19th National Award for Excellence in Energy Management

Transcription

1 19th National Award for Excellence in Energy Management Presented By: Indian Farmers Fertiliser Cooperative Ltd. Phulpur Unit-I 29th 31st August,

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 18.5 % to the total N and 29.2 % to the total P 2 O 5 produced in the Country during the year

3 3 Journey of 50 Glorious Years

4 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 5

6 Phulpur-I : Sp. Energy Consumption NUP Norm: (upto March 2018) 6.64 NUP Norm: 6.5 (From April 2018) in Gcal/MT of Urea 6.74 Best Ever Yearly Energy Year 6

7 Lakhs MT Phulpur-I: Production Performance Installed Capacity 7.58 Highest Ever Yearly Urea Production Installed Capacity Ammonia YEAR Urea 7

8 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (Gcal) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 1 Replacement of 2 nd Stage Intercooler of Process Air Compressor in Ammonia I Plant Installation of Vapor Absorption Machine(VAM ) for CO2 cooling in Urea-I Plant 3 Installation of VAM for Suction Chilling of Air in Gas Turbine Generator(GTG) Total (Thermal Energy)

9 9 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (KWh) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 4 Installation of 350 KWp Solar Power Panels at different locations in Phulpur- I Plant Replacement of 150 Nos 90 W LED Street Light fixture from front side of Plant gate to Gate No 3 in place of 220 W high pressure sodium Fixture 6 Replacement of 400 Nos 30 W LED Street Light fixture in Township branch road in place of 120 W high pressure sodium tube 7 Replacement of 100 Nos 72 W LED Street Light fixture in Township from Gate no 4 to Gate No 1 in place of 220 W high pressure sodium Fixture 8 Replacement of 160 Nos 19 W LED fixture in Bagging Platform in place of 40 W Normal Fluorescent tube light Total (Electrical Energy)

10 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (Gcal) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 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 Installation of New Medium Pressure Process condensate stripper (1104-E) Old Synthesis Gas Converter (105-D) Internal Revamp 5 Installation of Ammonia recovery section to recover ammonia from off gases of synthesis loop

11 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (Gcal) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 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 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 Total (Thermal Energy)

12 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (KWh) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 12 Replacement of 18 W LED tube light in Township quarter in place of 36 W Fluorescent tube light Replacement of 75 Nos 36 W LED Fixtures in place of 36 W 110 nos CFL fitting Total (Electrical Energy)

13 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (Gcal) Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) 1 Revamping of all 336 Nos of Primary Reformer tubes in Ammonia-I plant Use of Additive in Coal fire Boilers at Power Plant Total (Thermal Energy)

14 Major Energy Saving Schemes Implemented in S.No Energy Saving Schemes Yearly Energy Saving (KWh) 3 Installation of 50 Nos of Occupancy Sensor in Office Room Monetary Saving (Rs. Lakh) Investment (Rs. Lakh) Installation of 6 Nos Solar Light Pipes in Store building. 5 Replacement of 20 Nos of 400 Watt Flood Light by 200 Watt Induction Flood Light in Workshop & TG-I Area 6 Replacement of 250 Watt HPMV Flood Light by 150 Watt Induction flood light at Matri Park in Ghiyanagar Township 7 Replacement of Fluorescent Tube Light with Copper Ballast (53 Watt) & Electronic Ballast (39 Watt) by LED Tube Light (20Watt) Total (Electrical Energy)

15 15 1. Replacement of 2 nd Stage Intercooler of Process Air Compressor in Ammonia I Plant Earlier the 2 nd Stage intercooler of Process Air Compressor was leaking frequently. Thereby the Medium Pressure Steam consumed by Process Air Compressor Turbine was increased. But after replacement of old inter cooler with new one, the leaking problem was rectified and MS steam consumption in Process Air Compressor Turbine is reduced. Annual saving comes Gcal per year. 2 nd Stage Intercooler of Air Compressor

16 16 2.Installation of VAM System for CO2 cooling in Urea-I Plant: In Phulpur-I, a Vapour Absorption Machine (VAM) is installed to generate chilled water required for suction CO2 chilling of CO2 Compressor in Urea-I Plant. By this modification, the suction temperature of CO2 at the suction of CO2 Compressor is reduced to 20 deg C resulting saving of HP Steam consumption. The heating medium in VAM machine is waste heat of condensate from Ammonia-I Plant. Annual saving comes Gcal per year. VAM for CO2 Cooling

