pre-feasibility study iffco phulpur...

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Pre-Feasibility Report for Modification/ Revamping of Ammonia-Urea Plant Including installation of GT-HRSG at IFFCO Phulpur

Introduction Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit –II in Year 1997. Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plantis based on HaldorTopsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti’s Italy. Energy Consumption: The average Energy Consumption of Phulpur Unit –I & II in last 3 years is as follows:

Table-1 Unit 2012-13 2013-14 2014-15 Average

Phulpur-I Gcal / MT Urea 6.697 6.736 6.651 6.695 Phulpur-II Gcal / MT Urea 5.716 5.668 5.634 5.673

As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced to 7.145 Gcal/MT Urea for Phulpur-I and 5.744 Gcal/MT Urea for Phulpur-II for the period of 1st June, 2015 to 31st March, 2018 and 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II for the period of 2018-19.

Table-2 Unit Unit Energy Norms as

per new Urea Policy 2015

Present Average Energy (in last 3 years)

Difference

Phulpur-I Gcal/MT Urea 6.5 6.695 - 0.195 Phulpur-II Gcal/MT Urea 5.5 5.673 - 0.173

In view of the above, it is proposed to implement various Modification/ Revamping of Ammonia-Urea Plant including installation of GT-HRSG at IFFCO Phulpur to implement the latest available proven Technological solution to improve Reliability of Process / Equipments and to reduce the Energy Consumption by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II.

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CHAPTER-I Executive Summary

Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit –II in Year 1997. Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plant is based on Haldor Topsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti’s Italy. Total Urea Production Capacity of Phulpur Unit is 5145 TPD (18.78 lakh MT per annum considering 365 stream days). Initially, Phulpur Complex was designed and operated with Liquid Hydrocarbon & Naphtha to be used as Feed and Fuel. In line with the Government of India (GOI) directives, the Feed Stock and Fuel was switched over from Naphtha to Natural Gas in the year 2006.

The Site occupies an area of 432 hectares out of which about 130 hectares is occupied by the plant where industrial activity is performed.

1. The actual production for last 3 year is given below:

Products

Actual production(MT) 2012-13 2013-14 2014-15

UNIT-I : Ammonia Urea UNIT-II: Ammonia Urea

403801 673102 532376 992011

384930 651704 546520 950884

334354 577824 511604 883854

Total: Ammonia Urea

936177 1665113

931450 1602588

845958 1461678

2. The present Raw material consumption:

Particulars Unit Phulpur-I Phulpur-II Total

Urea Production MTPD 2115 3030 5145 Feed NG SM3/day 819450 1124816 1944266 Fuel NG SM3/day 350062 655203 1005265 Coal MT/day 784.6 - 784.6 Fuel to SG SM3/day 36000 248650 284650 Ammonia Energy Gcal/MT 8.692 7.197 7.811 Urea Energy Gcal/MT 6.305 5.390 5.751

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3. The utilities (Water, Power & Steam) consumption.

The Water consumption of Phulpur Complex is around 35,500 M3 per day.The water is being sourced through Borewells provided within IFFCO premises.Normally4,200 M3 per day waste water which includes around 2,400 M3 per day Cooling water blow down is being generated which is treated in the Effluent Treatment Plant.Part of the treated Waste water is being recycled in the plant after treatment in Reverse Osmosis (RO) Plant. The reject of RO Plant is being used for dust suppression in Coal Yard/Ash Pond. The balance treated waste water is being used for Green Belt development, Horticulture and for dust suppression in Coal Yard and Ash Pond. There is no dischargeof effluent from the complex. The quality of treated effluent meets the limit specified by Pollution Control Board. The Online monitoring system for flow and quality of treated Effluent has been installed.

The Steam Generation facil i ty consists of 3x125 MT/hr Coal Fired Boilers(2 working and 1 standby), 1x200 MT/hr LSHS/Gas Fired Boiler, with total Steam Generation capacity of 450 MT Steam per hr. Around 32.7 MT per Hour Coal and 12,387 SM3 per Hr NG is being used.For meeting the total power requirement, Phulpur unit is having two Turbo Generators of capacity 12.5 MW and 18 MW respectively.

The Offsites facil i t ies include water De-Mineralisation plant, Water Softening Plant, Ammonia Storage Tank, Inert Gas generation unit and Air Compressors for Instruments and Plants.

