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MAJOR ACHIEVEMENTS:

Ø Milestone:

Highest daily dispatch of NPK/DAP/WSF fertiliser of 15927.600 MT on 12.10.2014

surpassing the previous best of 15391.800 MT on 28.10.2007.

Ø IFFCO Kandla has achieved highest daily production of zinc sulphate monohydrate of

82.00 MT on 27.02.215, surpassing the previous best of 78.00 MT on 22.02.215.

Ø Phosphoric Acid Supply from JIFCO, Jordan: The phosphoric acid supply from JIFCO, Jordan has commenced. The first shipment of

10000 MT bulk phosphoric acid was received on 10th July-2014. Till date, we have received

2.65 lakh MT of bulk phosphoric acid.

The quality of acid is good for production of NPK/DAP fertliser.

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MAJOR AWARDS and CERTIFICATION

During 2014-15, IFFCO Kandla unit has won following major awards:

v IFFCO Kandla has won FAI Runner-up award for Technical Innovation on “Effective

utilization of heat energy from ammonia refrigeration system to heat liquid ammonia from -

330C to 0 - 50C for NPK plant resulting in elimination of steam” for the year 2013-14.

v IFFCO Kandla has been awarded for Best Unit for excellence in suggestion scheme for the

year 2013-2014 at the inter-unit creativity meet held at FMDI in May-2014.

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v IFFCO Kandla has received “Best Suggestion Scheme Implementation Award” from

INSSAN, New Delhi.

v IFFCO Kandla has received Gujarat Govt. Award of “Shram Ratna” and “Shram Veer” for

the year 2013-2014 for innovative implementation of Energy saving and productivity

improvement schemes.

v Shri Sukesh Nangal has won best suggestor award in INSSAN National seminar held at

Mumbai in Jan-15.

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v IFFCO Kandla unit received the "Certificate of Honour" for Accident Free Working "More

than Three Million Manhours" and "Certificate of Appreciation" for Accident Free Working

"More than One Million Manhours" from Gujarat Safety Council in the year 2015.

v OHSAS 18001:2007 certification

IFFCO Kandla has received OHSAS 18001:2007 certification from M/s Bureau Veritas in

Nov-14. The development of system and documentation was done in-house for obtaining

the certification. The whole documentation/audit process has been done on paperless basis

and complete system has been uploaded on the server for reference of all employees.

v ISO 14001:2004 certification for IFFCO Kandla Township

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IFFCO Kandla Township has received ISO 14001:2004 certification from M/s Bureau

Veritas. The development of system was done in-house and paperless documentation and

auditing was done for the certification.

V. TECHNICAL DEVELOPMENTS AT IFFCO KANDLA

Kandla Unit has taken various measures for technical development, retrofitting & revamping projects. A brief summary of the same is given below: Sr.No.

Title Benefit/ Annual Saving

1 Installation of Polishing Screen in K-I Quality improvement through better and uniform product size.

2 Fortification of NPK 12:32:16 product with 0.5% Zinc Addition of Zn micronutrient to fertiliser.

3. Replacement of process stack of A and B train with new stack. The discharge of fumes fan will go through cooler scrubber which will act as second stage scrubber.

Improvement in ammonia efficiency.

4. Modification in Granulator Pipe Reactor(GPR) by increasing the diameter from 3" to 6" and length by 1 m.

Quality improvement by improving reaction efficiency.

5. Slurry Header Relocation in Granulator Quality improvement through proper granulation.

6. Operation of scrubber at low mole ratio has been implemented in NPK plant

Ammonia scrubbing has improved.

7. Installation of DCS in A and B Train. Better monitoring and control of the process

8. Supply of Phosphoric acid directly to K-II GPR/DPR bypassing the day tank

Provides flexibility in operation whenever Phos. Acid tank is under cleaning/maintenance.

9. Two load cells in potash feeder in NPK/DAP plant Precision in feeding potash and better control of the process

10. Product pan feeder is in operation in all the trains of

NPK plant.

Continuous and un-interrupted flow of product.

11. Separtion of scrubber liquor feed to GPR and inclined

venture in K-II plant.

Better scrubbing operation.

12. Installation of Vibration Monitoring system for fumes and Safety of fan and motor has

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dryer fan in NPK plant. increased. 13. Mechanised Zinc Ash feeding in Zinc sulphate plant Fast and safe supply of zinc

ash to reactor. Environment friendly.

