th

18 National Award for

Excellence in Energy
Management - 2017

Presented By:
Indian Farmers Fertiliser Cooperative Ltd.
 Phulpur Unit-I
th st
30 August – 1 September, 2017
IFFCO: At a Glance
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 )

Installed/Revamped Annual Capacity (‟000 MT)

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 21% to the total „N‟ and 31.8% to the total “P2O5”
produced in the Country during the year 2016-17.

2
4
IFFCO Phulpur Unit-I : Profile
Plant Ammonia Urea
Process MW Kellog, Snamproget
Licenser U.S.A Italy
Daily 1215 2115
Capacity
(MTPD)
Annual 4.0 7.0
Capacity
(Lakhs MT)
Till Date 119 205
Production
(Lakhs MT)

5
IFFCO Phulpur Unit-I : Production Outline
RLNG COAL RLNG
Utility Boiler
GTG-HRSG Ammonia Plant

HP Steam

HP Steam CO2 Ammonia

Power HP
Steam
RAIL

Neem Urea
ROAD

Bagging Plant Urea Plant 6

Phulpur-I: Production Performance
Highest Ever Yearly
9.0 Urea Production
ESTIMATED
7.58 7.65
8.0
6.52 6.32
7.0
5.78
6.0

5.0 4.32 4.4

3.85 3.49
4.0 3.34 3.11
Actual Till
3.0 1.89 Date
2.0

1.0

0.0
2013-14 2014-15 2015-16 2016-17 2017-18

Ammonia Urea
7
Phulpur-I : Sp. Energy Consumption
6.1
6.0
5.9
7. 5.8
2
5.7
7.
1
7.
0
6.
9
6.
8
6.
7
6.
6
6.
5
6.
4
6.
3
6.
2
 6.74 6.74
6.70
in Gcal/MT
6.65 of 6.64
Urea
B
e NUP Norm: 6.5
s (From April 2018)
t 0.79
E
v
e 5.97
r 5.85
5.80
Y
e
a 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2017-18 2018-
r 19
l
upto upto
y
YearAug '17 March '18
E
8
n
e
r
g
y
Major Energy Saving Schemes
Implemented in 2016-17
S.No Energy Saving Schemes Energy Monetary Investment
Saving Saving (Rs. Lakh)
(Gcal) (Rs. Lakh)
1 Installation of New Gas Turbine 251262 7287 23914
Generator (GTG) - Heat Recovery
Steam Generation (HRSG)
2 Modification in CO2 Recovery 136851 3969 19004
Process- aMDEA Process in place
of Benfield Process
3 Installation of New Medium 73442 2130 1032
Pressure Process condensate
stripper (1104-E)
4 Old Synthesis Gas Converter 48961 1420 1331
(105-D) Internal Revamp
5 Installation of Ammonia recovery 24481 710 1025
section to recover ammonia from
off gases of synthesis loop
9
Major Energy Saving Schemes
Implemented in 2016-17
S.No Energy Saving Schemes Energy Monetary Investment
Saving Saving (Rs. Lakh)
(Gcal) (Rs. Lakh)
6 Replacement of Old Refrigeration 44145 1280 1443.5
Compressor Turbine with New
Turbine in Ammonia Plant
7 Replacement of Old Air 53777 1560 1443.5
Compressor Turbine with New
Turbine in Ammonia Plant
8 Replacement of Mixed Feed and 9632 279 1044
Process Air Coil and installation of
New VAM Coil in Ammonia Plant
9 New Urea Reactor with Casale 13959 405 460
High Efficiency Tray in Urea Plant
10 Installation of Ammonia Preheater 6980 202 167
in MP Section of Urea-I

10
Major Energy Saving Schemes
Implemented in 2016-17
S.No Energy Saving Schemes Energy Monetary Investment
Saving Saving (Rs. Lakh)
(Gcal) (Rs. Lakh)
11 Installation of CO2 Cooler through 5584 162 650
VAM in Urea Plant
Total (Thermal Energy) 669074 19404 51514