4. Energy Consumption of Plants: The average Energy Consumption of Phulpur Unit –I & II in last 3 years is as follows:


Phulpur-I Gcal/MT Urea 6.697 6.736 6.651 6.695 Phulpur-II Gcal/MT Urea 5.716 5.668 5.634 5.673

5. Revamping / Modification of the Plant:

Urea business in India is covered under Essential Commodity Act (ECA) and same is governed by Department of Fertilizer (DoF), Government of India. As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced w.e.f. 1st June, 2015 tp 31st March, 2018 to 7.145 Gcal/MT Urea for Phulpur-I and 5.744 Gcal/MT Urea for Phulpur-II and for 2018-19, 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II.

Table-2

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Unit Unit Energy Norms as per new Urea

Policy 2015


Difference


From Table 1 & 2, it may be concluded that with present energy consumptions, the operation of Phulpur Complex willbecome unviable. Therefore, in order to remain competitive, IFFCO has undertaken Modification/ Revamping of its Ammonia–Urea Complex to reduce the Specific Energy consumption of Plant.

6. Proposed Modification/Revamping Schemes: It is proposed to implement various Modification/ Revamping of Ammonia-Urea Plant including installation of GT-HRSG at IFFCO Phulpurto implement the latest available proven Technological solution to improve Reliability of Process / Equipments andto reduce the Energy Consumption by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II.The configuration of Ammonia Urea Complex of Phulpur Unit along with proposed Revamping/ Modification is placed at Annexure-I.

7. Scope of Work of Engineering Consultant:

M/s CASALE, Switzerland was appointed for Basic Engineering Design

package for the proposed Revamping.

8. Estimated Cost of the Revamping:

Phulpur-I S.No. Proposed Modifiaction Plant Estimated

Cost (Rs. Lakh)

1. Modification in CO2 Recovery Process – aMDEA Process in place of existing GV Process

Ammonia 13600

2. New Efficient LO / SO Backpressure Turbines Ammonia 500

3. Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement

Ammonia 3200

4. Installation of VAM for Process Air Compressor Suction Chilling Ammonia 950

5. Ammonia Recovery from Synthesis Loop LP Purge Gases Ammonia 800

6. Saturated MP Steam Export from Synthesis Loop to Urea Plants Ammonia 600

7. Installation of MP Stripper for Process Condensate Stripping Ammonia 1600

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8. New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C) Ammonia 800

9. Synthesis Gas Converter (105D) Revamp Ammonia 2500 10. Installation of HP Ammonia Preheater Urea 1100

11. Installation of VAM for Urea CO2 Compressor Suction Chilling Urea 800

12. New Urea Reactor Trays Urea 600

13. New GT-HRSG package (GT + Electricals) SGP 21000

14. Replacement of Process Air Compressor Turbine (101-JT) & Refrigeration Turbine (105JT)

SGP 6000

15. Installation of New Ammonia Storage Tank (double wall double integrity), Capacity 10000 MT

4500

14. Sub Total 58550 15. Contingency (3%) 1585 16. Total 60135

Phulpur-II

S.No.

Schemes under consideration Plant Estimated Cost

(Rs. Lakh)

1. Revamping of Synthesis Gas Compressor Ammonia 4000

2. Modification in CO2 Recovery Process - aMDEA Process in place of existing GV Process

Ammonia 13600

3. Ammonia wash (syn gas drying) in synthesis compressor interstageand loop reversal

Ammonia 1200

4. Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement

Ammonia 3200

5. Revamping of CO2 Compressors Urea 8000

6. Installation of HP Ammonia Preheater (2Nos.) Urea 950

7. New Urea Reactor Trays (2 Set) Urea 1000

8. Sub Total 31950 9. Contingency (3%) 950

10. Total 32900

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9. Raw Material and Utilities Basic purpose of implementation of Revamping Schemes is to conserve the

Raw Materials i.e. Natural Gas, Coal and Water. There will be over all

saving of Natural Gas, Coal and Water in Phulpur Unit. No additional Raw

Materials will be required.

10. Project Implementation Plan & Time Schedule The Revamping Schemes will be implemented in two Phases. The

Schemes which are having high energy savings potential and required

relatively short lead time will be implemented in during 2016 turnaround and

while the complete project will be completed in 2017 turnaround.

