21st national award for excellence in energy management

21st National Award for Excellence

in Energy Management - 2020

Team Member:

Praveen Kr. Mishra (Mgr)

Shankar Singh (Dy.Mgr)

Pranjali Yadav (Sr.Eng.)

Presented By:

Indian Farmers Fertiliser Cooperative Ltd.

Phulpur-II Unit

25th – 28th August, 2020

Installed/Revamped Annual Capacity (Lakh MT)

IFFCO: At a Glance

Urea : 42.4

NP/NPK/DAP : 43.3

Total ‘N’ : 26.3

Total ‘P2O5’ : 17.2

WSFs : 0.15

Zinc Sulphate Monohydrate : 0.30

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 )

1

JOINT VENTURES

IFFCO Phulpur Unit-II : Profile

Plant Ammonia Urea

Process Licenser HaldorTopsoe,

Denmark

Snamprogetti,Italy

Commissioned December, 1997

Daily Capacity(MTPD)

1740 3030

Annual Capacity(Lakhs MT)

5.7 10.0

Till Date Production(Lakhs MT)

124 214

2

Ammonia-II Plant

Urea-II Plant

Bagging Plant

RLNG

Utility Boiler

HP Steam

Power

Ammonia Plant

RLNG

AmmoniaCO2

Neem Urea

Urea Plant

HP

Steam

RAIL

ROAD

IFFCO Phulpur Unit-II : Production Outline

HP Steam

GTG-HRSG

3

5.47 5.126.06 5.86

5.38

5.97 6.92

9.518.84

10.549.92

9.55

10.44

12.16

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Ammonia Urea

Highest Ever Yearly Urea Production

Installed Capacity

Installed CapacityHighest Ever Yearly

Ammonia Production

Phulpur-II: Production Performance

YEAR

Lakh

sM

T

4

On-Stream Efficiency

89.9

83.9

91.8

100.0

75

80

85

90

95

100

2016-17 2017-18 2018-19 2019-20

On

-Str

ea

m E

ffic

ien

cy

85.5

82.3

90.0

97.0

75

80

85

90

95

100

2016-17 2017-18 2018-19 2019-20

On

-Str

eam

Eff

icie

nc

y

Ammonia Plant On-Stream Efficiency Urea Plant On-Stream Efficiency

One of the important factor which effects the Productivity / Energy of the fertiliserplant is the Downtime of the plant.

• Poor Reliability of Plant & Equipment leads to:

↑ Duration of Downtime days ↑ No. of Downtimes

↓ Productivity ↓Productivity / Energy Efficiency

5

Energy in Gcal/MT of Urea

Phulpur-II : Sp. Energy Consumption

5.58

5.88

5.27

5.17

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

2016-17 2017-18 2018-19 2019-20

Year

NUP Norm: 5.744(upto March 2018)

0.33

0.574

NUP Norm: 5.5(From April 2018)

Lowest Ever Yearly Urea Energy

6

5.5625.321 5.258

5.164

2016-17 2017-18 2018-19 2019-20

Sp

ec

ific

Th

erm

al

En

erg

y (

Gcal/

MT

)

5.02

3.94

5.61

1.62

2016-17 2017-18 2018-19 2019-20

Sp

ec

ific

Ele

ctr

ica

l E

ne

rgy (

kW

h/M

T)

Major Energy Conservation Measures in Phulpur-II Unit in the

year 2017-18

S.No Energy Saving Schemes Yearly Energy

Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

1 Modification in CO2 RecoveryProcess- aMDEA Process in placeof GV Process.

96656.0 2436.7 20100.0 99.0

2 Replacement of CO2 Compressorfrom M/s Hitachi, Japan in onestream of Urea –II Plant with newefficient CO2 Compressor.

31393.5 375.7 2051.0 65.5

3 Installation of AmmoniaPreheater in both 31 & 41 Unit ofUrea-II Plant.

8293.0 209.1 659.0 37.8

Total (Thermal Energy) 136342.5 3021.5 22810.0

Specific Thermal Energy(Gcal/MT Urea)

0.143

7

Major Energy Saving Schemes Implemented in

2017-18

S.No

Energy Saving Schemes Yearly Energy Saving (kWh)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back

(Month)

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

46108.0 2.8 5.6 24.4

5 Replacement of 400 Nos 30 W LED Street Lightfixture in Township branch road in place of 120W high pressure sodium tube.

