18 th National Award for Excellence in Energy Management

Transcription

1 18 th National Award for Excellence in Energy Management Presented By: Indian Farmers Fertiliser Cooperative Ltd. Phulpur Unit-I 30 th August 1 st September, 2017

2 IFFCO: At a Glance IFFCO was established as the farmers own initiative in Cooperative Sector on 3rd Nov Largest producer of fertilisers in the country. Nos. of Plant : Five (Kandla, Kalol, Phulpur, Aonla, Paradeep ) Installed/Revamped Annual Capacity Urea : NP/NPK/DAP : Total N : Total P 2 O 5 : WSFs : 15.0 Zinc Sulphate Monohydrate : 30.0 ( 000 MT) Contributed about 21% to the total N and 31.8% to the total P 2 O 5 produced in the Country during the year

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4 IFFCO Phulpur Unit-I : Profile Plant Ammonia Urea Process Licenser Daily Capacity (MTPD) Annual Capacity (Lakhs MT) Till Date Production (Lakhs MT) MW Kellog, U.S.A Snamprogetti Italy

5 IFFCO Phulpur Unit-I : Production Outline RLNG GTG-HRSG COAL Utility Boiler RLNG Ammonia Plant HP Steam RAIL Power HP Steam HP Steam CO2 Ammonia ROAD Neem Urea Bagging Plant Urea Plant 6

6 Phulpur-I: Production Performance Highest Ever Yearly Urea Production 7.58 ESTIMATED Actual Till Date Ammonia Urea 7

7 Phulpur-I : Sp. Energy Consumption Best Ever Yearly Energy NUP Norm: 6.5 (From April 2018) upto Aug '17 Year in Gcal/MT of Urea upto March '18 8

8 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Energy Saving (Gcal) 1 Installation of New Gas Turbine Generator (GTG) - Heat Recovery Steam Generation (HRSG) 2 Modification in CO2 Recovery Process- amdea Process in place of Benfield Process 3 Installation of New Medium Pressure Process condensate stripper (1104-E) 4 Old Synthesis Gas Converter (105-D) Internal Revamp 5 Installation of Ammonia recovery section to recover ammonia from off gases of synthesis loop Monetary Saving (Rs. Lakh) Investment (Rs. Lakh)

9 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Energy Saving (Gcal) 6 Replacement of Old Refrigeration Compressor Turbine with New Turbine in Ammonia Plant 7 Replacement of Old Air Compressor Turbine with New Turbine in Ammonia Plant 8 Replacement of Mixed Feed and Process Air Coil and installation of New VAM Coil in Ammonia Plant 9 New Urea Reactor with Casale High Efficiency Tray in Urea Plant 10 Installation of Ammonia Preheater in MP Section of Urea-I Monetary Saving (Rs. Lakh) Investment (Rs. Lakh)

10 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Energy Saving (Gcal) 11 Installation of CO2 Cooler through VAM in Urea Plant Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) Total (Thermal Energy) S.No Energy Saving Schemes Saving (KWh) 12 Replacement of 18 W LED tube light in Township quarter in place of 36 W Fluorescent tube light 13 Replacement of 75 Nos 36 W LED Fixtures in place of 36 W 110 nos CFL fitting Savings (Rs. Lakh) Investment (Rs. Lakh) Total (Electrical Energy)

11 1. Installation of New GTG-HRSG Key Features Power Generation: 25 MW Steam Generation: 60 MTPH RLNG Saving : 3600 Sm3/Hr Energy saving : 0.36 GCal/MT of Urea Monetary saving :Rs. 73 Cr. Investment :Rs. 239 Cr. The new GTG is catering the total power demand (24 MW) of the Phulpur Complex and existing Steam driven Turbo-generators TG-I and TG-II have been stopped. The 60 MT HP steam generated from HRSG is being used in process plants 12

12 2. Modification in CO2 Recovery Processs CO2 Absorber Modification in CO2 Recovery Process -amdea Process Modified HP Stripper CO2 Lean Absorber New HP/LP Flash Tower Old LP Stripper dismantled New CO2 Bulk Absorber CO2 Strippers With modification in CO2 Removal Section from Benfield to amdea, Regeneration Energy of CO2 has reduced from 950 Kcal/NM3 of CO2 to 450 Kcal/Nm3 of CO2. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : Investment (Rs. Crore) :

13 3. Installation of New Medium Pressure Process Condensate Stripper (1104-E) Old LP Stripper New MP Stripper In the Low Pressure Steam Process Condensate Stripper, around 8 MT/Hr of LP Steam was being consumed for Stripping. In new Medium Pressure Stripper, MP Steam is used as Process Steam. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 20.3 Investment (Rs. Crore) :

