Pollution Control and Wastage Minimization in Urea Plant

Pollution Control and Wastage Minimization in Fertilizers Industries

ByPrem BabooSr. Manager(Prod)National Fertilizers Ltd.,Indiapbaboo@hotmail.com , prem.Baboo@nfl.co.inMob +919425735974

Aims of the Pollution Control and Waste Minimization:Lowest Specific Energy ConsumptionLowest Specific Water ConsumptionMinimum Waste GenerationZero PollutionBetter Product Quality Resources ConservationEcological Balance

Contents:Part-APollution Control Part-BWastage Minimization Part-CDemand of Energy and Greenhouse Gases Part-D Role of Safety to Pollution and Waste Control Role of Goodhouse Keeping to Pollution Control and Waste minimizationPart -ESuggestions to the Pollution Control and Wastage minimizationPart-FConclusion

Part-A (Pollution Control)What is Pollution Types of Pollution Gases Pollution from Urea plant. Measures to Control Air Pollution from Urea Plant Water Pollution in Urea Plant

ZERO LIQUID POLLUTION FROM NFL ViJAIPUR

What is Pollution ? Any element, liquid, emitted waves and gas which have detrimental effects on wildlife, human habitation, environmental conditions; and the quality of life of living beings is being affected . Whenever any industries is established then is expected that any types of effluents and emissions will be zero to environmental safety.

Types of Pollution:1.Air pollution2.Water pollution 3.Soil Pollution4.Thermal Pollution5.Noise Pollution6. Odour Pollution 7.Shock and Vibration 8. Electromagnetic Pollution9. Visual Pollution10.Personal Pollution11.Light Pollution 12.E- Waste Pollution 13.Radioactive Pollution 14.Ocean pollution

1. Air Pollution: The released of gases, matters and chemicals from solid & liquid waste, and combustion of the conventional fuels into the atmosphere are air pollutants. They are CO, CO2, NOx, SOx, CFCs, SF6, NF3, H2O, pesticides, fly ash, particulate matters (as dust) etc produced by human , industrial activities and natural resources that are resulting acid rain , global warming, many diseases etc. 2. Water pollution:It is released by various human, dumped wastes, soil erosion, climate change, natural activities and industries that contaminants surface runoff water, rain water, river, drainage systems, ocean, groundwater, water ponds, etc causing health effects on the all living beings. Nearly 80% worlds river water has been contaminated. As a river in the Mexico has been polluted by the excessive use of chemical fertilizers in the agricultural activities. As in India, Punjab is a example for nitrate pollution in water resources, radioactive pollution and pesticide pollution.

3. Soil / Land Pollution: It occurs when chemicals and pollutants (solid , liquid and gases ) are released by leakage , exhaust, spill, seepage, fly ash/dust etc. Significant soil pollutants are acid rains, heavy metals, radioactive elements, pesticides, oil, electronic waste, fly ash, sewage, industrial waste , deforestation, Nitrate etc; ( as toxic waste of Union carbide dumped to Pithampur) etc. 4. Thermal pollution: It is due to change in temperature in natural environment (air, soil and water) caused by industrial activities (hot water, heat radiation) sun flame, PM, Clouds, glaciers melting (support to increase sea water temperature) and global warming (fluctuation in the atmospheric temperature causing headache, disturbance in the human metabolic reactions), deplete water oxygen, etc. Thermal pollution kills aquatic animals (fishes, etc).