85123.0 5.1 5.3 12.5

6 Replacement of 100 Nos 72 W LED Street Lightfixture in Township from Gate no 4 to Gate No 1in place of 220 W high pressure sodium Fixture.

34995.0 2.1 2.8 16.2

7 Replacement of 160 Nos 19 W LED fixture inBagging Platform in place of 40 W NormalFluorescent tube light.

15511.0 0.9 3.3 41.9

Total (Electrical Energy) 181737.0 10.9 17.0

Specific Electrical Saving (Gcal/MT of Urea) 0.0005

8


year 2018-19

S.No

Energy Saving Schemes Yearly Energy Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

1 Replacement of New Rotor in place of oldinefficient Rotor in Synthesis Gas Turbine ofAmmonia –II Plant.

18175.6 259.6 940.5 45.1

2 Installation of additional aMDEA Solution-Solution Plate Type Heat Exchanger (PHE) andDM water preheater in aMDEA Section ofAmmonia-II Plant.

31695.0 1097.9 250.0 2.8

3 In-house modification of Condensate Pumpdrive changed from Back Pressure Turbine toMotor (old spare available) in Ammonia-IIPlant.

5048.2 175.0 0.0 0.0

4 In-house modification of Bulk Absorber InletSeparator condensate Pump drive changedfrom Back Pressure Turbine to old spare Motorin Ammonia-II Plant.

9129.8 316.0 0.0 0.0


Specific Thermal Energy (Gcal/MT Urea) 0.061 9

Major Energy Conservation Measures in Phulpur-II Unit in

the year 2018-19

S.No

Energy Saving Schemes Yearly Energy Saving(kWh)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

5 Replacement of 100 Nos 90 W LED Street Light Fixture atPlant premises in place of 150 W High Pressure SodiumFixture.

30739.0 3.4 2.8 9.9

6 Replacement of 40 Nos 250 W LED Flood Light fixture in roadside of Power Plant, Ammonia Plant & Ammonia Storage Tankarea in place of 400 W High Pressure Mercury Vapour(HPMV).

33103.0 3.6 3.4 11.3

7 Replacement of 70 Nos 120 W LED Flood Light fixture inBadminton Hall and its premises of Township in place of 25Nos. of 1000 W Halogen light & 40 Nos. of 40 W Tube light.

32467.0 3.6 3.0 10.0

8 Replacement of 385 Nos 45 W LED Well Glass Fixture inAmmonia & Urea Plant in place of 125 W High PressureMercury Vapour (HPMV) Light.

118344.0 13.0 7.5 6.9

9 Replacement of 30 Nos 120 W LED Baylight Fixture inAmmonia-II Compressor house in place of 400 W HighPressure Mercury Vapour (HPMV) Light.

57816.0 6.4 2.0 3.8

Total (Electrical Energy) 272469 30.0 18.7



year 2019-20

S.No

Energy Saving Schemes Yearly Energy Saving (Gcal)

Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

1 Optimum Load Operation,Maximization of on-stream days &optimization of Process Parameters.

118881.7 3257.2 0.0 0.0

2 Revamping of Power Plant CoolingTower-II in Phulpur-II Plant.

2875.0 77.5 166.0 25.5


Specific Thermal Energy Saving(Gcal/MT of Urea)

0.10

11


the year 2019-20

S.No


Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

3 Online replacement of drift eliminator inAmmonia-II Cooling tower.

222501.0 22.2 59.5 32.2

4 Replacement of 385 Nos of 80 Watt HPMVWell Glass Fixtures with 45 Watt LED WellGlass Fixtures in Urea-II Plant.

73237.0 10.7 9.3 10.2

5 Replacement of 150 Nos of 125 WattHPMV Well Glass Fixtures with 45 WattLED Well Glass Fixtures in Ammonia-IICooling Tower.

105408.0 15.4 5.8 4.5

6 Replacement of 550 Nos of 80 Watt HPMVWell Glass Fixtures with 45 Watt LED WellGlass Fixtures in Ammonia-II (33 and 35area) and Urea-II Plant.

104625.0 15.3 13.3 10.4

7 Replacement of 30 Nos of 400 Watt HPMVBay Light Fixtures with 120 Watt LED BayLight Fixtures at below the Ammonia-IICompressor House.

