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First Prize Fertilizers (Urea)

NATIONAL FERTILIZERS LIMITED

Panipat (Haryana)

Unit Profile

The present installed capacity of National Fertilizers Limited (NFL) is 3.568 million

tonnes urea per annum. It is the 2nd highest producer of urea in the country.

NFL as a whole is also contributing ~16 % towards total production capacity of India

and total share of Panipat unit in Urea production from total NFL is also ~16%.

PANIPAT UNIT

• NFL Panipat Project was executed with the help of foreign contractor, M/s. Toyo

Engg. Corporation, Japan and Indian consultant M/s. Engineers India Ltd.

• The cost of project was Rs. 2210 million with Rs. 550 million as foreign

components.

• Unit has a total area of 574 acres. Factory area is 442 acres and a beautiful

township spread over an area of 132 acres

• Urea plant was designed to produce 1550 TPD urea. Ammonia plant was

designed to produce 900 MT/day Ammonia based on partial oxidation of Residual

fuel oil/LSHS by SHELL GASIFICATIION process. Commercial production of Urea

was achieved in Sept. 1979.

• A Captive Power Plant was also installed with 30 MW capacities at a cost of Rs.

1100 million in the year 1988.

• In the year 2001-02, Unit introduced the concept of Neem coating on urea. After

rigorous R&D the product was stabilized and test marketed. Seeing the

overwhelming response from the farmers unit started large scale production. In

view of this unit was awarded Golden Peacock Innovation Award by Institute of

Directors, New Delhi in 2005 (till date unit has produced 963485.65 MT of Neem

coated Urea).

Energy consumption in oil based plant was high. In view of this, Government of

India announced a policy for revamp of the FO/ Naphtha based fertilizer plants for

changing feedstock from FO/LSHS to NG/RLNG in January 2004 with equity to debt

ratio of 1:19.

In order to reduce the energy consumption under this policy, Unit has undergone for

revamp of the plant by changing the feedstock from fuel oil to NG/RLNG based on

proven process route of Steam Methane Reforming (AFCP). Zero date for the project

was 29th Jan, 2010. Commercial production was achieved on 28.3.2013. Till date

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Panipat unit has produced 16059551 MT of Urea. Of this 927083 MT has been

produced after the project of AFCP.

DESCRIPTION IN BRIEF OF AMMONIA FEEDSTOCK CHANGEOVER

PROJECT UNDERTAKEN TO REDUCE ENERGY IS AS UNDER

FEED PREPARATION (HYDROGENATION AND DE-SULPHURISATION)

The natural gas feedstock contains minor

quantities of sulphur compounds which have to

be removed in order to avoid poisoning of the

reforming catalyst in the primary reformer, and

the low temperature shift catalyst in the CO

converter. Particularly the low temperature

shift converter is sensitive to deactivation by

sulphur and sulphur bearing compounds. The

sulphur contained in the natural gas will be

reduced to a very low level, i.e. less than 0.1 ppm sulphur by weight.

REFORMING

The reforming of the hydrocarbon feed

takes place in two stages, a direct fired

primary reformer and an auto thermal

catalytic secondary reformer. The

hydrocarbon feed coming from the

desulphurization unit is mixed with

steam. The steam/carbon ratio is 3.0.

The reaction mixture is preheated and

taken to the primary reformer, where it

is decomposed into hydrogen, carbon

monoxide, and carbon dioxide over a nickel catalyst by heat supply.

In the secondary reformer preheated air is

added, and the heat thus generated by

burning of the gas decomposes the

methane. The methane concentration in the

outlet gas from the secondary reformer is

0.6 vol% (dry basis)

HIGH TEMPERATURE AND LOW TEMPERATURE CO SHIFT CONVERTER

The CO conversion takes place in two adiabatic stages. After reforming, about

12.7% CO is present in the gas (dry basis). In the high temperature CO converter,

the CO content is reduced to approximately 3.1 vol%, and the temperature

increases from 360 oC to 429 oC. It is then cooled to 205 oC and passed on to the

low temperature CO converter, in which the CO content is reduced to approximately

0.3 vol%, while the temperature increases to 226 oC.