5. Noise pollution: It is a undesirable or unpleasant sound .

Sources of Noise/Sound Pollution & Its Control: Sound is a form of energy; it is originated due to the non periodic vibrating and rubbing objects and transmitted through longitudinal waves from the source of sound (such as rail transportation, road traffic, manufacturing process, high speed machines, reverting, bearings, pressure pulsations, the fluid friction, gear error, PSV, vent, piping vibration, combustion process, jet, impact process (punch and hammer), metal contacting metal, unbalanced rotating parts (shaft), TV, radio etc) .It can be classified into two categories; (i) Musical sound, any sound that seems pleasant to hear is called musical sound and (ii) Noise, if sound appears unpleasant or unlike then it is called noise pollution. It is measured in decibel (dB) .One dB is a one- tenth of a Bell. Mechanical bearings (MBs) frictional noise in the electrical gadgets (motors, etc.), and other rotordynamic machines (heavy pumps, generators, turbines, compressors, etc.) is originated due to excess clearance in bearings, metal to metal contact, loss of lubrication, failure of the lubrication process and damaged bearings. In the Industry, metal contacting metal noise pollution is originated due to low quality and faulty Mech.Brngs. and unbalance rotor shaft.

Table1: Recommended ambient noise level limits for various area

S. No.Area Day (6:00 AM to 9:00 PM) dB (A)Night (9:00 PM ) dB (A)1.2.3.4.Industrial area (A)Commercial area (B)Residential area (C)Silence area (D)7565555070554540

Table 2: Permissible noise exposure limits for occupational and non-occupational zone (Max. exposure limits, hrs/ day)

S. No.Noise Level dB (A)For occupational zoneFor non occupational zone1.2.3.4.5.6.7.8.9.10.11.12.13.808590929597100102105107110115>120 -16864321.51.00.750.50 0.2504.002.001.00-1/2 -1/4 -1/ 7.5 -1/15 1/ 30 0

Table 3: Noise level dB (A) of some machines and traffic S.No.Name of machinesNoise level dB (A)1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.Road trafficRail transport (Surface)Subway trainSteam turbineDiesel generator (Domestic)Diesel generatorRivetingElectric motorsBlowerHeavy machine shopCompressorTurbineTextile weaving shedPower pressPneumatic riveterJet engineRocket engine70 -10271 - 83909185 - 9095 - 96.89585 - 969710095.9 - 113.4100.7102 - 114109 - 120130150180

Table 4: Noise absorption coefficient of some suitable materials. Sr. No.Name of materialsNoise absorption coefficient (a) Open Window Unit (OWU)1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.MarbleBricks wall paintedGlassBricks wall (30 cm thick)Plastered ceilingWooden floorDraperies (Varies with weaves, texture weight and fullness)Carpets (varies with weaves, texture, backing,etc.)Ordinary chairSprayed on fibers and bindersPlasters (porous, 3/8" 3/4") Foamed, open cell, plastics, elastomers, etc. (0.5"-2.0")Mineral or glass fiber blanket (0.5"- 1")Molded or felted tiles, panel and boards (0.5"- 1.25")Hair felt (2.5 cm thick)Cushion chair Open windowHuman body0.0100.0160.020.030.040.060.10 - .060.15 0.600.170.25 0.750.25 0.400.35 0.900.45 0.900.45 - 0.900.581.01.304.3 4.7

Effects on the Ear Temporary Deafness: This Persists for about 24 hours after exposure to loud noise. Permanent Deafness: Repeated or continuous exposure to noise of around or more than100 dB results in permanent hearing loss. Even single exposure to noise of 160 dB can lead to rupture of ear drum and permanent deafness.

Auditory Fatigue : Noise of 90 dB causes buzzing and whistling in the ears.

Noise Pollution Control In Industries:

Providing silences in the Vents. Insulation of Lines.Use personal protective devices e.g. ear muff/plug, etc .Plant more trees.Wear full sleeve noise reflected types of clothes as mixed cotton & polyester cloths.Proper barriers or sealing of the gates .

6. Odour Pollution:

It is a pleasant or unpleasant smell (scent), generated by the rotten waste, dead decayed organisms, chemicals , SW, gases etc; perceive by sense of olfactory.

