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PRESENTS

IFFCO AONLA UNIT, BAREILLY (U.P.). PRESENTS. ENERGY SAVING MEASURES IMPLEMENTED AT IFFCO AONLA PLANT. IFFCO - In Brief. Origin of IFFCO. IFFCO was established on 3rd Nov.,67 as a multi state co- operative society of farmers to produce & market fertilisers. Mission of IFFCO.

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PRESENTS

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  1. IFFCO AONLA UNIT, BAREILLY (U.P.) PRESENTS ENERGY SAVING MEASURES IMPLEMENTED AT IFFCO AONLA PLANT

  2. IFFCO - In Brief

  3. Origin of IFFCO IFFCO was established on 3rd Nov.,67as a multi state co- operative society of farmers to produce & market fertilisers.

  4. Mission of IFFCO To provide adequate high quality fertilisers in right time to farmers To make plants energy efficient and continually review various schemes to conserve energy Commitment to health, safety, environment and forestry development to enrich the quality of community life Educating, Training and guiding the farmers for improving their agricultural productivity and rural economy

  5. IFFCO – In Brief • Leading producer of fertilisers in India • No. of plant locations - Five • Installed Annual Capacity • Urea : 3.69 Million Tonne • NPK/DAP : 4.42 Million tonne

  6. IFFCO – In Brief (contd…) • Contributes 18.3% to the total”N” and 25% to the total “P2O5” produced in the country • Fertiliser marketed through around 38,150 cooperative societies and 158 Farmers Service Centres • Service to the farmers through a variety of programmes

  7. IFFCO – In Brief (contd…) PHULPUR UNIT KALOL UNIT Year of Commissioning - 1981/1997 Annual Ammonia Capacity - 8.24 Lakh MT Annual Urea Capacity - 14.16 Lakh MT Year of Commissioning - 1975 Annual Ammonia Capacity - 3.63 Lakh MT Annual Urea Capacity - 5.45 Lakh MT CORPORATE OFFICE NEW DELHI AONLA UNIT KANDLA UNIT PARADEEP UNIT Year of Commissioning - 1988/1996 Annual Ammonia Capacity - 10.03 Lakh MT Annual Urea Capacity - 17.29 Lakh MT Year of Commissioning - 1975 Annual NPK/DAP Capacity- 24.15Lakh MT Year of Acquiring - SEP-2005 Annual Capacity -20.00 Lakh MT (DAP + COMPLEX)

  8. IFFCO – In Brief (contd…) Highlights of Performance - Year 2007-08

  9. IFFCO – In Brief (contd…) Highlights of Performance - Year 2007-08 (Contd..)

  10. IFFCO AONLA UNIT ENERGY EFFICIENT COST- CONSCIOUS ECO-FRIENDLY & SAFETY CONSCIOUS HARMONIOUS INDUSTRIAL ENV. ISO-9001, ISO-14001 & OHSAS-18001 CERTIFIED

  11. SONIPAT SAHIBABAD HBJ Gas Pipeline Network 6” (20 KM) BAHADURGARH 6” (52 KM) DADARI DESU 24” (104 KM) 18” (47 KM) 12” (35 KM) TCL S’ BAD 24” (82 KM) MARUTI MATHURA 24” (90 KM) 14” (13 KM) OCFL 24” (143 KM) 36” (505 KM) 18” (217 KM) NTPC IGCL Jagdishpur 12” (2 KM) AURAIYA CS (5 NOS COMPRESSORS) 12” (32 KM) CFCL SAMCOR BORARI 30” (321 KM) 18” (110 KM) ANTA 12” (14 KM) NFL 18” (3.6 KM) VIJAIPURCS (8 NOS COMPRESSORS) LPG 36” (340 KM) Aonla Unit based on HBJ pipeline 1225 Km from Hazira GSFC 18” (1.1 KM) LPG JHABUA CS (10 NOS COMPRESSORS) IOC, IPCL 36” (150 KM) 18” (32 KM) VAGHODIA CS KAWAS 12” (8 KM) 36” (149 KM) DPD HAZIRA CS EX HAZIRA CONSUMERS - KRIBHCO, RPL, ESSAR, HWP, GGCL

  12. IFFCO Aonla Unit • IFFCO Aonla Unit was set up at Aonla, Bareilly in the year 1988 • In the year 1996 the production capacity was doubled with the commissioning of Aonla-II