S.No Energy Saving Schemes Saving Savings Investment

(KWh) (Rs. Lakh) (Rs. Lakh)
12 Replacement of 18 W LED tube 262800 15.77 20.44
light in Township quarter in place
of 36 W Fluorescent tube light
13 Replacement of 75 Nos 36 W LED 11038 0.66 217
Fixtures in place of 36 W 110 nos
CFL fitng
Total (Electrical Energy) 273838 16.43 237.44
11
1. Installation of New GTG-HRSG
Key Features

Power Generation: 25 MW

Steam Generation: 60 MTPH

RLNG Saving : 3600 Sm3/Hr

Energy saving : 0.36 GCal/MT of Urea

Monetary saving :Rs. 73 Cr.


Investment :Rs. 239 Cr.


The new GTG is catering the total power demand (24 MW) of the
Phulpur Complex and existing Steam driven Turbo-generators TG-I
and TG-II have been stopped.

The 60 MT HP steam generated from HRSG is being used in
process plants 12
2. Modification in CO2 Recovery Processs
CO2 Absorber Modification in CO2 Recovery Process
-aMDEA Process
CO2 Lean Absorber
Modified HP Stripper New HP/LP Flash Tower
Old LP Stripper New CO2 Bulk Absorber

dismantled

CO2 Strippers

• With modification in CO2 Removal Section from Benfield to aMDEA,

Regeneration Energy of CO2 has reduced from 950 Kcal/NM3 of
CO2 to 450 Kcal/Nm3 of CO2.
• Yearly Saving (Gcal) : 136851
• Yearly Saving (Rs. Crore) : 39.69
• Investment (Rs. Crore): 190 13
3. Installation of New Medium
Pressure Process Condensate
Stripper (1104-E)

Old LP Stripper New MP Stripper

• In the Low Pressure Steam Process Condensate Stripper, around

8 MT/Hr of LP Steam was being consumed for Stripping.
• In new Medium Pressure Stripper, MP Steam is used as Process
Steam.
• Yearly Saving (Gcal) : 73342
• Yearly Saving (Rs. Crore) : 20.3
• Investment (Rs. Crore) : 10.3 14
4. Synthesis Gas Converter Internal Revamp

Due to internal revamp, the

conversion efficiency of ammonia in
converter is increased & the recycle
gas flow rate is reduced which
resulted saving of Power in
Synthesis Gas Compressor.
Ammonia Conversion:

Particular Old Converter

105-D(Out)
Before (%) 15.48
After Revamp (%) 17.32 New Converter Internals
• Yearly Saving (Gcal) : 48961

• Yearly Saving (Rs. Crore) : 14.2

• Investment (Rs. Crore) : 13.3

15
5. Installation of Ammonia recovery section

• Ammonia recovery section has

been installed to recover ammonia
from off gases of synthesis loop
under Energy Saving Schemes.
• Earlier, Off gases from Synthesis
loop was sent to Primary Reformer
& used as a fuel but after
implementation of this scheme
ammonia in Off gases has been
recovered & thereby reduction in
specific energy consumption.

• Yearly Saving (Gcal) : 24481 New Ammonia Distillation

• Yearly Saving (Rs. Crore) : 7.10 Column (1501-E)
• Investment (Rs. Crore) : 10.25

16
6. Installation of new Refrigeration
Compressor Turbine in place of old
Turbine

• Inefficient Old Refrigeration

Compressor Turbine has been
replaced with New efficient
Turbine which has resulted in
reduction in Specific Steam
consumption.

• Yearly Saving (Gcal) : 44145

• Yearly Saving (Rs. Crore) : 12.8
• Investment (Rs. Crore) : 14.4 New Refrig. Compressor Turbine
17
7. Installation of new Process Air
Compressor Turbine in place of old
Turbine

• Inefficient Old Refrigeration

Compressor Turbine has been
replaced with New efficient
Turbine which has resulted in
reduction in Specific Steam
consumption.