7. Shock and Vibration:Shock is the force impact on a surface area which is form of stresses, and vibration is the movement either horizontal or vertical caused by any type of force or displacement, it is produced by the irregular motion of the machines and hammering. Occasionally shock and vibration is also resulted due to the sudden rapture of the lines, open of the PSV etc. They may be controlled by shock absorbers, dampers, vibration isolators, springs, shock isolators, etc. Isolation and shock absorbers are very useful tools in solving problems relating to shock and vibration. Psychologically should be aware to maintain your brain function to control cardiac funtion/blood pressure when you are working in industry that unpleasant high level sound may occur.

8.Electromagnetic Pollution:Emissions of the rays or wave motion from the sources are known as radiations it is in the category of invisible pollution , these radiations are characterized with ionization (due to the movement of ions or electrons or nuclear excitation) and non-ionization (many manmade sources) Rads, which comprise the form of waves of electric and magnetic fields as electromagnetic pollution. Electromagnetic radiation can be described in terms of a stream of photons, which are massless particles each traveling in a wave-like pattern and moving at the speed of light. Each photon contains a certain amount (or bundle) of energy.Radiation are from X rays, Gamma rays, UV rays, IR rays, cosmic rays, radioactive heavy particulate, hairdryer, mixer, TV, electric oven, mobile phones, toasters, radios, digital clock, analog devices, power stations, transmission lines, medical equipments, mobile, communications networks, wiring, electronic devices and many other electrical gadgets.

Body organs of the living beings work with tiny electrical impulse. mA/microT/picoT (like nerve signals and electrical activity of heart) and involve many chemical reactions. Long-term exposure to EMRads is harmful to the living cells because the absorbing rate of EMRads in tissues results in heating, which can cause many chemical & physical changes in the cells & body organs. High level of Non-IEMRads may interfere with the functions of the body organs, nerve signals, heart pacemaker devices, biological tissues (which consist of 60 80% water & elements which are sufficient to act with external magnetic fields due to presence of hydrogen and other elements).

Table . Electromagnetic field radiations surroundings the some electrical appliances.

Sr. No.Name of electrical gadgetsElectro-magnetic field in T(at 15 cm from the source)Electro-magnetic field in T (at 30 cmfrom the source)Sr. No.Name of electrical gadgetsElectro-magnetic field in T(at 15 cm from the source)Electro-magnetic field in T (at 30 cm from thesource)1.2.3.4.5.6.Microwave OvenMixersBlendersHairs dryersElectric saversDesk top computers20.012.07.528.012.03.23.51.41.00.20.61.07.8.9.10.11.12.Washing machinesElectric OvensElectric ironAir conditioners Pop corn makerRefrigerator2.51.20.90.82.00.30.60.30.10.20.30.2

9. Visual pollution: Which is due to overhead power Transmission & distribution lines, open storage of trash or solid waste, dumps solid & chemical waste etc .

10. Personal Pollution: Personal pollution is the contamination of one's body and lifestyle with detrimental actions.

Excessive smokingDrugAbuse emotionallyPhysical abuse Unhealthy living conditionsHabits (Foot on the table top )Poor personal attitudes

11. Light pollution: It includes light trespass, over-illumination etc.

12. Electrical and Electronic Waste Pollution:Thrown discarded and damaged electrical and electronic devices are known as EE pollution e.g. PC, TV, mobile, DVD, VCD, CFL etc which contains heavy metals (as Hg, Cd, Zn, As, Co, Cu, Fe, Li, Th, Ba, Bi, etc) pollute all environmental conditions. As a dumped CFL contains about 3-5 mg Mercury which is highly poisonous to living beings. 13. Radioactive Pollution: Radioactive pollution is rare but extremely detrimental, even deadly, when it occurs in nature. It is resulting from radioactive matters ( like Th, U, Co etc) and pollute all resources (air , water and soil).

14.Ocean Pollution:Pollution in the ocean is due to Oil spills, toxic wastes, nitrate and dumping of other harmful materials, leaking of landfills, mines, farming and melted glaciers. chemicals and heavy metals from industries can have a very harmful effect on marine life. Pollution in the ocean directly affects ocean organisms ( fish etc) and indirectly affects human health by food chains.