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CO2 REMOVAL

For removal of the carbon dioxide, the

activated MDEA process is used. Main

equipment in the MDEA process is the CO2

absorber and the CO2 stripping column. CO2

is removed from the process gas by

counter-current absorption in two stages. In

the lower part of the absorber, flash-

regenerated solution is used for bulk CO2

removal. In the upper part of the absorber,

strip-regenerated solution is used for

scrubbing. Thus, nearly a complete removal

of CO2 with only 0.05 vol % CO2 (on dry

basis) left in the treated gas.

METHANATION

After the CO2 removal, the gas contains

0.05% CO2 and 0.3% CO (dry basis).

These compounds are poisons to the

ammonia catalyst and must be removed

before the gas is taken to the synthesis

section. This is done in the methanator,

where CO and CO2 react with H2 to form

CH4, which is harmless to the ammonia

catalyst. The content of CO + CO2 is

reduced to less than 5 ppm. The inlet

temperature to the reactor is 300oC, and

the outlet temperature is 323 oC.

AMMONIA SYNTHESIS The synthesis gas after compression to

186 kg/cm2 is taken to synthesis loop

for recovery of Ammonia. In the

synthesis loop, the make-up gas is sent

directly to the ammonia converter (S-

300). The make-up gas contains about

1.04 % of inert gases (Ar+CH4). The

purge is taken from the outlet and is

sent to the new ammonia recovery unit.

AMMONIA RECOVERY and STORAGE Purge gas from the ammonia separator is sent to the purge gas absorber together

with letdown gas from the product let-down tank. In purge gas absorber, ammonia

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is washed out of the gases with water. The aqueous ammonia from purge gas

absorber is sent to the distillation column, where the ammonia is distilled off and

added to the ammonia product drawn from the product let-down tank. The off-gas

from the purge gas absorber is used as fuel in the primary reformer. Ammonia

produced is stored in two Horton spheres having a capacity of 1500 MT each.

BAR CHART SHOWING SPECIFIC ENERGY CONSUMPTION / MT OF

UREA

With the commissioning of Ammonia feed stock changeover project at the end of

2012-13, reduction in specific energy consumption/MT of Urea has been achieved

from 10.097 GCal/MT Urea to 7.687 GCal/MT Urea.

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Second Prize Fertilizers

(Urea)

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED

Bharuch (Gujarat)

Unit Profile

Gujarat Narmada Valley Fertilizers & Chemicals Limited. (GNFC) is a joint sector

enterprise promoted by the Government of Gujarat and the Gujarat State Fertilizer

Company Ltd. (GSFC). GNFC started its manufacturing and marketing operations in

1982. Over the next few years, GNFC successfully commissioned different projects -

in fields as diverse as chemicals, fertilizers and Information Technology.

Since beginning GNFC has embarked itself on the path of continuous modernization

and technology up gradation for almost all the plants with the help of In house

innovations as well as by incorporating latest technological advancements, not only

for production enhancement but also to reduce energy consumption as well to

improve environmental performance.

Production Performance (GNFC Bharuch)

Product Units Installed

Capacity

2012-13 2013-14

Actual Capacity

Utilization Actual

Capacity

Utilization

Ammonia MT 4,45,500 591,861 132.85% 608279 136.54 %

Urea MT 6,36,000 708,795 111.29% 696428 109.35 %

Methanol-II MT 1,88,100 130,456 69.35% 145347 77.27 %

Formic Acid MT 10,000 20,153 201.53% 20492 204.92 %

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Acetic Acid MT 1,00,000 157,093 157.09% 155236 155.24 %

Weak Nitric Acid-I MT 2,47,500 287307 116.08% 291183 117.65 %

Product Units Installed

Capacity

2012-13 2013-14

Actual Capacity

Utilization Actual

Capacity

Utilization

Weak Nitric Acid-II MT 100000 112,690 112.69% 123322 123.32 %

Conc. Nitric Acid - I MT 33,000 29,784 90.26% 32871 99.61 %

Conc. Nitric Acid - II MT 33,000 28,908 87.60% 35120 106.42 %

Conc. Nitric Acid III MT 50000 49,408 98.82% 53504 107.01 %

Amm. Nitro

phosphate MT 1,42,500 200,895 140.98%

188865 132.54 %

Aniline MT 35,000 41,717 119.19% 40473 115.64 %

TDI MT 14,000 17,875 127.68% 16317 116.55 %

Ethyl Acetate MT 50000 Under

Commissio

ning till

October

2012

Under

Commissio

ning till

October

2012

52088 104.16 %

Energy Consumption

At GNFC Ltd., Steam was generated mainly from 3 pulverized Coal fired Boilers,

each having capacity of 180 MT/hr of HPSH steam and HRSG of GT unit. The fourth

Boiler is gas based and was operated only in case of requirement. Required Power is

generated with the help of 2X25 MW Steam Turbines and a 35 MW Gas Turbine

based Co-generation unit. Natural Gas and LSHS were used as feed stocks in Feed

Stock Conversion Unit (ASGP Plant) and FO based Ammonia plant respectively.