• Yearly Saving (Gcal) : 53777

• Yearly Saving (Rs. Crore) : 15.6 New Process Air Compressor Turbine
• Investment (Rs. Crore) : 14.4
18
8.Replacement of Primary Reformer
Convection Section Coils and new VAM
Coil
• For higher heat recovery, old Mixed feed & Process Air coil has
been replaced with new coils in convection section of Primary
Reformer. Additional a new VAM Coil has been installed where the
process condensate is heated and this heated Process
condensate is utilized in VAM Machine. .

• Yearly Saving (Gcal) : 9632

• Yearly Saving (Rs. Crore) : 2.8
• Investment (Rs. Crore) : 10.4 19
9. New Urea Reactor High Efficiency Trays

• New Urea Reactor with High

Efficiency Trays (HET) in Urea
Plant has been installed.

• The function of the HET trays is to

increase the CO2 conversion, by
improving the heat and mass
transfer phenomena occurring
inside the reactor.

• Yearly Saving (Gcal) : 13959

• Yearly Saving (Rs. Crore) : 4.0 High Efficiency Trays
• Investment (Rs. Crore) : 4.6

20
10. Installation of Ammonia Preheater in Urea

• 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 is reduced.

Erection of Ammonia Preheater

• Yearly Saving (Gcal) : 6980

• Yearly Saving (Rs. Crore) : 2.0
• Investment (Rs. Crore) : 1.7 21
11. Installation of CO2 Cooler through VAM

• A Vapour Absorption Machine (VAM) is installed to generate chilled

water required for CO2 Gas chiller at the suction of CO2 Compressor
of Urea plant, resulting in saving of steam consumption in CO2
Compressor turbine of Urea plant.

Chilled Water

Return Water

VAM CO2 Cooler

• Yearly Saving (Gcal) : 5584

• Yearly Saving (Rs. Crore) : 1..6
• Investment (Rs. Crore) : 6.5 22
 Other Energy Saving Schemes

(A) Replacement of 18 W LED tube light

in place of 36 W Fluorescent tube
light
Yearly Savings

Power : 262800 kWh

Saving : Rs. 15.7 Lakh

Investment : Rs. 20.4 Lakh

(B) Replacement of 75 Nos 36 W LED

Fixtures for Control rooms in place of
36 W 110 nos CFL fitting
Yearly Savings

Power : 11038 kWh

Saving : Rs. 0.66 Lakh
 Investment : Rs. 2.1 Lakh
22
23
INNOVATIVE SCHEME

• Utilization of waste heat of process condensate from Urea Plants to

generate chilled water through VAM. This chilled water is being used
for suction chilling of GTG Air which has helped to augment GTG
Capacity by 4 MW and running additional motor driven pump instead
of turbine driven pumps.

• Removal of check valve in the low pressure (0.65 kg/cm2g) CO2 gas
line between Ammonia & Urea Plant (HAZOP is essential) which
helped in increment of CO2 Compressor Suction Pressure by 0.04
kg/cm2. This has resulted in HP Steam saving of 1.8 MT/Hr equivalent
to 11120 Gcal / Annum.

• Utilization of excess chilled water available in the complex to reduce

CW temperature at the suction of syn gas cooler by installing spare
plate type exchanger which helped to reduce the syn gas temperature
at suction of compressor by 3 degC.

24
ROADMAP FOR ENERGY CONSERVATION
2018-19 2019-20 2020-21
1. Installation of 1. No planned Annual 1. Replacement of 40
additional Syn loop waste shutdown to avoid years old CO2
heat boiler for additional unproductive energy Compressor Turbine
process steam consumption in the tune with highly efficient
production. of 0.05 Gcal/MT of Urea Turbine.
2. Replacement of LT which means special care
Superheat coil in Primary to be taken in maintaining
Reformer Convection the Cooling water quality
Section for higher steam and optimization of
consumption and process plants with
bringing down the stack minimum variation.
temperature to around
130 degC.
3. Replacement of
Secondary Reformer Air
Burner for reduced Air
Compressor Discharge
Pressure.
25
Carbon Foot Print
8.5 1.10