Gases Pollution from Urea Plant:(As air pollution) Gases from the C-3. Green House Emissions (CO2, H2O, NOx)Ammonia from the leakages and prilling tower emissions.VOC (form oil reservoir, bearings)

Particulate matter as Urea dust

Flow rate (Before revamp) : 37.16x2 Nm3/hr Flow rate After Revamp= 2x796 nm3/hrComposition (% Vol.):- (Yellow Before revamp and RED after revamp) NH3=8.6/1.8; N2=47.55/56;H2=27.55/15.8;O2=9.85/10.8; CH4=6.15/6.8; Ar=1.2; CO=7.6; H2O= Saturation 1 NM3 & O2 gas = 1.42 Kg ; H2 = 0.089 kg

Gases Emissions from C-3:

Prilling Tower Exhaust Air Total exhaust= 1260000 Nm3/HrUrea with air = 40-50mg/NM3 total loss of urea = 1.15-2.0 tonnes/ daytotal NH3 loss= 0.1 tonne

Vacuum system vent:-

Air as (water vapor) with max. NH3 from

E-44= Before revamp not defined

After revamp = 2x4 kg/hr of Air + NH3

Reasons for PM / Dust from Urea Plant

Chocking of bucket.High temperature of atmospheric air.Formation of mushrooms near bucket. High temperature of urea solution.High speed of bucket.High moisture in urea prill.

Measures to control Air pollution GHGs Emissions from Urea Plant:

Recovery of the dust from the prilling tower.Avoid overfilling of lubricants.Recovery of C-3 off gases(implemented)Recovery of Vacuum section vent emissions.

Recovery of flue gases from the vent stacks (which includes PSV, V5, V7, C2 emissions).

Note: Immediate controlling of the leakage of any feed (steam, CO2, NH3, water, etc) in urea plant is done efficiently.

Water & Air Pollution in Urea Plant

Wastewater Generation from Urea Plant:(Waste from process pumps and sections)NH3 pumps ( P1) =Ammonical waterVacuum section (urea & ammonical water)Carbonated water from carbonate feed pumps (P3 seal), Urea from urea pumps (P8, P9, P50), urea & ammonical water from pumps (P14, P15,P21, P52) and Bucket floor. Condensed steam in the form of condensate.Waste water from the vacuum sections Leakages of urea , carbonate, condensate from process valve gland and flanges. CO2 & H2O as GHGs emissions are product of carbonate solution.Leakages of service water and air from valve and gland.

Table: Chemical analysis at BL of urea. Sr. No.Name of componentsValue (mg/l as N)*19.12.131.2.3.Total NH3Free NH3PH16- 45/25 ppm/16.8*0.34- 5.09/5ppm/1.09*7-8

Leakage of water, steam and condensate damage valve & valve accessories (nut & bolt), as well as support structure causing accident during maintenance, losses of resources & energy, pollution etc.

Table: Parameters of the urea plant effluents (10/12/10; *19.12.13).Sr. No.Name of components % * 19.12.13V6NH3Urea~6.03~1.08

P18 NH3 3.4 ppm/6.8 *(4.2ppm Aft. Rev. Urea 0.7 ppm / 0.8 ppm (Aft. Rev.) Methanol 12-35 ppm

P33(Floor washing Pump) NH3 68 ppm or trace/272* Urea 75ppm or trace/ 196*

Effects of the Wastewater on Water Resources:Released chemical consume dissolved water oxygen for oxidizing the pollutants or chemicals known as chemical oxygen demand (COD).

Normal COD range= 10 mg/L or less.

If the biodegradable or organic matters are released in water stream then they consume dissolved water oxygen for bacterial and fungal activities known as biological oxygen demand (BOD).Normal BOD range= 6 mg/L ; Normal DO= 4-6 mg/l

Raw sewage may have BOD levels ranging from 150 300 mg/L .