73786.0 10.8 1.2 1.3

12


the year 2019-20

S.No


Monetary Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

Pay Back (Month)

8 Replacement of 110 Nos. of 72 Watt RecessMounting Luminaire Fluorescent lamp with38 Watt 90 Nos. Recess Mounting LuminaireLED Lamp at Power Plant Control room inPhulpur-II Plant.

24458.0 3.6 1.1 3.7

9 Replacement of 120 Nos. of 22 Watt RecessMounting Luminaire of compactFluorescent lamp with 38 Watt 60 Nos.Recess Mounting Luminaire LED Lamp atPurchase Section of Phulpur-II Plant.

1957.0 0.3 0.8 32.0

10 Replacement of 385 Nos of 35L StorageType Old Geysers with 35L Storage Type 5Star Geysers in Ghiyanagar Township.

24322.0 3.6 8.5 28.3

Total (Electrical Energy) 630294.0 81.9 99.5


13

List of Major Encon Projects Planned in 2020-21

S.No Energy Saving Schemes Annual Electrical

Saving (Million kWh)

Annual Thermal Saving (Gcal)

Investment (Rs. Lakhs)

1 Installation of Higher capacity Ammonia Condenser(E-3522) in place of existing Ammonia Condenserto reduce the Ammonia content at the outlet fromOff Gas Absorber.

0.0 697.6 20.0

2 Installation of 14” LP Steam Export Line fromPhulpur-I Yard Header to CDR Plant.

0.0 35982.1 41.0

Total 0.0 36679.7 61.0

14

1. Innovative way for on-line replacement of drift eliminator in Ammonia-II Cooling tower in Phulpur-II Plant:

In every cooling tower, drift is the undesirable loss ofliquid water to the environment via small droplets thatbecome entrained in the leaving air stream.

The drift loss through the cooling Tower was on higherside resulting the water droplets carry with themchemicals and minerals which impacting the surroundingenvironment.

Thus, the old and inefficient drift eliminator replacedwith latest designed efficient drift eliminators.

The Project was implemented successfully in runningplant without tripping of Ammonia –II Plant.

Thereby reducing the drift losses in cooling tower andpower consumption in motor of Bore-well Pumps.

The chemicals Consumption and make up water isreduced.

The yearly Power saving was 222501 kWh and in termsof Rs. 22.2 Lakhs.

Before Replacement

After Replacement

15

2. Revamping of Power Plant Cooling Tower-II in Phulpur-II Plant:

Originally, Power Plant Cooling Tower-II inPhulpur-II Plant had a conventional woodenstructure which deteriorated over a period oftime and has higher maintenance cost.

Therefore the original structure has beenrevamped with the latest Pultruded FibreReinforced Plastic (FRP) structure to increasethe reliability.

After revamping, the Cooling Tower approachcame down and the specific steamconsumption for power generation in Turbo-generator(TG) has been reduced.

Annual saving comes of 2875.0 Gcal and interms of Rs. 77.5 Lakhs.

Revamped Power Plant cooling Tower -II

16

3. Optimum Load Operation, Maximization of on-stream days & optimization of

Process Parameters:

17

Specific Feed, Fuel, Steam and Power 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, 2.0 % reduction in the overall energy per MT of Urea

has been realized.

Annual saving comes to 118882 Gcal and in terms of Rs. 3257 Lakhs.

4. Replacement of 385 Nos of 80 Watt HPMV Well Glass Fixtures with

45 Watt LED Well Glass Fixtures in Urea-II Plant:

18

To reduce the energy consumption, 385 Nos. of 80 W HPMV Well Glass Fixtures have

been replaced with 45 W LED Well Glass Fixtures in Urea-II Plant. Annual saving

comes 73237 KWH per year.

Before After

5. Replacement of 150 Nos of 125 Watt HPMV Well Glass Fixtures with

45 Watt LED Well Glass Fixtures in Ammonia-II Cooling Tower:

19

To reduce the energy consumption, 150 Nos. of 125 W High Pressure Mercury Vapour

(HPMV) Well Glass Fixtures replaced with 45 W LED Well Glass Fixtures in Ammonia-

II Cooling Tower. Annual saving comes 105408 KWH per year.