1.010 0.990 1.05

8.0
CO2 Emission in Lakh MT

0.979

nEmissio MT/MT
1.00
7.5 0.950 0.95
7.50
7.0 0.90
0.85
6.5
6.57

CO2
0.80
6.0 6.18
0.75

Sp.
5.5 0.70
5.49
5.0
0.65
4.5 0.60
2013-14 2014-15 2015-16 2016-17
Year

26
Benchmarking with other Fertilizer
Plants
• The fertilizer sector has been divided in the respective Vintage
Groups by Department of Fertilizer based on the year of
commissioning and the original feed stock.

• IFFCO Phupur-I had original technology of the 70‟s and Naphtha as

feed stock.

• Based on the same, our SEC norm shall be less than 6.5 Gcal/MT.

• With SEC of 5.85 Gcal/MT of Urea, IFFCO Phulpur is sitting on top of

the chart.
27
INTERNATIONAL ACCREDITATIONS

• Product Steward Excellence

Certification by International
Fertilizer Association (IFA).
28
Installation of Online
Environment Monitoring
System
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)

Local display for pH & TAN Flow Instrument & local display
29
Installation of Online
Environment Monitoring
System
PM (Particulate Matter) measurement in Boiler ducts
has been completed.

Installed Transmitter & Receiver on Boiler Duct and Local Display

30
Raw Water Consumption
9.0 CPCB Benchmark : 12 M3 / MT Urea
National Benchmark (FAI) : 7.3 M3 / MT Urea
8.5
Reduction : 47%
Raw Water , M3/ MT of Urea

8.0

7.5

7.0

6.5

6.0

5.5

5.0

Year

31
Substitution of Conventional Energy with
Renewable Energy
(A) Solar Street Lights:
40 Nos. 30W LED based Solar
street lights installed in plant
premises and township.

(B) Solar Power Pack:

585 KWp Solar power pack
installed in plant and is
connected to the LT Grid.

(C) Solar Light Pipes:

6 Nos. Solar Light Pipes have
been installed Store Building.
This has reduced the power of
the 36 Tube lights installed in
that area. 32
Substitution of Conventional Energy with
Renewable Energy

(D) Solar water Heaters

6 Nos. Water Heater in Guest

House

(E) Bio-Methanation Plant

Capacity : 25 m3/day

33
Environment & 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

34
35
Solar Power Plant Installation Status:

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

• Both the Solar Power Units are in continuous operation

generating Electic Power in the tune of 740 KWh and 1140 KWh
on daily basis.

• Additional Project for installation of 800 KWp Solar Power Panels

comprising of 7 different locations is in under progress.

36
WASTE DISPOSAL
Fly Ash Generated in Power
Plant being gainfully utilised
by Cement industries ,for Brick
Making, For Paving &
Boundary walls and for Usar
land reclamation.

37
Dry Fly Ash Disposal Fly Ash Utilised for Brick Making
WASTE DISPOSAL

Kitchen and Horticulture Waste Bio degradable wastes

from kitchen and horticulture are converted into very
good manure by vermi composting System. The manure is
used in horticulture, green belt area & 150 Acres farm
land

Vermi Compost Pits 38

Monitoring & Reporting System

No. of Reports are generated on daily/weekly/monthly/ quarterly
and yearly basis for Reporting & Monitoring the Energy
Consumption:

Daily
• Performance Report
• Steam Balance Report
• Cost report of Ammonia, Urea and Steam & Power
generation Plant

Weekly
• Weekly performance Report

Monthly
• Variance report actual vs. targeted as well as last year
• Form ECS/GC 4 to assess profitability
39
Sample Performance Reports

40
Employee 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 Republic Day 41

Procurement 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 N
Where:
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.

42
Awards & Recognition
National Energy Conservation Award- 2016 : 2nd Prize

43
Awards & Recognition
FAI Environment Protection Award : Joint Winner

44
45
46