  13. Main Plants & Auxilliary Facilities Aonla-I Aonla-II • Ammonia Plant 1520 MTPD 1520 MTPD • Urea Plant 2620 MTPD 2620 MTPD • S.G. facilities (116 Kg/Cm2, 515 Deg C) • Service Boiler 150 MTPH • Heat Recovery Unit 80 MTPH (80+120) MTPH • Gas Turbine18 MW 18 MW • Generator

  14. Environment Management Awards & Certifications • Bagged Indo-German Greentech Environmental Excellence Award for 2 consecutive years (in 1999-2000 and 2000-2001). • BaggedCorporate Environment Award 2002-03 (certification of participation) from TERIin recognition of the efforts made towards Environment Management and sustainable initiatives. • Bagged Golden Peacock Environment Management Award-2005 (Certificate of Commendation). • Achieved ISO 14001 certification for Plant and Township. • Achieved OHSAS-18001 certification.

  15. Production Performance - A Brief Overview

  16. Production Performance Annual Capacity v/s Actual Production (Lakh MT) UREA PLANT-I

  17. Production Performance (Contd…) Annual Capacity v/s Actual Production (Lakh MT) UREA PLANT-II

  18. Energy consumption Trend in Ammonia-I plant

  19. Energy consumption Trend in Ammonia-II plant

  20. Implementation of ENCON Strategy • Designated Energy Manager • External Energy Audit By Original Licensors & PCRA • All discipline Energy cells • Regular monitoring of Energy consumption, Steam balance & Overall performance • Targets reviewed periodically for compliance • Special budgetary support

  21. Implementation of ENCON Strategy • Employees participation ensured through awareness programs, incentives on suggestion scheme. • Interaction with Fertilizer industry for continual improvements • Consultation with machinery and catalyst vendors for performance review and upgrades • Liaison with Licensor for energy improvement options

  22. Implementation of ENCON Strategy • Energy Cell Objective: Energy Auditing, Plant Health, Performance Monitoring • Each Energy Cell consists of Experts from • Technical (Coordinator of the Cell – Energy Manager) • Production • Instrumentation • Maintenance

  23. ENCON and Cost Reduction are monitored through • Change in operating practices without any investment • Minor process modifications involving small investments • Major energy saving retrofits involving large investments • Monitoring & Optimization of plant performance and energy consumption on daily, monthly, and yearly reports basis • Periodic equipment performance evaluation, steam balance • Minor modifications implemented as per Energy Work Request (EWR), Suggestion Schemes • Development of In-house Computer Softwares • Inside/outside training programs for Plant Engineers and Operating personnel

  24. Strategy for Energy conservation • Advanced Process Design • Complex Integration • Improve Operating Practices • Major Modifications • Minor Modifications

  25. Advanced Process Design • High performance Catalysts • Process Equipment based on Advanced Technology (Ex: G.T. for Process Air Compressor and MP Condensate Stripper in Amm-II etc.) • Two –stage GV CO2 Removal System • Optimized Process & UtilityInterconnections • Advanced and Reliable Instrumentation & Control System

  26. Complex Integration • Optimized use of Steam & Power consumption for peak load of generators • Use of Surplus Steam • Common Steam & Electrical Power Supply • Common Utilities & Offsite • Common Finance & Admn

  27. Improved Operating Practices • Periodic In-house & External Audit • Scheduled check of NG/SG/Steam leaks/NH3 leaks and on-line rectification • Accelerated start up using the interconnections • Thrust for power & water saving in non-essential areas • Export & Import surplus Synthesis gas to minimize venting during upsets • Optimize NG/Naphtha ratio for maximum Urea production & NG consumption, no CO2 venting

  28. Additional Steps to improve Operating Practices • Rotary machines overhauling based on the performance evaluation, which results in substantial improvement in their efficiencies. • Plant wise steam balance and Overall steam balance helps in best utilization of steam and avoiding steam venting • Steam to Carbon ratio is being monitored on regular basis and is maintained near design value of 3.3. • Periodic steam lines insulation survey helps in reducing the loss of heat to atmosphere • Replacement/maintenance of leaking/passing steam traps

  29. Major Energy Saving Measures Implemented

  30. Energy Saving Project Implemented in Ammonia-I &II plant

  31. Introduction IFFCO in a big way has gone for Energy Saving Project in all its Ammonia plants at various units in consultation with the process licensor M/s Haldor Topsoe, Denmark. The schemes have been successfully commissioned between 2005 to 2007 in a phased manner and the benefits have been achieved by way of reduction in the specific energy consumption per metric ton of ammonia.