11. Estimated Project Capital Cost

The estimated capital cost of Revamping is as under (Rs. in crore):

Sr No Units Equipment Cost*

BEDP DEDP Total

1. Phulpur-I 601.35 19 7 627.35

2. Phulpur-II 329.00 16 4 349.00

3. TOTAL 930.35 35 11 976.35

• including 3% Contingency BEDP : Basic Engineering Design Package DEDP : Detailed Engineering Design Package

12. Financial Analysis of project:

The overall saving in Urea specific energy and the financial analysis will be as under:

Particulars UNIT P-I P-II Total Urea Plant Capacity MTPD 2115 3030 5145 Energy Saving Gcal/MT 0.947 0.386 0.467 Estimated Investment RsCrore 627.35 349.00 976.35Monetary Savings RsCrore 151 97 248 Payback Years 4.16 3.60 3.94

13. Consumption of Raw Material and Utilities after Revamp.

The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM3per day after Revamp at same production level.Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation.

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TheWater consumptionof Phulpur Complexwill not increase after Revamp and there will be reduction of wastewater generation. There will be reduction in emission of SO2 due to partial replacement of Coal with NG having Sulphur content as low as less than10 ppm. Further, there will be reduction in daily consumption of NG which will reduce the over-all pollution load in the surrounding environment.

14. Emission Load- Before and after Revamp: The present emission loads of CO2around 138.6 MT/hour considering the present Fuel consumption. After revamp the emission load of CO2 would be 95.3 MT / hour considering the projected Fuel consumption maintaining the same production level. Further, the emission level of PM, SOx&NOx is expected to reduce due to reduction in consumption of NG and Coal at same production level as explained above. Further, there will be reduction of wastewater generation around 900 m3 per day at same production level.

15. Capacity of the Plant after Revamp: The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remainthe same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days).

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CHAPTER-II SITE ANALYSIS

IFFCO Phulpurwas commissioned in the year 1981 and running successfully since then. Several modernization schemes have been implemented successfully in the past. The prime factor with respect to connectivity plays an important role in successful implementation of the project as per schedule.

IFFCO Phulpur is located at Phulpur Tehsil in Allahabad District of Uttar Pradesh. The site is located at a distance of 30 km North East of Allahabad city on the UP state highway no. 7, connecting Allahabad to Jaunpur and Gorakhpur. Phulpur, which is a Tehsil, is about 6 km away from the site and is linked with Broad Gauge Rail link on the Varanasi-Allahabad route.

Phulpur fertilizer complex is spread over an area of about 432.2 Ha of land. The ownership of the land is with Indian Farmers Fertiliser Co-operative Limited (IFFCO), a national level cooperative society engaged in the manufacture and marketing of various fertilizers. The proposed project shall be established within plant premises of existing complex near Urea-I Plant.

Since the project shall be implemented within existing plant premises, there would no change in existing land use pattern.

Eco-sensitive Areas:

The project is limited to installation of GT & HRSG without any change in production profile. There will be reduction in natural resource and energy per capital of finished production.

It is envisaged that there is no Wild Life Sanctuary, National Park, Reserved Forest within 10 km radius of the project area.

Topography:

Phulpur Fertilizer Complex is located in Phulpur tehsil of Allahabad district. The project area falls under the central Ganga alluvial plain. Ganga and Yamuna are the most important rivers of the district. Other rivers which flow in the district and at the end meet with Ganga or Yamuna are Tons and Belan, The holy Ganga and Yamuna confluence in 3 the middle of the district at Allahabad town and flow in the shape of 'Y' alphabet which divide the district in three physiographic tracts namely Trans-Ganga region, Doab region and Trans-Yamuna region. The northern part of Allahabad district, popularly known as Gangapar, is endowed with good fertile soil for cultivation of food grains, pulses, oil seeds and vegetables. The southern part of Allahabad, known as Yamunapar is partly hilly and agriculturally backward. (Source: District Industrial Profile of Allahabad.).

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Existing Facilities:

Indian Farmers Fertiliser Co-operative Limited (IFFCO) is a national level cooperative society engaged in the manufacture and marketing of various fertilizers. The Society, registered as an autonomous cooperative under the Multi State Cooperative Societies Act, 2002, was born out of the Indian farming community’s initiative along with the Government of India on 3rd November, 1967 for making available much-needed fertilizer at the farmer’s doorstep from plants owned by them through their own distribution channels.