Natural Gas was used as Fuel for Turbo generators and as well as Feed Stock in

Methanol / SGGU plants. Small quantity of Natural Gas is also used as fuel in some

of the plants. GNFC has also installed Wind Turbo Generators (WTG) having total

capacity of 21 MW, in Kutch District of Gujarat state in the years 2007 and 2008 and

operative since then. A 300 kW PV Solar plant was added to renewable portfolio and

commissioned in April 2014.

Energy Saving Achievements during 2013-2014

Ammonia Plant Feed stock conversion Unit (ASGP Project) began its commercial

production from 1.10.2013. This has significantly reduced energy consumption for

Urea Production.

Over and above, following energy saving measures/ schemes are implemented

FO based Ammonia plant • Three pump impellers were trimmed in Rectisol unit of, which resulted in power

saving of 1,98,000 kWh.

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• MP Boiler feed water transfer pump impeller was trimmed, resulted in power

saving of 5,14,800 kWh.

Urea Plant • Installation of small additional HP Carbamate pump, resulted in power saving of

10,32,294 kWh and steam saving of 10,936 MT.

• Condensate transfer pump’s 110 kW motors were replaced with 90 kW high

efficiency & increased safety motors, resulting in power saving of 79,440 kWh.

Formic Acid Plant • Use of condensate in place of DM water for steam pressure reduction station,

resulted in saving of 473 MT steam.

Ethyl Acetate Plant • Subsequent to the change in angle of the cooling tower fans’ blades, one of the

cooling water pump was stopped, resulting in power saving of 5,56,910 kWh.

Aniline/TDI Plant • With the increase in the size of supply pipe, one hot well pump was stopped,

resulting in power saving of 1,16,640 kWh.

Utility Plant • Replacements of raw water supply pump to demonstration farm with lower

capacity pump resulting in power saving of 42,522 kWh.

• Two pumps handling effluent discharge were replaced with energy efficient

pumps resulting in power saving of 23,400 kWh.

• Installation of 90 kW VFD at Filter water pump MP- 1701C, resulted in power

saving of 77,280 kWh.

Electrical System • On account of following actions, power saving of 2,82,657 kWh was achieved

• Replacement of old lighting fixtures with energy efficient ones in various Plants

and Buildings.

• Provided contactor and push button to keep normal lighting OFF and to make it

ON as per the requirement in CNA-II plant.

• Replacement of Split AC and fans with star rated AC and fans in Township area.

• Replacement of 6 nos. of Air Handling Unit motors in the Corporate Building.

Use of Solar Energy • Total 300 kW Solar Photo Voltaic power generation systems installed at (i)

Company Guest house building having capacity of 25 kW (ii) School building

having capacity of 125 kW and (iii) Corporate building is having capacity of 150

kW.

Steam traps management • Steam trap survey was carried out in various plants for identification of

defective traps and corrective actions initiated.

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Certificate of Merit Fertilizers

(Phosphate)

THE FERTILIZERS AND CHEMICALS TRAVANCORE

LIMITED

UDYOGAMANDAL COMPLEX-FERTILIZER PLANT

Ernakulam (Kerala)

Unit Profile

The Fertilisers and Chemicals Travancore Limited (FACT), one of the first large-scale

fertilizer plants in India located at Kochi in Kerala was incorporated in the year 1943.

FACT became a Public Sector company in 1960 and the Government of India became

the major shareholder in 1962. FACT has business interests in manufacturing and

marketing of fertilizers, Caprolactam, Engineering Consultancy and Fabrication of

equipment.

FACT’s mission is to be a market leader in Fertilisers / Petrochemicals and a

significant player in all its other businesses including engineering/ technology

services, providing maximum customer satisfaction and reasonable reward to

shareholders adhering to business ethics and professionalism with adequate concern

for the community and the environment.

