Presented by:

Mr. Neeraj Rajesh (Chief Manager- Urea),

Mr. J S Garcha (Chief Manager- Ammonia),

Mr. Sunil Kumar (Manager (GE)

Leading producer & marketer of fertiliser in India

No. of plant locations : 5

Installed Annual Production Capacity

• Urea : 4.24 Million MT

• NPK/DAP : 4.34 Million MT

IFFCO in Brief

IFFCO Aonla-II Unit

IFFCO Aonla Unit, located in northern part of India, operates

Two streams of Ammonia (1740 MTPD each) & 4 streams of Urea

(1515 MTPD each) and is based on Natural Gas as feed & fuel.

Last 3 Years Specific Energy Consumption

Year Specific energy consumption

(Gcal/MT Urea)

2015-16 5.308

2016-17 5.360

2017-18 5.224

Specific energy consumption for F.Y. 2016-17 includes

energy losses occurred during implementation of Energy

Saving Schemes (Phase-I) and energy consumed in ongoing

activities of ESP (Phase-II).

Description National

Benchmark

Average

Value (For All

Gas based

Plant)

International

Benchmark

Specific

Energy

Consumption

5.158 5.880 Not Available

IFFCO Aonla-II:

Urea Plant

(year: 2017-18)

5.224 5.224

5.224

Unit : (Gcal/MT of Urea)

Comparison with National & International Benchmark

Advanced Process Design

Complex Integration

Improve Operating Practices

Minor Modifications

Major Modifications

Roadmap to achieve National & International Benchmark

Title of Energy Saving project

implemented

Year of

Impleme

ntation

Total

Annual

Savings

(Rs

Lakhs)

Invest.

Made

(Rs

Lakhs)

Pay

back

(Years)

Provision of additional vent valve

(PIC) in final discharge line of

Process Air Compressor to prevent

compressor from surging

2015-16 189.0 3.0 < 1

Month

Replacement of CFT material spacer

rings and guide rings with PEEK

material rings in High Pressure

Ammonia Pump (P-1C)

2015-16 7.8 2.2 3.0

Replacement of conventional lighting

fixtures with energy efficient lighting

fixtures

2015-16 5.3 26.3 5.0

List of Energy Conservation Projects

Title of Energy Saving project

implemented

Year of

Impleme

ntation

Total

Annual

Savings

(Rs

Lakhs)

Invest.

Made

(Rs

Lakhs)

Pay

back

(Years)

Energy Saving Project (Phase-I) 2016-17 3745 7660 2.1

Utilisation of Flash Steam generated

in Steam Condensate Tank as motive

fluid in booster ejector (EJ-2) in Urea-

II Plant.

2016-17 200 3 < 1

Month

Replacement of conventional lighting

fixtures with energy efficient lighting

fixtures

2016-17 4.9 15.0 3.1

List of Energy Conservation Projects

List of Energy Conservation Projects

Energy Saving Project (Phase-I)

1) Installation of New Ammonia Wash System at 2nd stage discharge

of Synthesis Gas Compressor followed by synthesis loop

modification.

2) Revamp of Synthesis Gas Compressor involving replacement of HP

& LP case internals

3) Replacement of existing CO2 compressors by new higher efficiency

compressors in Urea-II Plant

Title of Energy Saving project

implemented

Year of

Impleme

ntation

Total

Annual

Savings

(Rs

Lakhs)

Invest.

Made

(Rs

Lakhs)

Pay

back

(Years)

Energy Saving Project (Phase-II) 2017-18 7722 26440 3.4

Utilisation of process heat (MV-2 off

gases) for saving of LP steam during

urea melt recovery.

2017-18 130 5 < 1

Month

Replacement of conventional lighting

fixtures with energy efficient lighting

fixtures

2017-18 11.9 23.2 1.9

List of Energy Conservation Projects

List of Energy Conservation Projects

Energy Saving Project (Phase-II)

Replacement of existing GV solution based CO2 removal section by

aMDEA solution based CO2 removal section for less energy

requirement.

Installation of Ammonia Preheaters in 31 & 41 streams of Urea Plant at

upstream of Carbamate Recycle Ejector

Modification in exhaust duct of Gas Turbine Generator (GTG-II).

Utilization of process heat

available in

MP Decomposer Separator

off-gases

for concentrating recovered Urea

Melt in Urea-II Plant

Original System

Urea synthesis of NH3 and CO2 at high pressure & temperature.

Urea formation in High Pressure Synthesis Section is around 60%.

Mixture of urea, ammonia and carbamate solution from HP section is

passed through:

Medium Pressure,

Low Pressure,

Pre-Concentrator,

Vacuum & Evaporation Sections and

Prill Tower to make urea prills

Vacuum & Evaporation Section: (Urea concentration: 80%- 99.97%)

1st stage Vacuum system- 0.3 kg/cm2a ,

2nd stage Vacuum system- 0.03 kg/cm2a

Original System (Contd…)

Original System (Contd…)

Urea Solution Recovery Tank receives around 500 MT Urea solution per

week (of 70% concentration) from following sources:

During weekly preventive maintenance of backend equipments

Urea slurry from urea dissolving tank

During urea melt recovery cycle, this urea solution was concentrated in

1st Stage Evaporator and resulting in additional LP steam consumption

of around 3.0 MT/hr.

Modified System

Vacuum Pre-Concentrator at the upstream of Vacuum & Evaporation

section utilizes process heat of MP Decomposer off-gases to

concentrate Urea solution from 70% to 80%.

Balance heat available with off-gases has to be extracted by cooling

water in MP condenser, before sending to MP Absorber. Around 6.6

Gcal/hr, process heat was being thrown into cooling water.