17 17 3. Installation of VAM for Suction Chilling of Air in Gas Turbine Generator(GTG): In Phulpur-I, a Vapour Absorption Machine (VAM) is installed to generate chilled water required for suction air chilling of Air Compressor in GT-HRSG. By this modification, the suction temperature of Air in Air Compressor is reduced resulting in saving of Power consumption. The heating medium in VAM machine is waste heat of condensate from Urea Plant. Annual saving comes Gcal per year. VAM for Suction Chilling of Air in GTG

18 4. Installation of 350 KWp Solar Power Panels in Phulpur I. 350 KWp Solar Power Panels has been installed at different locations such as Bagging & Material Handling-I, Raw water Pump house, Central canteen and Raw water storage tank to reduce power consumption. Annual saving comes KWH in Solar Power Panels Solar Power Panel in Phulpur-I 18

19 5. Replacement 220 W Street Light with 90 W LED: To reduce the energy consumption, 150 Nos. of 220 W high pressure Sodium Fixture has been replaced with 90 W LED Street light Fixture from front side of Plant gate to Gate No 3. Annual saving comes KWH per year. Before After 19

20 6. Replacement of 120 W HP Sodiun Fixture with 30 W LED: To reduce the energy consumption, 400 Nos. of 120 W High Pressure Sodium Fixture has been replaced with 400 Nos of 30 W LED Street Light fixtures in Branch Road of Township. Annual saving comes KWH per year. Before After 20

21 7. Replacement of 220 W HP Sodiun Fixture with LED Street Light of 72 W : To reduce the energy consumption, 100 Nos. of 220 W high pressure Sodium Fixture has been replaced with 72 W LED Street light Fixture in Township from Gate 4 to Gate No 1 in Township. Annual saving comes KWH per year. Before After 21

22 8. Replacement of 40 W Normal Fluorescent tube light with 19 W LED Fixture: To reduce the energy consumption, 160 Nos. of 40 W Normal Fluorescent tube light has been replaced with 19 W LED Fixture in Bagging Platform. Annual saving comes KWH per year. Before After 22

23 UTILISATIONS OF RENEWABLE ENERGY SOURCES Solar Power Pack: 585 KWp Solar power pack installed in plant and is connected to the LT Grid. Bio-Methanation Plant Capacity : 25 m3/day Solar Water Heaters 6 Nos. Solar Water Heater in Guest House 23

24 Solar Power Plant Installation : Two Units of Solar Power Plant of Capacity 585 KWp (235 KWp KWp) were commissioned in the January and February 2016, respectively. Additional Project for installation of 800 KWp(350 KWp KWp) Solar Power Panels comprising of 7 different locations were commissioned in November Both the Solar Power Units(1385 KWp) are in continuous operation generating Electric Power in the tune of KWh and KWh for both Phulpur-I & II respectively in In the Year , total Solar Power Generation was MWh Unit (Both Phulpur I & 2) which is equivalent to reduction of Tonne of CO2 emission. 24

25 INTERNATIONAL ACCREDITATIONS Product Steward Excellence Certification by International Fertilizer Association (IFA). 25

26 26 INTERNATIONAL CERTIFICATIONS

27 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 27

28 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 28

29 On-Going Projects: Installation of new Electrostatic Precipitator in Coal Boilers The Coal Based Boilers in Phulpur were designed with the emission norm of 250 mg/nm3 based on then prevailing Emission norms of Central Pollution Control Board (CPCB). These Electro-static Precipitators(ESP) are very old and their performance has deteriorated in due course of time and needed improvement. Boiler No.1 commissioned in Dec & emission is less than 30 mg/nm3. The other Boilers are also being revamped for emission less than 50 mg/nm3. ESP of Boiler No. 1 29

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

31 CO2 Emission in Lakh MT Sp. CO2 Emission MT/MT of Urea Carbon Foot Print Year

32 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 32

33 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 33 Fly Ash Utilised for Brick Making

34 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 34

35 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 35

36 Sample Performance Reports 36

37 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 Independence Day 37

38 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. 38

39 Awards & Recognition 18th National Award for Excellence in Energy Management by CII. FAI Safety Award in Nitrogenous Fertiliser: Winner FAI Environment Protection Award :Joint Winner National Energy Conservation Award : 2nd Prize 39

40 40 ENCON PROJECT BUDGET ALLOCATION Total turn over of company/plant (Rs. Million) Amount Invested in ENCON Projects (Rs. Million) Investment %

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