IFFCO Phulpur Unit is a well established fertilizer complex spread over an area of 432.2 Ha of land. In addition to industrial activities, there exists residential area for providing accommodation to its employees. The residential accommodations are well furnished and well connected with metallic road with water supply and electricity. Water is being supplied to the residential colony through underground pipelines. Source of power is own power generation plant. All the other infrastructural facilities like school, play grounds etc are well maintained. In addition to above facilities, IFFCO has established Diary, Fishery and Agro Farms to provide training to the farmers and best uses of fertilizers. The colony has a good sewerage system and the township sewage are treated in a dedicated Sewage Treatement Plant. The treated sewage is used as irrigational water.

Soil Classification:

Phulpur area falls in northern part of Allahabad district, popularly known as Gangapar and is endowed with good fertile soil for cultivation of food grains, pulses, oil seeds and vegetables. The soil texture is predominantly clayey in nature and of light grey colour. The pH of soil is slightly alkaline having pH around 8.0 to 8.5. The porosity varies from 46 to 50%. The cation exchange capacity varies from 12.2 to 19.0 meq/100g of soil. Nitrogen & Phosphorous ratio has been found around 1:10.

Climate of Phulpur:

PhulpurTehsil falls under humid subtropical climate that is common to cities in north-central India. Phulpur experiences three seasons: hot dry summer, cool dry winter and warm humid monsoon. The summer season lasts from April to June with the maximum temperatures ranging from 40 °C (104 °F) to 48 °C (118 °F). Monsoon begins in early July and lasts till September. The winter season lasts from December to February.

The temperature of the area has been found to vary between 3.8 to 480C. The Humidity has been found to vary 13 to 97%. Annual rainfall of the area is about 1000mm with an average rainy day of 48 days. The wind speed of the area varies from 1.8 to 13.0 Kmph. The dominant wind direction is W & SW.

Social Infrastructure

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The residual colony of IFFCO Phulpur falls in SaraiAbdulmalikPanchayat of Phulpur tehsil. SaraiAbdulmalik is a Census Town city in district of Allahabad, Uttar Pradesh. The SaraiAbdulmalik Census Town has population of 4,815 of which 2,509 are males while 2,306 are females as per report released by Census India 2011.

Population of Children with age of 0-6 is 496 which is 10.30 % of total population of SaraiAbdulmalik (CT). In SaraiAbdulmalik Census Town, Female Sex Ratio is of 919 against state average of 912. Moreover Child Sex Ratio in SaraiAbdulmalik is around 765 compared to Uttar Pradesh state average of 902. Literacy rate of SaraiAbdulmalik city is 80.62 % higher than state average of 67.68 %. In SaraiAbdulmalik, Male literacy is around 89.72 % while female literacy rate is 70.92 %.

SaraiAbdulmalik Census Town has total administration over 930 houses to which it supplies basic amenities like water and sewerage. It is also authorize to build roads within Census Town limits and impose taxes on properties coming under its jurisdiction.

Caste Factor

Schedule Caste (SC) constitutes 7.46 % of total population in SaraiAbdulmalik (CT). The (CT) SaraiAbdulmalik currently doesn’t have any Schedule Tribe (ST) population. Work Profile

Out of total population, 1,242 were engaged in work or business activity. Of this 1,087 were males while 155 were females. In census survey, worker is defined as person who does business, job, service, and cultivator and labour activity. Of total 1242 working population, 77.21 % were engaged in Main Work while 22.79 % of total workers were engaged in Marginal Work.

The plant area of phulpur fertilizer complex falls in Tisaura village. Tisaura is small village located in Phulpur Tehsil of Allahabad district, Uttar Pradesh with total 285 families residing. The Tisaura village has population of 1952 of which 1033 are males while 919 are females as per Population Census 2011.

In Tisaura village population of children with age 0-6 is 291 which makes up 14.91 % of total population of village. Average Sex Ratio of Tisaura village is 890 which is lower than Uttar Pradesh state average of 912. Child Sex Ratio for the Tisaura as per census is 753, lower than Uttar Pradesh average of 902.

Tisaura village has higher literacy rate compared to Uttar Pradesh. In 2011, literacy rate of Tisaura village was 75.20 % compared to 67.68 % of Uttar Pradesh. In Tisaura Male literacy stands at 89.50 % while female literacy rate was 59.57 %.