The main products of FACT are complex fertiliser NP 20:20:0:13 (FACTAMFOS),

Ammonium Sulphate and Caprolactam.

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FACT has two manufacturing divisions (Udyogamandal Complex and Cochin

Division), a consultancy unit (FACT Engineering and Design Organization - FEDO), a

fabrication division (FACT Engineering Works – FEW) and Marketing Division.

FACT Udyogamandal Complex – Sections

FACT Udyogamandal plant, which started production of Ammonium phosphate in

1947 using fire wood gasification process, has undergone several stages of

expansion and diversification, giving up old and obsolete technology and installing

new and sophisticated plants. Apart from fertilizers like Ammonium Sulphate and

Ammonium Phosphate Sulphate (Factamfos) FACT Udyogamandal plants also

manufacture chemicals like Sulphuric acid, Ammonia, Sulphur Dioxide, Oleum etc.

As a replacement to the high energy consuming old ammonia plants at

Udyogamandal, a new 990 TPD capacity Ammonia plant at a cost of 642 Crore was

put up in March 1998.

Energy Management and Production Performance

FACT achieved an important landmark during 2013 – 14, by converting the feed and

fuel for Ammonia production from Naphtha to RLNG. The changeover was done

online - without stopping the plant - at 80% load and it was the first time in India, a

conversion of this kind was carried out without stopping the plant.

Specific energy consumption of Ammonia, with this conversion, improved from

9.626 GCal/ MT in 2012 - 13 to 9.511 GCal/ MT in 2013 – 14, in spite of the fact

that the plant run for just 4 months on RLNG.

The production figures for Ammonia and the Products for the year 2013 – 14 are as

below.

Item Installed Capacity

2013 - 14

Ammonia 3,26,700 MT 1,41,056 MT

Factamfos (NP 20:20) 1,48,500 MT 1,65,432 MT

Ammonium Sulphate 2,25,000 MT 1,78,792 MT

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Energy Conservation Measures Implemented

Particulars Description Major Benefits

Use of RLNG as feedstock in Ammonia Plant

The feedstock in 990 MT/ day Ammonia Plant was changed over from naphtha to Re-gasified LNG

• Better energy efficiency

• Reduction in carbon-dioxide gas emission & lesser pollution

• Capacity

enhancement

Use of RLNG for fuel in Boilers

The fuel used for boilers (5 X 60 T/ hr Capacity) was changed over from FO to RLNG by replacing burners and associated control system

• Cost reduction in steam production

• Lesser pollution

Particulars Description Major Benefits

Condensate

Recovery System in Sulphuric Acid Plant

Replacement of thermodynamic type

steam traps with Twin Orifice Float traps and installation of flash vessel with steam operated pump so as to recover steam condensate

• Better energy

efficiency of Acid Plant

• Cost recovery

Operational

changes in Plants, improved maintenance programmes etc.

Conducting Energy Audit and

implementing audit recommendations. The following programmes, without incurring any considerable expenditure, were carried out.

a) Providing saturated steam for heat exchangers in Ammonia Plant

b) Energy saving by reducing exit flue gas temperature by adjusting air-inlet damper

c) Replacing/ Cleaning of suction filter in Main Air Blower in Acid Plant

d) Proper maintenance of Air Compressor for increased

efficiency e) Lighting improvements

• Better energy

efficiency • Cost saving

Specific Energy Consumption of Products

Specific energy consumption of major products viz. Factamfos and Ammonium

Sulphate for the last three years is as below:

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The specific energy consumption of Ammonia improved from 9.626 GCal/ MT in

2012 - 13 to 9.511 GCal/ MT in 2013 - 14 due to RLNG conversion of feedstock and

fuel.

Energy Policy

FACT Udyogamandal Complex is committed to responsible energy management and

will ensure utilization of all forms of energy in most efficient, cost-effective and

environment-friendly manner in all our activities, products & services. The Company

will implement effective energy management programmes for continual

improvement in energy performance and ensure a safe and comfortable working

environment to all.

To accomplish this we shall:

1. Monitor closely and control the consumption of various forms of energy through

an effective Energy Management Information System

2. Implement effective programmes for increasing energy conservation awareness

throughout the organization

3. Conduct regular management reviews to ensure continual improvement

4. Reduce specific energy consumption of products by 2 % (from the present

average values) by the year 2016

5. Generate/ purchase 1% of our energy use from renewable sources by the year

2022