14. Increase in Height of Zinc Sulphate Reactors by 1.5 m. For enhancing reliability by increasing capacity of reactor.

15. Installation of two additional filters with Mud washer tank (MWT) in zinc sulphate plant

To increase capacity and improve production reliability

16. Installation of steep conveyors and FFS in water soluble NPK 18:18:18 plant.

Automation in water soluble packaging and saving labour cost.

17. Effective Utilization of Heat energy gained from AHU of central AC to heat ammonia for process and return chilled water for AC.

Rs. 9 crore (electrical energy saving of Rs. 2.73 crore and steam saving of Rs. 6.27 crore)

18. Use of STP treated water and DM regeneration water for Horticulture.

Saving of water consumption of 200 MTPD equivalent to monetary saving Rs. 80 lakhs.

19. Renovation of old potash storage by enhancing the capacity storage shed from 20000 MT to 30000 MT.

Simplification in reclaiming system for material transfer to plant and also saving electrical and maint. Cost.

20. UV testing of PP bags through 8 nos. of QUV Accelerated Weathering tester of M/s Q-Lab Corporation (U.S.A.).

Bags Quality checking is ensured.

21. Introduction of D Cut provision in water soluble pouches.

Easy and safe handling of pouches.

22. Energy saving by installation of total 175 nos. of energy efficient HT and LT Motors.

Energy saving of Rs. 1 crore.

23. Increase in speed of conveyors by modification of 70 no. of gear box internals in plant(K-I,K-II,Offsite and PH).

Reduction of spillages and faster handling

24. Monetary Saving due to Power Trading Rs. 6.78 crore during 2014-15 till Feb.-15. Rs. 9.92 crore since inception (Dec -13).

25. Installation of a new DG Set of 1010 kVA.

Availability of emergency power.

VI. QUALITY IMPROVEMENT MEASURES AT IFFCO KANDLA

1. Installation of Polishing Screen in K-I

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Polishing screens have been successfully installed in all four steams of K-I plant. 95% of

the final product is between -4 mm to +2 mm range.

2. Fortification of NPK product with 0.5% Zinc Kandla Unit has started producing 12:32:16:0.5 (Zn) from Nov-14. Zinc sulphate liquor

produced in zinc sulphate plant is transferred to zinc sulphate liquor storage tanks of

K-I and K-II plants. The zinc sulphate liquor is fed to PN/Scrubber Effluent tank of NPK

plants through automated feeding system. 51021 MT of zincated Gr-II has been

produced till Jan-15.

3. Modification in Granulator Pipe Reactor (GPR) in K-II.

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In house modification in Granulator Pipe Reactor (GPR) of E & F Trains has been

carried out by increasing the diameter from 3" to 6". Also, length of GPR is increased by

1 meter, resulting in improved mole ratio from 1.30 to 1.36. This has resulted in

improvement in reaction efficiency due to higher reaction time and product quality has

improved.

4. Slurry Header Relocation in Granulator The slurry header has been elevated with the beam resulting in increased slurry

distribution area over the bed. This has resulted in better granulation.

5. Stack Replacement Job in “A” and “B” Trains

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Process stack of “A” and “B” trains has been replaced with new stack. The discharge of

fumes fan will go through cooler scrubber which will act as second stage scrubber and

improve ammonia efficiency (reduce ammonia by 10-20 ppm after second stage

scrubbing). Annual Saving is about Rs. 48 lakh.

6. Bags Quality Improvement IFFCO Kandla unit has procured 8 nos. of QUV Accelerated Weathering tester

from M/s Q-Lab Corporation (U.S.A) in which bags are exposed to UV rays for 144hours

and its tensile strength before testing and after testing is measured. This has helped in

ensuring bag quality.

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VII. ENERGY SAVING/ COST REDUCTION MEASURES AT IFFCO KANDLA

1. Effective Utilization of Heat energy gained from AHU of central AC to heat ammonia for process and return chilled water for AC.

A system has been installed to heat ammonia by gaining the heat of central AC units.

1) The ammonia at -330C is heated to 00C and the chilled water is generated.

2) The chilled water goes to the AHU of four central AC units and gains the heat.

3) The hot water goes again to the ammonia system.