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As per constitution of India and PanchyatiRaaj Act, Tisaura village is administrated by Sarpanch (Head of Village) who is elected representative of village.

Caste Factor

Schedule Caste (SC) constitutes 17.16 % of total population in Tisaura village. The village Tisaura currently doesn’t have any Schedule Tribe (ST) population. Work Profile

In Tisaura village out of total population, 602 were engaged in work activities. 85.38 % of workers describe their work as Main Work (Employment or Earning more than 6 Months) while 14.62 % were involved in Marginal activity providing livelihood for less than 6 months. Of 602 workers engaged in Main Work, 190 were cultivators (owner or co-owner) while 125 were Agricultural labourer.

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CHAPTER-III Land Use Planning

IFFCO fertilizer complex is spread over an area of 432.2 Ha of land. Total available is being used as under:

DESCRIPTION AREA (HA) Percentage

of Total Land Plants and Storage 130 30.08 Township 74.5 17.24 Green Belt Development (Plant) 26.4 6.11 Roads/Guard Pond /Township Gre 50.2 11.61 Ash Pond 74.8 17.31 Demonstration Form of (CORDET) 76.3 17.65 Total Land 432.2 100.00

Total green belt area within IFFCO Phulpur premises (Plant, Township, Cordet, Ash Pond): 123 HA As the project proposal is limited to installation of Gas Turbine (GT) in place of Steam Turbine (ST) as well as installation of Heat Recovery Steam Generation (HRSG) as energy saving only. Hence, additional land use planning is not envisaged.

Green Belt Development :

About 350 acres of land is under green belt.The land provided for the factory and township was originally “USAR” land and was lying unutilized from long time. IFFCO had taken a challenge to reclaim this usar land and it has been converted into a green land. 50 to 200 m wide green belt has been developed around the complex. Today, the entire area is full of trees and vegetation. About 3.0 Lakh trees of wide variety of about 30 species including some of

medicinal species imparts scenic beauty besides providing suitable habitat for

birds and other flora and fauna. The greenery and the scenic beauty of

SanjivaniVatika, Buddha Vihar, NandanUdyan, SarasKunj, etc. are remarkable

and imparts healthy environment. The species of plants planted are Peepal,

NeemShesham, Pakad, Jamun, Guava, Arjun, Amla, Bel, Kanji, Ashok,

Casurina, Gulmohar, Amaltas, Harre, Bahera, Karenj, Bottlebrush etc.

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CHAPTER-IV 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. The complex has won number of awards for its environment improvement efforts.

Assessment of Infrastructure Demand: The existing infrastructural facilities available at IFFCO Phulpur are having all the basic requirements and are updated from time to time. Hence, there shall be no demand of infrastructure during establishment of proposed project.

Amenities/ Facilities: IFFCO Phulpur is having all the required amenities and facilities. Safety, healthy, environmental, social, cultural requirements are periodically assessed and updated as per requirements.

Proposed Infrastructure: The existing infrastructure of IFFCO Phulpur with respect to residential colony, green belt, Social infrastructure, road and rail facilities, supply of water, sewerage facilities, power requirement etc. are readily available and are working efficiently. In view of the size and magnitude of proposed project, no additional infrastructure is envisaged.

Rehabilitation & Resettlement Plan: IFFCO Phulpur fertilizer complex is spread over an area of 432.2 Ha of land. The total area of land is in possession of IFFCO Management since 1967. The proposed project shall be established within plant premises of existing

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PhulpurFertilizer Complex. Hence, any planning with rehabilitation & resettlement is not applicable.

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CHAPTER-V Description of Energy saving schemes to be implemented in Ammonia plant Phulpur-I Unit

Scheme-1: Reduction in Steam to Carbon ratio in Reforming Section from

3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal Section.

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas.

Scheme-2: Replacement of Process Air Compressor Turbine and Refrigeration Compressor Turbine in Ammonia-I Plant.

The Turbines will be replaced with new efficient turbines. The Replacement will be on the same base frame and inlet & outlet connections will be hooked-up with existing lines

Scheme-3: New Efficient LO / SO Back Pressure Turbines.

After changeover from GV to aMDEA System the LP Steam reboiler will be no more required. If the inefficient lube oil and seal oil turbines are not replaced, the LP Steam will be required to vent. With the replacement of New Efficient Steam Turbines there will be less generation of LP Steam and avoiding venting of steam.