Conductivity: It is dependent on the presence of the inorganic elements or compounds. Temperature : Thermal pollution in the water stream increases the biological, fungal and algae development causing odour pollution, emissions of methane etc . Oxygen is more easily dissolved in cold water. If the temperature increase then the dissolved oxygen will deplete and then living organisms may die. pH: pH (= log [1/{H+}] is an important limiting chemical factor for aquatic life. If the water in a stream is too acidic or basic may killing the stream organisms. Streams generally have a pH values between 6-9, depending upon the presence of dissolved substances that come from bedrock, soils and other materials.

Part-VZERO LIQUID POLLUTION FROM NFL ViJAIPUR

Total wastewater in urea plant is treated in wastewater section and send to DM plant for reuse; remaining wastewater from the tranches and oil pit is sent to ETP and reused after treatment in industrial boundary.

Part-B Why Waste Minimization What is Wastage. Types of Waste.

Sources of Waste generation in urea plant.

Waste Minimization.

Solutions to Increase Efficiency and Waste Minimization

Ways of Energy Conservation to Reduce Pollution and Waste Minimization

Why Waste Minimization: Saving of resources and energy Pollution Reduction Increasing the efficiency of plant Increasing the productivity Meeting the Production targets

What is Wastage ?:

Losses of the any resources due to the waste is known as wastage.

Types of the waste:

Types of wastesGases(CO2, NH3, CO, VOCs, Cl, Steam, )Liquid( Waste water, Lube oils, Condensate, Service water, CW chemicals, etc)Solid ( Wood, Iron scraps, other heavy metals abrasive, dust, etc)Semi Solid ( Grease, etc)

Sources of Waste Generation in Urea Plant:Leakage from flanges, glands and seals.Leakage of the gases and fluids from pin wholes.Air leakage from 6mm whole at 7 kg/cm2 loss more than 8 lakh/yearUsed and usable thrown hose, gaskets, nut, bolt, aluminum insulation sheet, lubricants (oil and grease), etcOver use of lubricants, water, steam, cotton jute, etcOveruse of water and air for cleaning.Overuse of condensate in pumps and line flushing.Cotton waste due to oil & grease leakage and spillage

Lubricants ( oil and grease) mixed cotton waste; is burnt in the safe pit (oil can be extracted for recycle).

Leakage of oil from the bearings (it is accumulated in the oil pit and collected in the drums and sold to recycle.

Waste Minimization: By the best equipments operative practices. All energy conservation efforts help in the minimization of input energy . Recovery, Reuse and recycleReduction in leakage of lubricants reduce cotton waste consumption

( Waste minimization is preferred to green productivity and to eliminate toxicity in the environment.)

Solutions to Increase Efficiency and Waste Minimization:By Insulation:- Initial thickness of one inch of thermal insulation reduces heat loss by about 85% and several inches of insulation reduces loss by about 95%. It-Control process temperature.- Reduce energy cost.- Reduce GHGs emissions.- minimize surface condensation.

(Per tonne Cost of KS~Rs1700; MS~Rs1600;LS~Rs1550)

Ways of Energy Conservation to Reduce Pollution and Waste Minimization

Each steam line should be insulated if line temperature is >20 0C than ambient.

Steam leakage from 3.0 mm diameter whole at 7 kg/cm2 waste about 25 kg of furnace oil in a year as well as water and its feed power cost also.

Installing auto ON/OFF switches of the cooling tower fan saves up to 40% electrical costs.

Leakage of air from 6 mm whole at pressure 7 kg/cm2 waste about ------- equivalent to Rs 8 lakh/year

Maintain steam pipe insulation. It has been estimated that a bare steam pipe, 150mm in diameter and 100 m in length, carrying saturated steam at 8 kg/cm2 wastes 25 kilolitre of furnace oil in a year. Properly organized maintenance of machines is important, efficiency of the worn out pump drop by 10-15%; unless maintained improperly. Rewinding of motors practically has an efficiency loss of upto 5%.Clean the lamps and fixers regularly, Illumination levels fall by 20-30% due to collection of dust. As 15 0C rise up in the bearing temperature reduce the life of the lubricants.