To utilize this additional process heat in Pre-concentrator, discharge of

melt recovery pump is connected to the inlet of Pre-Concentrator.

With this modification, process heat of MP Decomposer off-gases is

utilised to concentrate the recovered urea solution and resulting in

saving of LP steam in 1st Stage Evaporator.

Modified System (Contd…)

Benefits

Additional LP steam requirement during melt recovery cycle has

eliminated.

Heat thrown in cooling water is also reduced due to temperature

reduction of MP decomposer off-gases at MP Condenser inlet where

cooling water is used as cooling medium.

Saving & Payback

Energy Saving achieved : 4900 Gcal/annum

Monetary saving : Rs. 130 Lakhs/annum

Investments : Rs. 5.0 Lakhs

Payback Period : Less than a Month

Replication Potential

The modification is innovative in the sense that

energy saving have been achieved by utilizing the

heat available with off-gases which was earlier

dumped in cooling tower.

The modification has high replication potential in any

fertiliser industry where such type of urea recovery

arrangements are in operation.

Solar Water Heating System

Solar Street Light System

Roof Top Solar Photovoltaic Panel at various building

Renewable Energy Sources

Roof Top Solor Power at PH Plant

Particulars Unit FY 2015-16 FY 2016-17 FY 2017-18

Roof Top Solar PV KWH/day - - 378

Solar Water Heating KWH/year 34800 34800 34800

Solar Street Light KWH/year 1100 1100 1100

Utilisation of Renewable Energy

Sources

Utilization of Waste

Waste Utilization

Purge Gas Recovery (PGR) unit to recover Hydrogen and

recycle it back for achieving energy saving.

Carbon Dioxide Recovery Unit

Use of treated effluent water for the irrigation of green belt

Particulars Unit FY 2015-16 FY 2016-17 FY 2017-18

Purge Gas Recovery Gal/year 116879 106757 95740

GHG Inventorization

Particulars Unit CO2 Gen./MT Urea

FY 2015-16 Gal/year 0.486

FY 2016-17

Gal/year

0.478

FY 2017-18

Gal/year

0.490

CO2 generation per MT Urea:

Note: CO2 generation sources includes fuel consumption in

Primary Reformer, GT and HRU in Ammonia Plant and

Purchased Power Used:

Team work,

Employee Involvement

&

Monitoring

Methodology :

1. Estimation of saving in

terms of steam, power,

gas etc.

2. Calculation of saving in

terms of Raw Material,

i.e. natural gas

3. Derive Total energy

Saving based on energy

value of raw material.

4. Total yearly production is

used for calculating

specific energy

consumption.

Energy Monitoring & Methodology

Daily review meeting

chaired by Unit Head

Energy Conservation Cell

Energy monitoring cells for Ammonia, Urea, Product

handling, Offsites and Power plant.

Each cell consists of persons from Technical, respective

Production, Maintenance and Instrumentation sections.

Management Representative – reporting to top

manangement

Energy Manager

Preparation of plant performance and energy reports on

daily, monthly and yearly basis and accordingly corrective

actions are taken.

Energy Efficiency / Awareness Training Program

Steps taken based on the recommendations of energy cell

Monitoring and achieving the most optimum vacuum in

surface condensers.

Based on the performance evaluation, compressors/turbines

are recommended for overhauling.

Trimmed operation of cooling towers to achieve most

optimum cooling water temperature.

Steam lines insulation survey helped in reducing the loss of

heat to atmosphere.

Energy Efficiency / Awareness Training Program

Involvement of plant personnel through Plant Suggestion

Schemes

Employees are motivated through “Innovation &

Creativity Meet” organized at Corporate level.

IFFCO Aonla won Champion – Maximum Participation

Award from INSAAN-NIC for employee involvement in

Suggestion scheme.

Plant personnel are encouraged to give their valuable ideas

on last Friday of each month through ‘Idea Friday’.

Energy Efficiency / Awareness Training Program

Certifications

Energy Saving Project in IFFCO Aonla-II Unit has implemented in two Phases.

ESP Phsae-I (FY 2016-17)

ESP Phase-II (FY 2017-18)

Apart from ESP, Various energy saving schemes are implemented inhouse regularly.

Investment for the ESP and inhouse energy saving modifications are given below for FY 2017-18:

% investment on turnover

% investment for energy

conservation projects on

turnover

12.94%

(Rs. 2137.8

Million)

NSCI Safety Award-2017

(Sarvashreshtha Suraksha

Puraskar) from National

Safety Council of India.

National Energy Conservation

Award-2017 (Second Prize) from Bureau of Energy

Efficiency, Ministry of Power,

Government of India.

Excellent Energy Efficient Unit Award-2017 in

Fertiliser sector from Confederation of Indian

Industry (CII).

Most Innovative Environmental Project Award from

Confederation of Indian Industry (CIl) under CII

Environmental Best Practices Award-2017.

FAI Safety Award-2017 (Runner up) for excellence in

safety from The Fertiliser Association of India.

Uttar Pradesh State Energy Conservation Award-2017

(Second Prize) from Uttar Pradesh New & Renewable

Energy Development Agency (UPNEDA).

Excellence Award for Case Study presented & Best

Suggestor Award from (INSSAN-NIC) in 19th National

Creativity Summit-2017.

7th Annual Greentech HR Award-2017 (Gold Award)

from Greentech Foundation.

Safety Innovation Award in Fertiliser & Chemicals

sector from Institute of Engineers (India).

16th Annual Greentech Safety Award-2017 (Gold

Award) in Fertiliser sector from Greentech

Foundation.