Scheme-4: Installation of Fuel Gas Expander with power generator.

NG fuel which is let down in existing system from around 40 kg/cm2g to 4.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW.

Scheme-5: Installation of Vapour Absorption Machine for the cooling of inlet air to Process Air Compressor.

A Vapour Absorption Machine (VAM) shall be installed in Ammonia-I to generate chilled water for new process air chiller to be installed at the suction of Process Air Compressor. This shall cool the inlet air of Process Air Compressor from 40°C to 15°C, resulting in saving of NG being used as fuel for Gas Turbine drive of Process Air Compressor. The heating medium in VAM machine shall hot water from Primary Reformer Convection Coil.

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Scheme-6: Ammonia Recovery from Synthesis Loop LP Purge Gases.

It is proposed to recover ammonia from the flash gas from synthesis loop off gas in new Flash Gas Washing Column. This modification shall result in additional Ammonia Recovery of 2 MT/Day.

Sweet Water Cooler system shall be replaced with new heat exchanger using cooling water directly as cooling medium for better cooling of syn gas. This shall also reduce loop pressure by around 5 kg/cm2 and steam saving in Syn Gas Compressor turbine by around 2 MT/hr.

Scheme-7: Saturated MP Steam Export to Urea Plant.

The Saturated MP Steam will be exported to Urea Plant for use of Process Steam at 25 ata pressure after letdown from 39 ata. This will reduce requirement of Inlet Steam in CO2 Compressor Extraction- cum- Condensing Turbine of Urea Plant as there will be less requirement of extraction steam.

The Net Saving will be realized in terms of less condenser load of Synthesis Turbine and CO2 Turbine together.

Scheme-8: Installation of MP Stripper for Process Condensate Stripping.

The existing system will be replaced with MP Steam Process Condensate Stripper. With the proposed modification, the MP Steam is used which after stripping off the gases goes back to the steam circuit.

Scheme-9: New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C).

Existing 115-C is not sufficient enough to cool down the syn gas to the optimum temperature of 39 – 40 degC. With additional Exchanger I parallel the cooling water availability will be increased which will reduce the syn gas temperature.

In the new system one additional BFW Heater will be installed to recover heat from the hot process gas before it enters the CO2 Removal Section.

Scheme-10: Synthesis Gas Converter (105D) Revamp.

It is proposed to revamp the internals of Synthesis Gas Compressor with new patented technology internals. This intervention will result in improvement in the NH3 Conversion from 2.5 to 17 mol% and maximizing the heat recovery in the form of steam generation.

Description of Energy saving schemes to be implemented in Urea plant of

Phulpur-I Unit

Scheme-1: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion.

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The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor.

Scheme-2: Installation of Ammonia Preheaters.

In Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce.

Scheme-3: Installation of Vapour Absorption Machine for the cooling of inlet CO2 gas to CO2 Compressor.

A Vapour Absorption Machine (VAM) shall be installed to generate chilled water required for CO2 Gas chiller to be installed at the suction of CO2 Compressor of Urea plant. This shall cool inlet CO2 gas of CO2 Compressor from 45°C to 20°C, resulting in saving of steam consumption in CO2 Compressor turbine of Urea plant. The heating medium in VAM machine shall be LP steam.

Description of Energy saving schemes to be implemented in Ammonia Plant ofPhulpur-II Unit

Scheme-1: Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section for less energy requirement.

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated in three stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The source of regeneration energy shall be only process gas. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas.

Scheme-2: New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge.

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In order to increase the energy efficiency of the synthesis loop, a syngas dehydration system based on liquid ammonia washing shall be introduced at Synthesis Gas Compressor second stage discharge. The oxygenated compounds (H2O, CO and CO2) available in Syn Gas shall be separated in ammonia wash system. With this modification, Syn Gas Compressor 3rd stage discharge which is free from oxygenated compounds, can be mixed directly with recirculator discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st Ammonia Synthesis converter. With this modification, there shall be reduction in power requirement in tubine drive of Synthesis Gas Compressor by around 900 KW.

Scheme-3: Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency.

Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced by new barrels for increasing the efficiency of Syn Gas Compressor. This shall result in saving in steam requirement in turbine drive of Synthesis Gas Compressor by around 10 MT/hr.