This has resulted in

v Zero consumption of steam resulting in annual saving of 21000 MT steam equivalent

to Rs. 6.27 crore.

v Stopping of AC unit compressors resulting in annual saving of 3400 MWH. Other

electrical energy saving of 106 MWH is on account of reduction in load of ammonia

compressors and stoppage of cooling tower fans.

v Total electrical energy saving is Rs. 2.73 crore.

Overall monetary saving on annual basis is Rs 9.0 crore.

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2. Monetary Saving Due to Power Trading

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IFFCO Kandla Unit has entered into power purchase agreement through Indian Energy

Exchange (IEX) and Power Exchange India Ltd. (PXIL) under provisions of short term open

access.

During 2014-15, Rs. 6.78 crore has been saved by Power trading.

Cumulative saving since inception i.e. Dec-13 is Rs. 9.92 crore.

3. Total 175 nos. of energy efficient HT and LT motors of IE3 class have been installed. Total

saving is approx. Rs. 1 crore. Payback period is 1.5 years.

4. One 60 HP & 100 HP VFD were installed at Primary air Blower & Quench air fan D train in

order to conserve energy by operating the fans at desired speed.

5. Installation of 600 nos. of 18 watt/15 watt LED fixtures in place of 36 watt conventional

fixtures at IFFCO Kandla plant office buildings.

VIII. VARIOUS PLANT MODIFICATIONS CARRIED OUT IN 2014-15.

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1. Installation of DCS in A Train DCS installation has been done for A and B trains. Now all the six streams are on DCS.

DCS will help in better monitoring and control of the process.

2. Upgradation of MOC of RM bins of A and B trains:

Raw Material bins of A and B trains have been replaced with new MOC of SS304L/316L

(conical portion) except top portion which is MS. This will help in operation by

maintaining consistent material flow, reduced corrosion and improved reliability of raw

material bins.

3. All sulphuric Acid handling lines has been replaced with SS 316L from Mild steel for

enhancing safety in the Plant.

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4. Preneutraliser (PN) tank level indicator has been relocated outside of PN and proper

jacketing is also ensured for continuous & reliable readings of PN level.

5. In NPK-I, all trains have been retrofitted by replacing solid shaft PN agitator with hollow

shaft agitator for better gearbox life and cost reduction of maintenance and power.

6. The Reco make slurry pump has been put to use against the traditional wilfley slurry

pump. As the Reco pump has carbon-steel material with gland packing (which provides

more secure sealing), seal failure has been reduced significantly. Also the

maintenance cost of seals has reduced. Reco pumps cost less than wilfley pumps.

7. Ramp of ammonia sparger in K-II has been modified by suitable positioning of

proximity sensors.

8. CDR 480 fluid coupling has been replaced with FCU type fluid coupling in RMTE A &

B. This will reduce breakdown of elevator chains in case of excess load.

9. Raw material feed conveyor (Potash feeder) speed measurement instrument has been

replaced from Tachometer to Decoder(Electronic sensor), which has high pulse rate

(1025 per second). This increases the sensitivity and accuracy of measurement

10. Use of STP treated water and DM regeneration water for Horticulture A piping network has been provided for usage of STP treated water and DM

regeneration water which are mixed and same is used for horticulture and general

cleaning purpose. It has helped in conserving 200 MTPD water.

Annual saving is Rs. 80 lakh.

11. Renovation of old RMS System

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The capacity of Urea & Filler storage shed has been increased from 20000 MT to 30000

MT. Reclaiming system for material transfer to plant has been simplified with few

conveyors for material feeding.

12. Dedicated water supply from GWSSB

70% of the water requirement of the plant is supplied by private parties (bore well water)

which is expensive and has high TDS. The scheme will be executed by GWSSB after

final clearance from Chief Engineer which is expected by mid April-15. This will increase

water supply from GWSSB to plant.

13. Programme has been prepared in SCADA PLC of Ammonia Storage for calculation of

Ammonia stock of ammonia storage tank with reference to the level in respected tank.

14. CCTV cameras has been installed at Slat conveyors of the bagging Plant for

performance monitoring of bagging and stitching.

15. Signals are provided on the rail tracks and a wall has been constructed to separate the

rail track from road. This has increased safety for rail movement

16. Ultrasonic level sensors have been installed in bunkers. These are more reliable than

load cell and have helped operations in timing the operations to fill the bunker.

