Energy Saving Measures in IFFCO Phulpur Unit A

Energy Saving Measures in IFFCO Phulpur Unit A Case Study Sunil Khandelwal Sr. Manager (Elect. ), IFFCO, Phulpur

IFFCO Phulpur-I UNIT q Commercial production started in March, 1981 with 977 MTPD Ammonia Plant and 1670 MTPD Urea Plant q Three coal fired boilers having 125 MT/hr capacities each q 12. 5 MW Turbo-Generator along with associated offsite facilities. q In 2006, feed stock of ammonia plant was changed from Naphtha to RLNG. q Capacity Enhancement Project (CEP) was carried out in 2008. q In 2016 -17, Energy Saving Project has been completed along with New Gas Turbine and Heat Recovery Steam Generation(GT-HRSG). q Presently Unit is running with 100% of their revamped capacity of 1215 MTPD of ammonia and 2115 MTPD of urea in Phulpur-I.

IFFCO Phulpur-II UNIT q Commercial production started in December, 1997 with a capacity of 1520 MTPD of Ammonia and 2620 MTPD Urea respectively. q Other facilities including 18 MW Captive Power generation, High Pressure steam generation and associated offsite facilities. q In 2006, feed stock of ammonia plant was changed from Naphtha to RLNG. IFFCO Phulpur was the first fertilizer plant in India to implement the changeover to RLNG from Naphtha. q Capacity Enhancement Project (CEP) was carried out in 2008. q Presently Unit is running with 100% of their revamped capacity of 1740 MTPD of ammonia and 3030 MTPD of urea in Phulpur-II.

Energy Consumption Ammonia and Urea manufacturing is highly energy intensive. it contributes more than 80% of the total cost of production Urea. The saving in energy consumption affects the cost of production in a big way and saves the valuable fast depleting natural resources such as Natural Gas and Coal. Therefore, the Energy conservation is a major corporate objective at IFFCO and it is a continuous process at all its units. IFFCO-Phulpur complex has become one of the lowest energy consuming units amongst fertilizer plants in India. IFFCO Phulpur Unit-I has received 7388 Nos of Energy Saving Certificates (Ecerts) and IFFCO Phulpur Unit-II has received 13824 Nos of Energy Saving Certificates (Ecerts) under PAT Cycle-I (20122015) for compliance with the Energy norms and standards specified by the Ministry of Power, Govt. of India.

SPECIFIC ENERGY CONSUMPTION of Ammonia Year Specific Energy (Gcal/ MT of NH 3) Thermal Energy Saving (MTOE) Electrical Energy Saving (Thousand k. WH) Phulpur-II Phulpur-II 2014 -15 8. 89 7. 57 3560 2802 4970 2015 -16 8. 82 7. 52 3254 867 830 1200 2016 -17 9. 00 7. 44 15169 13727 1130 1610 2017 -18 7. 99 7. 42 6867 10438 2510 3420

Energy Conservation Procedures/ Steps at Unit § The energy consumption is monitored on daily basis. § A task force, comprising senior persons from various departments headed by Unit Head. § Daily Meeting of Task Force to discuss and take corrective action for the various loss points either due to plant operating troubles or owing to design limitations or development of new technology. § Various studies are carried out and modifications are done inhouse for improving the energy efficiency within the existing facilities.

Energy Conservation Procedures/ Steps at Unit § In house / outside training programs and Seminars on Energy conservation for the Engineers and operators / technicians from each plant. i. For creating their interest in this area. ii. Make them aware of the latest methods / developments in the field of Energy conservation. § Reputed professionals are also invited as Faculty for the in - house training programmes. § IFFCO Phulpur has always been a frontrunner in the Industry towards energy conservation and adoption of greenergy. § IFFCO Phulpur is committed towards implementation of energy efficient schemes with the mission to become the most energy efficient unit in the fertilizer sector.

OFFICIALS for Energy Efficiency Cell

Registration Certificate Energy Management System ISO 50001: 2011 IFFCO Phulpur Unit is the first in the Fertilizer Sector to be accredited with Energy Management Certification in 2012.

Electrical Energy Consumption in Phulpur Year (2017 -18) Purchase Electricity from UPPCL Phulpur-I (MWH) Phulpur-II (MWH) 2, 730. 1 3, 603. 1 Gross Generation from 191, 439. 7 CPP 5992. 7 Year (2016 -17) Purchase Electricity from UPPCL Phulpur-I (MWH) Phulpur-II (MWH) 3, 466. 4 4, 985. 6 Gross Generation from 110, 848. 4 72, 097. 2 CPP

Consumption of Raw Materials at Phulpur-I and Phulpur-II Year (2017 -18) Consumption Net Calorific Value Coal 127881 MT 3901 Kcal/ Kg HSD 126. 473 MT 10269 Kcal/ Kg RLNG 1066. 23 Million SM 3 8307. 936 Kcal/ SM 3 Consumption Net Calorific Value Coal 214563 MT 4168 Kcal/ Kg HSD 164. 840 MT 10257 Kcal/ Kg RLNG 1066. 89 Million SM 3 8317. 201 Kcal/ SM 3 Year (2016 -17)