Scheme-4: Installation of Fuel Gas Expander with power generator.

NG fuel which is let down in existing system from around 40 kg/cm2g to 5.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW.

Description of Energy saving schemes to be implemented in Urea plant of Phulpur-II Unit

Scheme-1: Replacement of existing CO2 Compressors by new higher efficiency compressors.

In both 31 & 41 Units of Urea plant, existing CO2 Compressor shall be replaced with new CO2 Compressor of higher efficiency. This shall result in saving in steam consumption in steam turbine drive of CO2 Compressor by around 9 MT/hr.

Scheme-2: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion.

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor.

Scheme-3: Installation of Ammonia Preheaters.

In both streams of Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the

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ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce.

Description of Energy saving schemes to be implemented in Steam & Power Generation Plant.

Scheme-1: New GTG-HRSG Package for Power and Steam Generation.

The Proposed System, GTG-HRSG will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam.

In Phulpur Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is 12500 Sm3/Hr RLNG and 250 MTPD Coal. Whereas, the same quantity of Electric Power & HP Steam will be generated by only 9455 Sm3/Hr RLNG in GT-HRSG

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CHAPTER-VI The Impact of proposed Revamp:

1. Energy Consumption:

The average Energy Consumption of Phulpur Unit –I & II in last 3 years is as follows:


Phulpur-I Gcal / MT Urea 6.697 6.736 6.651 6.695 Phulpur-II Gcal / MT Urea 5.716 5.668 5.634 5.673

As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced to 7.145 Gcal/MT Urea for Phulpur-I and 5.744 Gcal/MT Urea for Phulpur-II for the period of 1st June, 2015 to 31st March, 2018 and 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II for the period of 2018-19.

Table-2 Unit Unit Energy Norms as

per new Urea Policy 2015


Difference


Modification/ Revamping of its Ammonia–Urea Complex has been undertaken to reduce the Specific Energy consumption of Plant by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II.

2. Consumption of Raw Materials:

The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM3per day after Revamp.Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation from 274 MT to about 91 MT.

3. Consumption of Utilities (Water, Steam & Power);

(i) Power Consumption:

Presently the total power requirement of 23 MW is being met by two Nos. of Turbo Generator (TG) of 12.5 MW and 18.0 MW Capacity.Now it is proposed to install GTG-HRSG which will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam.

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In Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is 12500 Sm3/Hr RLNG and 250 MTPD Coal. The GTG-HRSG will generate 23.65 MW Electric Power &60 MT/HrHP Steam by using only 9455 Sm3/Hr RLNG in GT-HRSG. Hence, the Coal consumption will reduce by 250 MTPD. After installation of GT-HRSG both the TG will be stopped. Further, one No. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped.The Power Balance before and after Revamp are as under:

Before Revamp

After Revamp

Increase after Revamp

1. Generation MW MW MW

(i) TG-I 10.5 - (ii) TG-II 12.5 - (iii) New GT-HRGS - 23.65

Total generation 23.0 23.65 0.652. Consumption (i) Ammonia-I 0.55 0.37 (-)0.18

(ii) Urea-I 2.58 2.57 (-)0.01(iii) Ammonia-II 1.10 2.50 1.40(iv) Urea-II 3.50 3.18 (-)0.32

(v) Ammonia-I CT 1.40 1.40 0

(vi) Urea-I CT 1.80 1.82 0.02

(vii) Ammonia-II CT 1.00 2.55 1.55

(viii) Urea-II CT 2.50 2.60 0.10(ix) Offsites& nonplants 4.26 4.26 0

(x) CDR 1.10 1.10 0

(xi) SGP I&II 3.15 1.30 (-)1.85

Total consumption 22.94~ 23.00

23.65 0.65

(ii) Steam (HP) balance:

There are three Nos. Coal Fired Steam Generation plants of 125 MT/hrcapacity Coal Fired Boilers(2 working and 1 standby), and one No.LSHS/Gas Fired Boiler of 200 MT/hrcapacity. Further, in Ammonia-II, 94.40 MT/Hr HP Steam is generated.

After installation of GT-HRSG, one Nos. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped.

