3_development of energy consumption norms fert ind-rev1

8/9/2019 3_Development of Energy Consumption Norms Fert Ind-Rev1

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Fertilizer Sector Workshop,New Delhi

1

Development of EnergyConsumption Standards/ Norms

forAmmonia/ Urea Plants for

Implementation of EA-2001

R V Nesari

1st Sept. 2008


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2

Energy Conservation Act-2001Objectives

Bridging the gap between energydemand & supply.

Reducing environmental emissions

through energy saving and Reduction in the energy import bill.

The Act provides the much needed

legal framework and institutionalarrangement for embarking an energyefficiency drive.


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3

Provisions of EA-2001 Act

Identify Energy intensive sectors ofindustries/ establishments and specify asDesignated Consumers of energy.

Establish and prescribe energy consumptionstandards/ norms for DesignatedConsumers.

This study is being conducted for setting up

Energy consumption standards & norms forFertilizer Industry specified as one of thedesignated consumers.


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4

Fertilizer Industry as DesignatedConsumer

Any fertilizer unit having annual energy consumptionequal to or more than 30,000 metric tonnes of oilequivalent (MTOE) per year.

Evaluation of energy consumption levels and notification

of norms for specific energy consumption by BEE. The limit of annual energy consumption in terms of

MTOE shall be reviewed every three years.

A high powered technical committee represented by

senior officials/executives from ministry, FAI andfertilizer units shall be constituted for evaluation ofrecommended energy consumption norms.


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5

Factors Affecting Energy Consumption inFertilizer Industry

Diversified technologies,

Variety of raw materials/ feedstock,

Fuel characteristics, Age factor of plants,

Location,

Plant capacity & capacity utilization, Performance of critical equipment.


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6

Broad Activities of Study

1.Categorization/ Groups.

2.Design of the data collection format.

3.Design of the Annual reporting format.

4.Collection and compilation of data.

5.Data analysis for setting up specific energyconsumption standards/ norms.

6. Preparing draft report on Sp. Energy consumptionstandards/ norms and discuss with all participating

units and FAI and Govt. representatives throughmeetings/ workshops to finalise the norms.

7. Report presentation to High Power TechnicalCommittee.


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7

Fertilizer Industry in India

Ammonia Plants: 32 No.

Urea Plants: 31 No.

DAP based NPK Plants: 12 No. ANP Plants: 3 No.

Sulphuric Acid/ Phosphoric Acid

Plants: 10 No. SSP Plants: small scale not likely to fall

under Designated Consumer Category.


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Ammonia/ Urea Plants

Controlled price of sale of urea to farmers.

Fixation of preset energy consumptionnorms of individual units for calculating NPS.

6 groups of plants based on feed-stock useand starting year of commercial productionviz. Pre-1992 gas, Post-1992 gas, Pre-1992Naphtha, Post-1992 Naphtha, FO/ LSHS andMixed Feedstock.


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9

Gokak Committee Report on EfficientEnergy Levels for Urea Plants

Committee constituted by GoI in June 2001 tosuggest efficient energy levels based onprevailing energy norms and norms expectedfrom modern plants.

Committee recommended target energy levelsfor six groups.

Committee felt that targets suggested wererelevant as milestones to achieve national goal

of energy conservation. Committee View: Major decisions on efficientenergy levels to be taken by BEE to implementEC Act-2001


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10

Energy Norms for NPS-III

Actual norms fixed for NPS-III are different thanthose suggested by Gokak Committee.

Norms fixed based on historic data of operation

i.e. energy norm for NPS-II or actual specificenergy consumption of 2002-03, whichever islower.

Norms does not take into account energy

conservation potential. Norms are more than 5 years old; need a fresh

look.


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11

NPS-III Policy Objectives

Promote usage of most efficient and cheaperfeedstock NG/LNG for urea production.

Conversion of all non-gas based units to gas (9

units running presently on naphtha/ LSHS)within 3 years from 1.10.2006.

Progress on conversion to NG/LNG still slowdue to various constraints including fertilizerpolicy faced by units as well as uncertainty ofLNG supply.


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12

Comparison of NPS-III Energy Norms

with Actual Sp. Energy Consumption

S.No.

