

ESP of Boiler No. 1

29

PHULPUR UNIT-IRaw 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

30

PHULPUR UNIT-I

6.57

5.49

7.50

6.18

1.010

0.950

0.9900.979

0.710

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 2017-18

Sp

. C

O2 E

mis

sio

n M

T/M

T o

f U

rea

CO

2 E

mis

sio

n in

Lakh

MT

Year

5.15

Carbon Foot Print

31

PHULPUR UNIT-IEnvironment & 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

32

PHULPUR UNIT-I

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

33

PHULPUR UNIT-I

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

34

PHULPUR UNIT-I

➢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

Monitoring & Reporting System

35

PHULPUR UNIT-ISample Performance Reports

36

PHULPUR UNIT-IEmployee 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 Independence Day 37

PHULPUR UNIT-IProcurement 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.

38

PHULPUR UNIT-I

National Energy Conservation Award- 2016 : 2nd Prize

Awards & Recognition

39

FAI Environment Protection Award :Joint Winner

18th National Award for Excellence in Energy Management by CII .

FAI Safety Award in Nitrogenous Fertiliser: Winner

PHULPUR UNIT-I

40

2016-17 2017-18

Total turn over of company/plant (Rs. Million)

12013.6 15264.7

Amount Invested in ENCON Projects (Rs. Million)

5153.3 372.5

Investment % 42.89 2.44

ENCON PROJECT BUDGET ALLOCATION

41

42