The Steam Balance before and after Revamp are as under:

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Before Revamp

After Revamp

Decrease after Revamp

1. HP Steam Generation MT per hr MT per hr MT per hr

(i) SGP-I 189.70 72.00 117.70(ii) SGP-II 94.60 0 94.60(iii) Ammonia-II 94.40 93.80 0.60(iv) New GT-HRGS - 48.80 (-)48.80

Total generation 378.70 214.60 164.102. HP Steam Consumption (i) Ammonia-I 41.50 37.60 3.90(ii) Urea-I 87.20 54.70 32.50(iii) Urea-II 128.00 122.30 5.70

(iv) TG-I 56.80 0 56.80(v) TG-II 65.20 0 65.20

Total consumption 378.70 214.60 164.10

(iii) Water Balance:

TheWater consumptionof Phulpur Complex is around 35,500 M3 per day. Out of this 25,680 M3 per day is being used in Cooling Tower, 4,345 M3 per day is being used inDM Plant, 1,370 M3 per day is being used for Service Water requirement and 4,105 M3 per day is being used in Township.TheWater consumptionof Phulpur Complex after Revamp will reduce to 30,120 M3 per day, at same production level (reduction by 5,400 M3 per day) which includes 22,800 M3 per day is being used in Cooling Tower and 1,850 M3 per day is being used inDM Plant. The Water requirement for Services and Township may remains unchanged. Due to reduction in water consumption, there will be substantial reduction of about 900 m3/day of wastewater.

The Water Balance before and after Revamp are as under:

Before Revamp After Revamp Decrease after Revamp

M3/ hr M3/ day M3/hr M3/day M3/hr M3/ day 1. Raw Water

supply 1479 35496 1255 30120 224 5376

2. Consumption (i) Cooling Tower 1070 25680 950 22800 120 2880(ii) DM Plant/CPU 181 4344 77 1848 104 2496

(iii) Service Water 57 1368 57 1368

- -

(iv) Township use 171 4104 171 4104 - -

Total 1479 35496 1255 30120 224 5376

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consumption

3. Waste water generation (i) C.T. Blow

down 100 2400 70 1680 30 720

(ii) DM/CPU waste

75 1800 68 1632 7 168

(iii) Waste water from

Ammonia/ Urea/SGP

- - - - - - (occasional) (occasional)

Total waste watergeneration

175 4200 138 3312 37 888

(iv) Pollution Load: The Natural Gas (NG)is being used as Feed and Fuel whereas Coal is being used as Fuel. The consumption of NG and Coal at three scenario i.e. (i) Present Production of 5145 MTPD Urea; (ii) Production of 5145 MTPD Urea after Revamp;and (iii) Production of 5660 MTPD Urea after revamp (10% increase in capacity) have been derived as under: S No. Particular Plant / Section Unit Present 5145

MTPD 5145 MTPD

after Revamp

1) Feed Phulpur-I Sm3/Hr 34144 33450

Phulpur-II Sm3/Hr 46867 46860

Total Phulpur-I + II Sm3/Hr 81011 80310

2) Fuel Ammonia-I Primary Reformer

Sm3/Hr 12486 12200

Ammonia-I Aux. Boiler

Sm3/Hr 2100 1950

SGP Boiler 1,2,3 Sm3/Hr 1500 1500 Ammonia-II

Primary Reformer Sm3/Hr 16551 15910

Ammonia-II PAC GT-HRSG

Sm3/Hr 10749 9284

SGP Boiler 4 Sm3/Hr 10887 -

GTG-HRSG Sm3/Hr - 9597

Total Phulpur-I + II Sm3/Hr 54273 50441

3) Total Feed+ Fuel

Phulpur-I + II Sm3/Hr 135284 130751

MMSCMD 3.2468 3.1380

4) Coal SGP Boiler 1,2,3 MT/Hr 32.7 11.0

MTPD 785 264

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5) CO2 Emission

Phulpur-I + II MT/Hr 138.6 95.3

Emission factors: Source IPCC GudlinesVol 2 Table 1.4

It may be observed that the NG consumption will reduce by 1,08,800 SM3 per day after Revamp, whereas there will be reduction of 521 MT per day Coal at this production level. Hence, CO2emission will reduce by 43.30 MT/Hrafter Revamp.

(iv) Production Capacity:

The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remainthe same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days).

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Brief description of Modification/ Revamping of Ammonia-Urea Plant Including installation of GT-HRSG at IFFCO Phulpur

Layout of the Plant

pre-feasibility study iffco phulpur...

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