17. Ceramic pulley has been used in few product handling conveyors. This has helped in

avoiding off-center of belt and spillage of material. Also the material does not stick to

the surface of pulley. This has improved reliability of the material handling operation.

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18. In bagging plant, Scrapper loader of two trains has been installed with torque regulated

mono spiral CRD. This has given advantage of continuous operation without need to

change over for plug in cable at various location, which was tedious operation with old

CRD. This will ensure safety and continuity of operation and also manual intervention

is avoided.

19. MOC for Scrapper Loader chain bush and bush link has been changed to EN 19 &

SAE 8620 which has more Mn content and has 0.2-0.4% Mo(earlier material was

20MnCr5 & 16MnCr5).

20. Sack grip of bagging machine of product handling plant has been modified with curve

shape in place of existing flat sack grip. This has increased sealing area between the

machine discharge chute and bag resulting in better gripping of bag.

21. Colour printing of strips on NPK/DAP bags has been implemented in place of weaving

colour strips for identification of bags.This has reduced lead time of bags procurement

and it will reduce the inventory of bags.

22. MS hand-railing in plant has been replaced with SS 304. This has increased reliability.

23. Mechanized Zinc ash feeding to all four reactors of Zinc Sulphate plant has been

implemented. This has resulted in uninterrupted feeding of Zinc ash, resulting in better

control, manual handling of zinc ash and avoiding spillages.

24. Increase in Height of Zinc Sulphate Reactors

Height of all reactors of Zinc Sulphate plant has been increased by 1.5 m. This has

increased the capacity of reactors for higher production.

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25. Filter press outlet mother liquor line MOC (Material of Construction) has been changed

from MSRL(Mild Steel Rubber Lining) to SS . This has increased reliability of the pipe

line.

26. Agitator has been provided in Reaction Holding Tanks (RHT) of zinc sulphate plant.

This has improved thorough mixing of the slurry and prevention of settling of mud in

RHTs.

27. Two additional filters with Mud washer tank (MWT) are being installed to increase

capacity and improve production reliability.

28. Primary Mud washer tank agitator MOC has been changed from MSRL to SS 904L in

Zinc Sulphate Plant. This has increased reliability of the agitator as earlier agitator got

frequently damaged due to low pH condition.

29. Reaction Holding Tank (RHT) pump of Zinc sulphate plant has been replaced with

Warman make. This has reduced seal leakage of the pump and increased reliability of

operation.

30. Control logic has been developed for using FFS machine for product from either of

the two dryers of Zinc Sulphate plant. This has improved the operational flexibility for

packaging of product.

31. Slope of Urea Phosphate dryer has been reduced by lifting the trunion. This has

increased retention time and improved moisture content to 0.5% or less in urea

phosphate product resulting in free flowing of product.

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32. Agitator has been provided in Urea Phosphate Mother Liquor Tank which has ensured

continuous transfer of mother liquor recycled to K-II plant and reactor and prevents

settling of impurities at tank bottom and also reduced downtime while cleaning of tank.

The recovery of nutrient has also increased in urea phosphate plant.

33. Installation of steep conveyors and FFS in NPK 18:18:18 plant Steep conveyor has been installed in NPK-18:18:18 (R & D plant) along with FFS(form,

fill and seal) machine. This has resulted in automation of water soluble product

packaging, reducing manual handling process, labour and handling losses and overall

housekeeping has improved.

34. Installation of New DG Set

A new DG set of 1010 kVA has been successfully installed near Main Receiving

Substation(MRSS). It has auto RUN/STOP control panel and power distribution panel.

This ensures the availability of power supply to fire pumps, lifts, agitators, lighting etc.

during GEB power failure condition.

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35. Minimum oil circuit breaker of 66 kV switchyard, installed since inception, was replaced

with Sulphur Hexa fluoride (SF6) circuit breaker which has high dielectric strength and

capacity.

36. 2000 kVA transformer has been installed by replacing old 1500 kVA transformer in

order to improve the operation reliability in A train.

IX. PROJECTS UNDETAKEN AT KANDLA UNIT: 1. Implementation of fuel changeover project by installation of Hot Air Generator

(HAG) and Coal Fired Boiler.

IFFCO – Kandla is presently using fuel oil for generation of steam and drying of fertilisers.