  32. Energy Saving Project - Background • GOI implemented the New Group Pricing Schemes for Urea Fertilizer Industry w.e.f. April 2003. • Energy Norms were made more stringent. • Incentive were provided for Energy Efficient Plants. • No mopping of Energy Efficiency and no recognition of Capital Invested. • In order to lower the Energy Consumption below the prescribed Norms Energy Saving Project was envisaged for all the five Ammonia Plants at Kalol, Phulpur-I, Phulpur-II, Aonla-I and Aonla-II Units.

  33. Energy Saving Project - Background Project was bifurcated in two Phases viz. Phase-I and Phase-II Project for ease of implementation and to accrue the early benefits

  34. Energy Saving Project - Milestones • Feasibility Study & Basic Engineering : HTAS Denmark • Detailed Engineering : PDIL Noida • Cost of Project : Rs 141 Crores PROJECT HIGHLIGHTS Zero DateCompletion Date Phase-I : September 2003 March 2005 Phase-II : September 2003 June 2007

  35. Energy Saving Project at Ammonia-I • PHASE–I • LTS Guard Bed System • Revamp of CO2 Removal System • Replacement of Cooling Water Pump Turbine and GV Booster Pump Turbine to Motor • PHASE–II • S-50 Synthesis Converter & HP boiler • Final Gas Chiller • Energy Savings Guaranteed : 0.334 Gcal/MT Ammonia

  36. Energy Saving Project at Ammonia-I L.T.S Guard Bed System CO Slip : Before : 0.25 % After : 0.16 % BFW Preheater LT S Guard Bed

  37. LTS Guard and BFW Preheater in Ammonia-I &II plant

  38. Energy Saving Project at Ammonia-I CO2 REMOVAL SECTION REVAMP FROM 1-STAGE to 2-STAGE GV PROCESS Regeneration Energy Before : 1322 KCal/NM3 CO2 After : 747 Kcal/NM3 CO2 Savings : 575 Kcal/NM3 CO2 LP-Stripper

  39. CO2 REMOVAL SECTION REVAMP FROM 1-STAGE to 2-STAGE GV PROCESS New Major Equipment added in GV system • LP GV Stripper • Lean Solution pump • CO2 Booster compressor • LP Steam Boiler • Overhead condenser of LP GV Stripper • DM Water Heater • Process Condensate pump

  40. Energy Saving Project at Ammonia-I S-50 CONVERTOR & HP BOILER Ammonia Conversion Before : 30 % After : 36 % New S-50 Converter

  41. S-50 CONVERTOR & HP BOILER IN AMMONIA-I &II PLANT S-50 CONVERTOR & HP BOILER

  42. Energy Saving Project at Ammonia-II • PHASE–I • LTS Guard Bed System • Replacement of Cooling Water Pump Turbine to Motor • PHASE–II • S-50 Synthesis Converter & HP boiler • Final Gas Chiller • Additional Process Condensate Exchanger • New Combustion Air Module • Energy Savings Guaranteed (Gcal/MT Ammonia) : 0.160

  43. Energy Saving Project at Ammonia-II LTS Guard Bed System LTS Guard Bed BFW Pre-heater CO Slip : Before : 0.21 % After : 0.14 %

  44. Energy Saving Project at Ammonia-II S-50 CONVERTOR & HP BOILER Ammonia Conversion Before : 30 % After : 36 % HP-Boiler New S-50 Converter

  45. Energy Saving Project at Aonla-II Additional Condenser O/H Ist Regenerator (Phase-II) CO2 Supply Temp. to Urea Plant : Before : 46.0 deg C (Summer) After : 40 deg C (Summer) Additional Condenser Energy is saved in CO2 Compressor of Urea Plant

  46. Energy Saving Project at Aonla-II Make Up Gas Chiller (Phase-II) Make Up Gas Chiller Synthesis Compressor Suction Temp. : Before : 30 deg C After : 6.0 deg C Energy Saving : 0.02 Gcal/Te Amm. (Free Chilling)

  47. Make Up Gas Chiller in Ammonia-I& II Plant )

  48. Energy Saving Project at Aonla-II Additional Feed / Effluent Exchanger (Phase-II) Process Condensate Temp. At Inlet of MP Stripper : Before : 205 deg C After : 230 deg C Additional Exchanger Energy Saving : 0.04 Gcal / Te Ammonia

  49. Energy Saving Project at Aonla-II Additional Combustion Air Module (Phase-II) Combustion Air Temp. To Primary Reformer : Before : 301 deg C After : 318 deg C Energy Saving : 0.02 Gcal / Te Ammonia

  50. Major Energy Saving Measures Implemented in Urea-I &II Plant

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