Replacement of tube light by LEDs saves 90% electrical power and Na lamps also saves 40% power than Hg lamps.Function of the belts of the driven devices should be observed seriously by the operating and maintenance staff because looseness of belts result 15-20% power losses.As unusual a drop wastage per second of any fluid (such as water, DM water, lubricating oil and oil fuels) flow more than 2200-3500 lits per annum (it also depend on the size of the drops and flow). Proper ACs room doors shielding and maintaining temperature 24-26 0C is the best practice to energy conservation. Increase in inlet air temperature by 3 0C in the compressor increase power consumption by 1%, So low temperature suction air must be provided in summer.

Utilization of Urea plant MP section Off-gas as fuel in primary reformer.

-Reduce emissions of GHGs-Reduce the energy consumption-Water sparser at CO2 line in summer to reduce temperature of feed gas and compressor RPM (~300).- Reduce steam consumptionAll traps condensate outlet to be recycled through V-2

Table . Causes of conventional oil bearings failures.

Sr. No.Causes of failureMachines failure (%)1.2.3.4.5.6.Inadequate lubricationContaminationsInstallation errorsOverloadStorage and handling errorsOthers34.4019.6017.706.902.8018.60

condenser flushing by P16 and NO use of condenser LW lines.Direct Torr condensate and Steam are sufficient to clean deposited urea from ejector and condenser.Cone flushing by P8 discharge line solution. As followed(Reduction of load in waste water section)

Flushing of Vacuum System:

Good house keeping to Wastage minimization:

Clean and obstacle free area support to increase work efficiency.

Proper storage of lubricants and tagged method reduce wastage of time.

Proper arrangements of the safety equipments support to reduce systems operation time.

Part-CDemand of Energy and Greenhouse GasesEffect of Global Warming on the Fertilizers IndustriesEffect on Cooling Water Temperature Clean Development Mechanism Opportunities to GHG emission reductions Benefits of Plant Revamping

WASTE UTILIZATION Pollution Mitigation Measures Company Energy Policy (Box: 1) for energy conservation

Figure 1. World total energy consumption by fuels, in Quadrillion (1015) Btu (1Btu=2.92x10-4 Kwhr & 1Kwhr=3414 Btu)

Fig. 2. Estimated NG demand for the fertilizers and power sectors (million standard cubic meter per day).

Figure 3. Concentration of CO2 into the atmosphere, 1750-2008. as in 2013~400 ppm; Threshold/Danger limit 450ppm

Table : Global warming potential of some GHGs (with a time span of ~100 years).

Sr.No.Name of GHGsGWPAtmospheric life time (~years)1.2.3.4.5.6.7.8.9.10.11.12.Carbon dioxide (CO2)Methane (CH4)Nitrous oxide (N2O)Chloroflorocarbon-12 (CFCs-12)Hydroflorocarbon-22 (HFC-22)Hydroflorocarbon - (HFC-152a)Hydroflorocarbon (HFC-23)Perfloromethane (CF4)C6F14SF6 NF3Sulfural chloride 1213106200-71001300-140038001170065007400239001400-Variable12.212010212.1--50,000-3200--

Table . Emission of CO2 by fuels.

Sr. No.Category of FuelsCO2 (~Kg)1.2.3.4.5.6.7.8.9.1011.12.LPG (/Kg)CNG (/Kg)Kerosene (/l)Diesel (/l)Petrol (/l)Air (per passenger/km)Train-Diesel (per passenger/km)Train-electric (per passenger/km)Bus (per passenger/km)Firewood (/Kg)Gobar (/Kg)Gobar gas (/Kg)2.782.672.412.462.140.135-0.260.130.170.0301.071.072.67