The requirement of fuel oil is 75 MTPD. A proposal to replace the costly fuel oil with coal

was studied and project implementation for installation of two indirect fired HAGs of 50

lakh kcal/hr each for the two streams of zinc sulphate plant, six direct HAGs of 50 lakh

kcal/hr each for the six streams of NPK plant and one coal fired boiler of 14 MTPH with

steam generation pressure of 12 kg/cm2 was initiated. The order was placed on

28.10.2013 on M/s Thermotech Systems Ltd., Ahmedabad on turnkey basis. The civil work

consultant is M/s VMS, Ahmedabad and the civil contractors are M/s Paresh Construction

for piling work, M/s B T Patel for K-II plant building of HAG , M/s KK Construction for coal

storage, conveyor system, crusher house and superstructure of K-I plant for HAG & coal

fired boiler. The total cost of project is Rs. 61.00 crore.

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A) Successful commissioning of HAG for K-II and zinc sulphate plant: IFFCO Kandla has successfully commissioned direct coal fired HAG for “E” and “F”

streams of K-II plant on 16.3.2015 and indirect coal fired HAG for zinc sulphate plant on

29.3.2015. This will save expensive 38 kL/day of FO by utilizing cheaper coal of

101 MTPD.

B) Progress in HAG K-I area: i) Civil Work: Foundation work for equipments is in progress for HAG A & B.

Dismantling of boiler roof is in progress. Piling and foundation work for CD duct is in

progress. Civil site shall be handed over for execution by 10th April-2015.

ii) Overall Project Schedule: Erection of equipments for HAGs in K-I shall be started

by second week of April-15. Commissioning of four direct HAG in K-I and coal fired

boiler is expected to be done by Aug. – 15.

The annual savings on replacement of fuel oil with coal will be about Rs. 40 crore @ FO cost

of Rs. 39400/MT and coal cost of Rs. 4500/MT. Based on current market scenario, at FO

price of Rs. 27267/MT and coal price of Rs. 3800/MT, current annual saving on replacement

of fuel oil with coal of HAGs will be about Rs. 30 crore.

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X. ENVIRONMENTAL IMPROVEMENT/ USES OF RENEWABLE ENERGY SOURCES

a) Installation of light pipes and turbo ventilator 30 no. of day light pipe in mechanical workshop, 15 no. of day light pipe in electrical

workshop and 62 no. of turbo ventilator have been installed in store building which reduces

the use of conventional energy. Annual saving is Rs. 2.1 lakh approximately.

b) Installation of solar water heaters Total ten nos. of Solar Water heater system were installed at Udaynagar Township. This

has saved electrical energy consumption equivalent to monetary saving of Rs. 3.2 lakh per

annum approximately.

c) Installation of LED lights 470 nos. LED lights were installed at Township street lighting in place of 125 watt HPMV/

70Watt HPSV under the scheme Conservation of energy and reducing carbon emission.

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Installation of approximately 400 nos. of 20 watt/18 watt/15 watt LED fixtures in place of 36

watt conventional fixtures at IFFCO Kandla plant office buildings. This has saved electrical

energy consumption equivalent to monetary saving of Rs. 9 lakh per annum

approximately.

d) Mass Tree Plantation at township IFFCO Kandla as a part of state level celebration of Independence Day 2014 has organised

a massive tree plantation in its township land at Gandhidham. The trees planted during the

programme include mango,lemon etc. This new fruit garden occupies area of around 5

acres consisting of more than 500 trees/plants.

Plantation of total 14760 Trees & Plants has been carried out in township in 2014-15.

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IKBLL Barge Jetty a) Material Handled at Barge Jetty Operation

During 2014-15, total cargo of 9.66 lakh MT solid cargo has been handled at barge jetty.

The total cargo handled at Barge Jetty since inception i.e. Nov.-13 is 12.35 lakh MT.

b) Construction of covered storage shed at IKBLL Barge Jetty back up area

A storage shed of 35000 MT capacity is under construction at Barge Jetty and will be ready

by August-2015. The storage will be used for storing the solid cargo received at jetty as per

requirement of IFFCO and third party.

c) Mangrove Plantation IFFCO Kandla has carried out mangrove plantation in an area of 200 hectares at Sat Saida

Bet, Kandla. IFFCO has constructed a Captive barge jetty and committed to maintain the

balance eco system by plantation of Mangroves. Gujarat Institute of Desert Ecology

(GUIDE) was the consultant and has executed the plantation work.