Before After

6. Replacement of 550 Nos of 80 Watt HPMV Well Glass Fixtures with 45 Watt

LED Well Glass Fixtures in Ammonia-II (33 and 35 area) and Urea-II Plant

20

To reduce the energy consumption, 550 Nos. of 80 W HPMV Well Glass Fixtures have

been replaced with 45 Watt LED Well Glass Fixtures in Ammonia-II (33 and 35 area)

and Urea-II Plant. Annual saving comes 104625 KWH per year.

Before After

7. Replacement of 30 Nos of 400 Watt HPMV Bay Light Fixtures with 120 Watt

LED Bay Light Fixtures at below the Ammonia-II Compressor House:

21

To reduce the energy consumption, 30 Nos. of 400 W High Pressure Mercury Vapour

(HPMV) Bay Light fixtures replaced with 120 W LED Bay Light Fixtures at below the

Ammonia-II Compressor House. Annual saving comes 73786 KWH per year.

Before After

8. Replacement of 110 Nos. 72 Watt Recess Mounting Luminaire Fluorescent

lamp with 38 Watt 90 Nos. LED Lamp at Power Plant Control room:

22

To reduce the energy consumption, 110 nos. of 72 Watt Recess Mounting Luminaire

Fluorescent lamp replaced with 38 Watt 90 nos Recess Mounting Luminaire LED Lamp at

Power Plant Control room in Phulpur-II Plant. Annual saving comes 24458.0 KWH per year.

Before After

9. Replacement of 120 Nos. of 22 Watt Recess Mounting Luminaire of compact

Fluorescent lamp with 38 Watt 60 Nos. LED Lamp at Purchase Section:

23

To reduce the energy consumption, 120 nos. of 22 Watt Recess Mounting Luminaire of

compact Fluorescent lamp replaced with 38 Watt 90 nos Recess Mounting Luminaire LED

Lamp at Purchase section of Phulpur-II Plant. Annual saving comes 1957.0 KWH per year.

Before After

10. Replacement of 385 Nos of 35L Storage Type Old Geysers with 35L Storage

Type 5 Star Geysers in Ghiyanagar Township:

24

To reduce the energy consumption, 385 Nos. of Storage Type Old Geysers have been

replaced with 35L Storage Type 5 Star Geysers in Ghiyanagar Township. Annual saving

comes 24322.0 KWH per year.

Before After

Details 2016-17 2017-18 2018-19 2019-20

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

17754.6 17996.2 25431.8 27003.0

Amount Invested in ENCON Projects (Rs. Million)

727.4 2282.7 120.92 26.55

Investment % 4.1 12.68 0.48 0.10

ENCON PROJECT BUDGET ALLOCATION

25

Solar Power Pack: 800 KWp Solar power pack installed in

plants and is connected to the LT Grid. The Solar Power Units (800 KWp) are in

continuous operation generating ElectricPower there by reduction of CO2 emission.

Solar light installed at different locationsinside the plant and as well as alsotownship.

Total Electrical Power generated by SolarPower Unit during the year 2019-20 is966527.0 kWh.

UTILISATIONS OF RENEWABLE ENERGY

Solar Water

Heaters

6 Nos. of Solar Water Heater

installed in Guest House.

Bio-Methanation Plant

Solar Power pack at raw water Pump House and Bagging Top Floor

Capacity : 25 m3/day

26

5.37

4.90

0.510

0.494

0.7100.421

0.403

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.55

0.60

3.5

4.0

4.5

5.0

5.5

6.0

6.5

2015-16 2016-17 2017-18 2018-19 2019-20

Sp

. C

O2 E

mis

sio

n M

T/M

T o

f U

rea

CO

2 E

mis

sio

n in

La

kh

MT

Year

4.15

4.41

4.90

Carbon Foot Print

Our endeavours for every year is to reduce specific energy consumption, which will also

result in lesser CO2 emissions. We have also installed solar power plants which also

reduce CO2 emission.

27

Environment monitoring system and reduction of Stack

emission:Installation of Carbon Di Oxide Recovery Plant, to recover CO2 from flue gases of Ammonia-II:

28

Our endeavour for every year is to reducespecific energy consumption which will alsoresult in lesser CO2 emissions.

IFFCO Phulpur-II Unit has already installed aCarbon Di Oxide Recovery (CDR) Plant of 450MTPD capacity in the year 2006-07, to recoverCO2 from flue gases of Ammonia-II Plantprimary reformer furnace.