14 4. Synthesis Gas Converter Internal Revamp Due to internal revamp, the conversion efficiency of ammonia in converter is increased & the recycle gas flow rate is reduced which resulted saving of Power in Synthesis Gas Compressor. Ammonia Conversion: Particular Old Converter 105-D(Out) Before (%) After Revamp (%) New Converter Internals Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 14.2 Investment (Rs. Crore) :

15 5. Installation of Ammonia recovery section Ammonia recovery section has been installed to recover ammonia from off gases of synthesis loop under Energy Saving Schemes. Earlier, Off gases from Synthesis loop was sent to Primary Reformer & used as a fuel but after implementation of this scheme ammonia in Off gases has been recovered & thereby reduction in specific energy consumption. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 7.10 Investment (Rs. Crore) : New Ammonia Distillation Column (1501-E) 16

16 6. Installation of new Refrigeration Compressor Turbine in place of old Turbine Inefficient Old Refrigeration Compressor Turbine has been replaced with New efficient Turbine which has resulted in reduction in Specific Steam consumption. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 12.8 Investment (Rs. Crore) : 14.4 New Refrig. Compressor Turbine 17

17 7. Installation of new Process Air Compressor Turbine in place of old Turbine Inefficient Old Refrigeration Compressor Turbine has been replaced with New efficient Turbine which has resulted in reduction in Specific Steam consumption. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 15.6 Investment (Rs. Crore) : 14.4 New Process Air Compressor Turbine 18

18 8. Replacement of Primary Reformer Convection Section Coils and new VAM Coil For higher heat recovery, old Mixed feed & Process Air coil has been replaced with new coils in convection section of Primary Reformer. Additional a new VAM Coil has been installed where the process condensate is heated and this heated Process condensate is utilized in VAM Machine.. Yearly Saving (Gcal) : 9632 Yearly Saving (Rs. Crore) : 2.8 Investment (Rs. Crore) :

19 9. New Urea Reactor High Efficiency Trays New Urea Reactor with High Efficiency Trays (HET) in Urea Plant has been installed. The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor. Yearly Saving (Gcal) : Yearly Saving (Rs. Crore) : 4.0 Investment (Rs. Crore) : 4.6 High Efficiency Trays 20

20 10. Installation of Ammonia Preheater in Urea The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper is reduced. Erection of Ammonia Preheater Yearly Saving (Gcal) : 6980 Yearly Saving (Rs. Crore) : 2.0 Investment (Rs. Crore) :

21 11. Installation of CO2 Cooler through VAM A Vapour Absorption Machine (VAM) is installed to generate chilled water required for CO2 Gas chiller at the suction of CO2 Compressor of Urea plant, resulting in saving of steam consumption in CO2 Compressor turbine of Urea plant. Chilled Water Return Water VAM CO2 Cooler Yearly Saving (Gcal) : 5584 Yearly Saving (Rs. Crore) : 1..6 Investment (Rs. Crore) :

22 Other Energy Saving Schemes (A) Replacement of 18 W LED tube light in place of 36 W Fluorescent tube light Yearly Savings Power : kwh Saving : Rs Lakh Investment : Rs Lakh (B) Replacement of 75 Nos 36 W LED Fixtures for Control rooms in place of 36 W 110 nos CFL fitting Yearly Savings Power : kwh Saving : Rs Lakh Investment : Rs. 2.1 Lakh 22 23

23 INNOVATIVE SCHEME Utilization of waste heat of process condensate from Urea Plants to generate chilled water through VAM. This chilled water is being used for suction chilling of GTG Air which has helped to augment GTG Capacity by 4 MW and running additional motor driven pump instead of turbine driven pumps. Removal of check valve in the low pressure (0.65 kg/cm2g) CO2 gas line between Ammonia & Urea Plant (HAZOP is essential) which helped in increment of CO2 Compressor Suction Pressure by 0.04 kg/cm2. This has resulted in HP Steam saving of 1.8 MT/Hr equivalent to Gcal / Annum. Utilization of excess chilled water available in the complex to reduce CW temperature at the suction of syn gas cooler by installing spare plate type exchanger which helped to reduce the syn gas temperature at suction of compressor by 3 degc. 24

24 ROADMAP FOR ENERGY CONSERVATION Installation of additional Syn loop waste heat boiler for additional process steam production. 2. Replacement of LT Superheat coil in Primary Reformer Convection Section for higher steam consumption and bringing down the stack temperature to around 130 degc. 3. Replacement of Secondary Reformer Air Burner for reduced Air Compressor Discharge Pressure. 1. No planned Annual shutdown to avoid unproductive energy consumption in the tune of 0.05 Gcal/MT of Urea which means special care to be taken in maintaining the Cooling water quality and optimization of process plants with minimum variation. 1. Replacement of 40 years old CO2 Compressor Turbine with highly efficient Turbine. 25