Name of Unit NPS-IIINorm,Gcal/ MTof urea

2004-05 2005-06 2006-07

1 CFCL-I 5.621 5.709 5.611 5.613

2 CFCL-II 5.678 5.608 5.556 5.603

3 IFFCO-Aonla-I 5.69 5.738 5.618 5.673

4 IFFCO-Aonla-II 5.522 5.544 5.494 5.510

5 IFFCO-Kalol 6.607 6.347 6.179 5.981

6 IFFCO-Ph-I 7.584 7.630 7.433 7.091

7 RCF-Thal 6.938 6.477 6.505 6.506


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Comparison of NPS-III Energy Norms

with Actual Sp. Energy Consumption

(Contd.)S. No. Name of Unit NPS-IIINorm,Gcal/MTof urea

2004-05 2005-06 2006-07

8 NFL- Vijaipur-I 5.952 5.807 5.795 5.756

9 NFL- Vijaipur-II 5.712 5.464 5.488 5.415

10 KRIBHCO 5.952 5.872 5.902 NA

11 IGFL 5.534 5.43 5.38 5.31

12 NFCL-I 5.712 5.711 5.62 NA

13 TCL 5.417 5.23 5.13 5.18

14 GNFC 7.989 7.56 7.45 7.65


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Benefits of Developing Energy Norms

Encouraging efficiency improvementthrough benchmarking.

Adopting newer technologies to reduceenergy losses

Improving bottom line of Balance Sheet

Reduction in environmental emissions(GHGs).

Key to continual improvements.


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15

Questionnaire for Data collection

A first step towards developing energynorms

A draft questionnaire developed for the

data collection was presented in MumbaiWorkshop in May 2008.

Feedback of the questionnaire contents.

Modifications required have been done. Units to fill in the questionnaire and send

to me/ BEE.


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Contents of Questionnaire

General:

1. Name of Unit:

2. Name of Organization:

3. Units Postal Address:

4. Name of CEO/ Contact Person, designation,communication contact details.

5. Name of Energy Manager6. Energy Management Policy of Unit


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Ammonia Plant

1. Daily rated capacity, MTPD:

2. Month and year of commissioning:

3. Month and year of starting commercial production:

4. Feedstock used:5. Process technology:

a) Front End:

Desulphurisation:

Gasification Process Gas Purification Process

CO2 Removal Process


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Ammonia Plant (contd.)

b) Synthesis: Loop pressure:

Synthesis Convertor flow: Axial/ Radial/ Axialradial

c) Purge Gas Hydrogen recovery:Membrane/ Cryogenic

d) Other related facilities in Ammonia plant: Naphthahandling/ Cooling Tower/ IA/ IG/ Ammonia storage

and handling6. PFD with design/ actual material balance at key

points.


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7. Operating data of Energy consumption for last 3years (earlier 5 years):

Production

Raw materials consumption:a) Feed

b) Fuel

Steam consumption (import):

Steam Export:

Power Consumption (Captive/ Purchased):


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8. GCV and NCV of feedstock and fuel used.

9. Specific Energy Consumption data:

10. Stream days achieved:

11. Data on Best performance achieved so far:

12. Whether external energy audit carried out?13. If yes, name of EA organization:

14. Main recommendations made and implemented:

15. Improvements through internal energy audit and suggestions:

16. Major revamps/ retrofitting carried out:17. Energy saving schemes studied but not implemented with reasons:

18. Next three years planning of energy conservation:


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Fertilizer Sector Workshop,New Delhi 21

Urea Plant and Utilities

Questionnaire contents similar toAmmonia plant

CDR unit data (added)

Utilities:1. Steam

2. Power

Details of utilities supplied to other plantsnot included in Ammonia and urea plantoperation.


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Energy Conservation Activities

Energy Management Policy of Company/Unit

Appointment of Energy Manager

Formation and Functioning of EC Cell

Encouragement to employees to pass

Energy Auditor/ Energy ManagerExamination; List of EAs/ EMs

Any other scheme like Suggestion scheme


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Questionnaire Feedback

Group Norms instead of Single norm: Yes

Factors related to Equipment/ machinery andtheir operating parameters in Energy

Consumption Capacity related: Original or revamped- data forthe plant being operated now.

Fuel for Boilers- coal/fuel oil/ naphtha etc.

Use of RLNG or any other gas/ feedstock-Questionnaire may be modified by EM of Unitsuitably.


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Questionnaire Feedback

NCV and GCV values: per NM3 or per SM3

Energy Consumption for Gas turbines andWHRB

Energy factors for utilities like steam,purchased power

PFD of Ammonia/ Urea plants with key

parameters- to identify difference in designand operating parameters which affectsspecific energy consumption.


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Conclusions

Development of Energy Consumption standards/ normsfor Fertilizer Sector essential to implement EnergyConservation Act-2001, in spite of various factors anddifficulties.

Norms considering all factors- group based Development through consensus and not by force and

without clashing with existing Govt. policies. Cooperation of all Ammonia and Urea Manufacturing

units prerequisite for the success of this execise.

Units to fill up the questionnaire and send to R V Nesari,Coordinator for the Study. Self Evaluation through BEE software to be developed. Encouraging energy conservation and energy efficiency

improvement efforts.

Benefits to stakeholders and the country.


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3_development of energy consumption norms fert ind-rev1

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