Phulpur - II was commissioned way back in1997. Feed and fuel for both ammonia plantswas naphtha which was later changed to R-LNG(Re-gasified Liquid Natural Gas) in 2006-07after the availability of R-LNG.

As the Carbon/Hydrogen (C/H) Ratio of R-LNGis much lower than that of Naphtha, Carbon Di-oxide Recovery (CDR) Plant has been installeddownstream of the Primary Reformer ofPhulpur Unit-II to convert Urea.

View of CDR Plant

WASTE DISPOSAL

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 at CORDET.

Vermi Compost Pits

29

Liquid Effluent Treatment

Rejection water of Reverse Osmosis Plant used in Coal yard in Phulpur Unit:

We are using cooling tower

blowdown for RO Feed. The

recovered RO product is being

used in softening plant as make-up

water and the reject water is being

used in coal yard to supress the

coal dust. The Plant Capacity is

3000 M3 /day (Recovery 85 %).

Sewage Treatment cum Recycle Plant:

The sewage generated in Plant

Township is treated in Sewage

Treatment Plant and is being

used for irrigation purpose at

Farm Land. The Plant Capacity is

125 M3 / hr.

30

Installation of Online Environment Monitoring System

Local display for pH & TAN

Liquid Effluent Monitoring: IFFCO Phulpur Unit continuously monitored the pH, Ammonical Nitrogen at guard pond area and Flow in pipeline of liquid effluent generated in the complex. After treatment, the liquid effluent reused effluent inhorticulture & irrigation of farmland within IFFCO’s premises.

Flow Instrument & local display

Installation of Ammonia Sensor at strategic locations of Plants:

To monitored ammonia leakage, ammonia sensor is installed at strategic

locations of Ammonia-I, Urea-I and Ammonia Storage Tank area of IFFCO

Phulpur Unit. In case of any leakages in the plants, the Panel operator shall

identify the location of Ammonia Leakage and take action accordingly to

arrest the leakage. Water curtain has been provided at the periphery of the

control room and as well as ammonia feed pumps for safety of the Plant

personnel.31

Environment & Sustainability

Rain Water Harvesting System

32

Measures Taken for Raw Water Conservation:

1. Monitoring of Raw Water Consumption

2. Measurement with Portable Ultrasonic Flow meter

3. Monitoring of Blowdowns of Cooling Towers

Rain Water Harvesting Systems:

• Total 5 Nos. Rain Water Harvesting systems

are installed in township.

• Besides this, IFFCO is planning to install

more Rain water harvesting systems at

different locations.

• Study by Consultant is in progress.

Monitoring & Reporting System

Energy is monitored daily in presence of Unit Head, to facilitate this various reports are

prepared and corrective actions are taken immediately to rectify the problem area.

Various types of Reports are generated on daily/weekly/monthly/ quarterly and yearly

basis for Reporting & Monitoring the Energy Consumption:

Daily

• Plant & Performance Report

• Steam Balance Report

• Power generation Plant

Sample Performance Reports

Sample Steam Balance Reports

33Sample Weekly Energy Reports

Employee Engagement

IFFCO Phulpur Unit encourages its employees through Suggestion Scheme to give

ideas of energy conservation.

In our Unit, the have a suggestion scheme for all Employees. All Employees

(Workman & Supervisor Level) participated the Suggestion Scheme Awards.

Approx. 1000 suggestions are received every year from employees.

The selected candidate awarded in in-house /National /International level.

A View of Suggestion Award Ceremony

on Republic Day 34

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 being 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.

35

• Product Steward Excellence Certification

by International Fertilizer Association (IFA).

INTERNATIONAL ACCREDITATIONS

36

INTERNATIONAL CERTIFICATIONS

37

Awards & Recognition 2019-2020

20th National Award for Excellence in Energy Management by CII .

19th Annual Greentech EnvironmentAward – 2019 : Winner

38

Awards & Recognition

18th Annual GreentechSafety Award – 2018: Winner

Product Steward Excellence Certification by IFA under IFA Protect & Sustained Product Stewardship Programme

Green Rating Project Awards “3 Leaves”

39

Praveen Kr. MishraMob: 9415428883

21st national award for excellence in energy management

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