It will increase prill temperature causing dust formation. It will increase prilling tower emissions .It will increase the temperature of the lubricants, rotordynamic machines and electrical machinesSudden icing/or heavy snow fall/heavy rain fall/ may system break down. Such situations will suddenOverall plant energy consumption will increase

Effect of Global Warming/Climate Change on the Fertilizers Industries:

Effect on Cooling Water Temperature

Example: In peak summer (May 2010):- when day and night temperature was 40.8 0C back to CT ; 34.1 0C to process (Max. Diff. = 10 0C)Present (Dec. 2010): - When day and night temperature was 33.8 0C back to CT ; 26.5 0C to process(These parameter may be affected by the estimated increasing trend of the atmospheric temperature due to global warming as by the end and before 2100 atmospheric temperature may reach up to 5.8 0C more than the normal earth temperature.)Increasing trends of temperature would increase the CW temperature, evaporation rate of CW from CT and load on the ID fans and will require more water make up.

CDM:The following opportunities can be followed to the CDM:-1. CDR (450 MTonnes/ day)2. C-3 off gas to Pr. Reformer as fuel as saving of NG equivalent to 150 SM3 NG/hr (31+41).3.Using of renewable energy (solar/ biogas) for street lighting. 4. Algae developments in the water ponds for biofuels.5. Biofuels from the biomass (tree/ plant) waste, sewage, township solid waste etc.

7.Forset area and afforestation.8.Rainwater harvesting.9. LED light in all residential houses in township and offices.10.Using of jute bags for urea bagging this support for agriculture developments and jobs.11.Reducing Carbon Foot Print by new technology establishment and individual efforts.

Auditing of water consumption Auditing of paper consumption in offices must. (As per the latest estimation of the FICCI, Indian industries can earn over the 150 billion by 2012 by CDMs efforts.)

Table 1. CDM potential in the Indian sectors .

Sr.No.Name of SectorsEmissions of GHGs (CO2) per year (MT)CDM Potential (MT CO2)1.2.3.4.5.6.PowerIndustrial EEcyREAgriculture and LivestockMSWLand use and land use change & Forestry343.9150.67480.286012.2214.29241590351.278.17

Table 2. GHGs mitigation potential (MP) of Indian sectors by 2012

Sr. No.Name of Key sectors GHG MP (MTCO2 eq)Name of sub-sectors division for GHG MPGHG MP (MTCO2 eq)1.Power319 (76%)MSW to EnergyFossil fuel basedRenewable631021542.Transport41 (10%)--3.Industries57 (14%)CementIron and SteelAluminiumFertilizersN2OHFC-235143141012

Fig. 1: Investment potential (Rs Billion) for the energy efficiency in Indian sector.

Fig. Energy conservation potential (up to %) in the different sectors of India; as of Indias whole economy (~23%)

Table: Urea production and Sp energy consumption Lowest monthly energy : 5.368, ( April 2004); Year: 5.42, (2006-07);2013YearUrea production (MT)Sp. Energy consumption (Mkcal or Gcal/Mt of urea)1997-988102686.0191998-998618565.8481999-009031545.7602000-018534055.7372001-028534125.7132002-038669195.7362003-048647885.6282004-059445005.4662005-069262035.4932006-079746055.4202007-088665865.5312008-099379755.5322009-10 18.12.1364536311046005.5015.33-5.437

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Opportunities to GHG emission reductions:

Energy saving process by revamping of conventional plants with latest technology as ACES Utilizing of atmospheric and flue gas CO2 as the feedstock for urea production.

Switching new feedstock of existing ammonia plants ( like gas hydrates, CBM etc.)

Benefits of Plant Revamping:

Energy SavingPollution controlProduct Quality EnhancementCapacity increase Upgrading the plant processMaximizing efficiency of plant

WASTE UTILIZATION

Bio gas & electricity generation from township garbage, garden waste ,dry leaves etc.