25 Carbon Foot Print CO2 Emission in Lakh MT Sp. CO2 Emission MT/MT Year

26 Benchmarking with other Fertilizer Plants The fertilizer sector has been divided in the respective Vintage Groups by Department of Fertilizer based on the year of commissioning and the original feed stock. IFFCO Phupur-I had original technology of the 70 s and Naphtha as feed stock. Based on the same, our SEC norm shall be less than 6.5 Gcal/MT. With SEC of 5.85 Gcal/MT of Urea, IFFCO Phulpur is sitting on top of the chart. 27

27 INTERNATIONAL ACCREDITATIONS Product Steward Excellence Certification by International Fertilizer Association (IFA). 28

28 Installation of Online Environment Monitoring System Liquid Effluent Monitoring: Monitoring of ph, Ammonical Nitrogen and Flow in pipe line (Reuse of Treated effluent in horticulture & irrigation of farm land within IFFCO s premises) Local display for ph & TAN Flow Instrument & local display 29

29 Installation of Online Environment Monitoring System PM (Particulate Matter) measurement in Boiler ducts has been completed. Installed Transmitter & Receiver on Boiler Duct and Local Display 30

30 Raw Water Consumption Raw Water, M3/ MT of Urea CPCB Benchmark : 12 M3 / MT Urea National Benchmark (FAI) : 7.3 M3 / MT Urea Reduction : 47% Year 31

31 Substitution of Conventional Energy with Renewable Energy (A) Solar Street Lights: 40 Nos. 30W LED based Solar street lights installed in plant premises and township. (B) Solar Power Pack: 585 KWp Solar power pack installed in plant and is connected to the LT Grid. (C) Solar Light Pipes: 6 Nos. Solar Light Pipes have been installed Store Building. This has reduced the power of the 36 Tube lights installed in that area. 32

32 Substitution of Conventional Energy with Renewable Energy (D) Solar water Heaters 6 Nos. Water Heater in Guest House (E) Bio-Methanation Plant Capacity : 25 m3/day 33

33 Environment & Sustainability (A) Rain Water Harvesting Systems Total 5 Nos. Rain Water Harvesting systems are installed in township. Rain Water Harvesting (B) Installation of Ammonical Nitrogen analyser at Guard Pond (C) Modification in Neutralization facility of DM Plant and CPU Unit (D) Installation of new Ammonia sensor near boundary wall (E) Installation of Vent Silencer in Ammonia-I Plant 34

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35 Solar Power Plant Installation Status: Two Units of Solar Power Plant of Capacity 585 KWp (235 KWp KWp) were commissioned in the January and February 2016, respectively. Both the Solar Power Units are in continuous operation generating Electic Power in the tune of 740 KWh and 1140 KWh on daily basis. Additional Project for installation of 800 KWp Solar Power Panels comprising of 7 different locations is in under progress. 36

36 WASTE DISPOSAL Fly Ash Generated in Power Plant being gainfully utilised by Cement industries,for Brick Making, For Paving & Boundary walls and for Usar land reclamation. Dry Fly Ash Disposal 37 Fly Ash Utilised for Brick Making

37 WASTE DISPOSAL Kitchen and Horticulture Waste Bio degradable wastes from kitchen and horticulture are converted into very good manure by vermi composting System. The manure is used in horticulture, green belt area & 150 Acres farm land Vermi Compost Pits 38

38 Monitoring & Reporting System No. of Reports are generated on daily/weekly/monthly/ quarterly and yearly basis for Reporting & Monitoring the Energy Consumption: Daily Performance Report Steam Balance Report Cost report of Ammonia, Urea and Steam & Power generation Plant Weekly Weekly performance Report Monthly Variance report actual vs. targeted as well as last year Form ECS/GC 4 to assess profitability 39

39 Sample Performance Reports 40

40 Employee Engagement IFFCO Phulpur Unit encourages its employees through Suggestion Scheme to give ideas of energy conservation Approx suggestions are received every year from employees. Selected suggestion are awarded by the management. A View of Suggestion Award Ceremony on Republic Day 41

41 Procurement Process IFFCO Phulpur has taken care of Energy optimization right from Procurement process among Vendors / Suppliers / Contractors The Evaluation of a Bid is done on the basis of Operating Cost Loading is be done to take care of the Performance and Productivity of equipment offered. In case the consumption of utilities are different for different Bidders. Extra operating cost over the minimum one shall be calculated as below for loading. Operating cost = Difference in utilities consumption x Unit cost of Utility x 8760 x 0.9 x x N Where: 8760 is number of available hours in a year 0.9 is availability factor is discount factor at an interest rate of 10% per annum for one year erection/commissioning and ten years operational period. N is the number of operating equipment items. 42

42 Awards & Recognition National Energy Conservation Award : 2nd Prize 43

43 Awards & Recognition FAI Environment Protection Award : Joint Winner 44

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