Pollution Mitigation Measures:

-Increasing efficiency reduce waste generation. -Change of technology to reduce feed and pollution. -C-3 gas recovery as fuel-By regular environmental monitoring. -By Improving environmental awareness. -By Auditing of Water, Paper and electricity consumption

Company Energy Policy for energy conservation

Optimum utilization of electrical and thermal energy.Reducing breakdowns by detailed study of each failure and taking appropriate measured.Maximizing recovery of waste energy.

Creating energy conservation awareness among employees and their families through training programmes.

Motivating employees through recognition and awards their energy conservation suggestions/ initiatives.

Carry out internal and external energy audits to identify likely areas in need of improvement.Up grading process technology and machinery based on energy audit report.Bringing down energy consumption by 0.5% every year during the next three years .

Part-D Role of Safety to Pollution and Waste Control Role of Goodhouse Keeping to Pollution Control and Waste minimization

Part-FConclusion

Role of Safety to Pollution and Waste Control:Always electrical cable and wires should be arranged on the cable racks than on surface , it may cause accident during plant emergency.Temporary point or stand should be arranged to hook up 24 volt electrical board whenever required during the shutdown other purposes.All the hot lines should be insulated to avoid burn, fire and energy loss.All the combustible items (like jute, bags, PVC pipes, share PVC wire etc) should be kept away from the flammable items (like lubricants) in separate rooms.

No any fire activities should be done near the oil storage areas, flammable liquids should be kept at the distance of 6 meter from the other places.

Fire activities should not be brought within 10 meter of flammable liquid areas.

Methanol is a low flush point flammable liquid its vapor travels a long distance along with ground , can flash back resulting in serious fire.

In welding working area, water supply must be on the working floor and whenever work is completed then water supply should cut off .To reduce effect of the noise pollution, use ear pugs.

Role of Goodhouse Keeping to Pollution Control and Waste minimization :It follows to prevent fire prevention, fatal accidents.Better area, cleanness and better work performance.Empty pouches of the Gutakha/ tobacco and peak should not be in open areas , always use dustbin.Rubbish should be dumped in proper place/ pit etc.All the usable items (like hand gloves, handles, iron wires, oil cans, helmets, face sheet, gas mask, hose, fire extinguishers etc) should be placed in the proper place and on stands to safe work culture & safety and to reduce plant operation time.

Immediate inform to S/I , whenever lubricants, steam, water, condensate are leaking otherwise they may cause slippery area and fire hazard.

Clean and obstacle free area support to increase work efficiency. Proper storage of lubricants and tagged method reduce waste of time.

Table : Safe limits of the gases and vapors.Sr.No.Gases/ vaporThreshold Limit Value (8 hr)LEL, % UEL, % 1.2.3.4.5.6.7.8.NH3COH2MethanolCO2Cl2H2SO4LPG25 ppm50ppm-200ppm5000ppm1ppm1ppm-1612.546---1.92574.274.236.5---9.3

Part -ESuggestions to the Pollution Control and Wastage minimization:

Work should be Done in Team Mode for minimization of plant breakup time and to reduce energy losses.

Vehicle Washing Must be Strictly Prohibited.

Once a week , each person should come on duty by bicycle or on foot.Oil from the oil contaminated cotton waste must be extracted for recycle.Energy auditing systems must for every section & offices and responsibility of the energy consumption will be of in-charge and every individuals.Filling and draining of the lubricants (lube oil, grease) and methanol should be maintained by the proper systems to avoid a single drop of wastage.

Part-FConclusionAwareness regarding the micro saving of energy and resources are major sources to achieve production targets Teamwork efforts add energy saving. Even a little planning and concentrated effort towards energy conservation gives lot of profit, green productivity and clean environment. Minor improvements in the energy efficiency give a opportunities to lower production cost. Energy efficiency improvements of process and willingness of employee avoid wastage of resources and energy to protect environmental conditions.

THINK FOR FUTURE CAN YOU & YOUR GENERATION BREATH FRESH AIR, EAT PURE FOOD & DRINK PURE WATER ?Thank you ByPrem