Energy Saving Projects Implemented in Phulpur-I in 2017 -18 S. No. 1 2 3 4 5 Improvement Replacement of 2 nd Stage Intercooler of Process Air Compressor in Ammonia –I Plant. Installation of VAM System for CO 2 cooling in Urea-I Plant. Installation of VAM for Suction Chilling of Air in Gas Turbine Generator (GTG). Installation of 350 KWp Solar Power Panels at different locations in Phulpur- I Plant. Replacement with LED Street Light fixtures in Plant and Township in lieu of HPSV Fixture and Tube light Fixture. Elect. Energy Fuel Investment Saving (in Lakhs) (Lakhs Kwh) (MTOE) - 2002. 7 62. 55 - 886. 7 833. 00 - 3977. 3 2175. 00 1. 24 - 166. 08 1. 26 - 11. 90

Energy Saving Projects Implemented in Phulpur-I in 2016 -17 S. No. Improvement 1 Installation of GT-HRSG Modification in CO 2 Recovery Process-a. MDEA Process in place of Benefield Process Replacement of Old Air Process Compressor Turbine with new one. Replacement of Old Refrigeration Compressor Turbine with new one. Replacement of Process Condensate Stripper with new MP Process condensate Stripper. Replacement of old Mixed Feed, Air & VAM Coil with new one in Primary Reformer Convection Section. 2 3 4 5 6 Elect. Energy Fuel Investment Saving (in Lakhs) (Lakhs Kwh) (MTOE) 10106. 0 23914. 0 - 1723. 66 20773. 00 - 721. 69 1443. 50 - 449. 30 1443. 50 - 968. 7 1032. 00 - 156. 8 1044. 00

Energy Saving Projects Implemented in Phulpur-I in 2016 -17 S. No. 7 8 9 10 Improvement Installation of Ammonia recovery section to recover ammonia from off gases of synthesis loop Internal Revamping of Synthesis Gas Converter. Installation of Casale High Efficiency Trays. Replacement of 36 W Fluorescent tube light and CFL Fixtures with LED Fixtures in township Quarters and Control Rooms. Elect. Energy Fuel Saving (Lakhs Saving Kwh) (MTOE) Investment (in Lakhs) - 87. 91 1025. 00 - 475. 09 1331. 00 - 479. 99 355. 00 1. 13 - 9. 29

Energy Saving Projects Implemented in Phulpur-I in 2015 -16 S. No. Improvement 1 Revamping of all 336 Nos of Primary Reformer Tubes. Installation of 585 KW Solar Power Plant at the roof of Raw water storage tank. Installation of 50 Nos of Occupancy sensor in Office Rooms. Replacement of 400 Watt HPMV Flood Light by 200 Watt Induction Flood Light in Workshops. 2 3 4 Elect. Energy Fuel Investment Saving (Lakhs Saving (in Lakhs) Kwh) (MTOE) - 2037. 03 3700. 00 0. 39 - 122. 50 0. 34 - 1. 52 0. 06 - 1. 60

Implementation of Innovative Schemes: Scheme for converting Urea-I Ammonia Pump-D (P 1 D) from Turbine driven to Motor Driven: § Ammonia Pump (P 1 D) in Urea-I Plant which was coupled with backpressure turbine (23 – 4 ata). The normal steam requirement in T-P 1 D is around 8 MT/Hr @ normal operating pump speed is 110 RPM and Gear Box Ratio is 27. 931. Steam Turbine rated power output is 428 KW. § For motor drive one obsolete motors of 450 KW (Ammonia-II old Lean Solution Pump-B) was identified for the service § This modification helped in reduction of HP Steam requirement in the tune of 1. 5 MT/Hr (1. 5 Gcal/Hr). The electrical power requirement will increase by 450 KW (0. 70 Gcal/Hr). Net saving shall be 0. 8 Gcal/Hr equivalent to 643 MTOE. § The scheme was implemented by in-house team with total implementation cost of Rs. 15 Lakh only with payback of just 1 month.

Energy Saving Projects Implemented in Phulpur-II in 2015 -16 S. No. Improvement 1 Installation of Vapour Absorption Machine System & CO 2 Cooler. Installation of 585 KW Solar Power Plant at the roof of Raw water storage tank. Replacement of 20 Nos of 400 Watt HPMV Flood Light by 200 Watt Induction Flood Light in Workshop & TG-I Area Replacement of Fluorescent Tube Light with Copper Ballest (53 Watt) & Electronic Ballest(39 Watt) by LED Tube Light(20 Watt). 2 3 4 Elect. Energy Fuel Investment Saving (in Lakhs) (Lakhs Kwh) (MTOE) - 867. 00 600. 0 0. 56 - 175. 5 0. 07 - 1. 51 0. 06 - 0. 59

Energy Saving Projects Implemented in Phulpur-II in 2016 -17 S. No. 1 2 3 4 Improvement Elect. Energy Fuel Investment Saving (Lakhs Saving (in Lakhs) Kwh) (MTOE) Revamping of Synthesis Gas 8641. 81 4000. 0 Compressor in Ammonia-II Plant Installation of Ammonia wash Unit 1623. 7 1200. 0 in Ammonia-II Plant Replacement of CO 2 Compressor 3461. 85 2051. 0 in 41 Unit of Urea-II Plant Replacement of 36 W Fluorescent tube light with 18 W LED tube light in township Quarters. 1. 55 - 12. 04

Energy Saving Projects Implemented in Phulpur-II in 2017 -18 S. No. Improvement 1 Modification in CO 2 Recovery Process- a. MDEA Process instead of GV Process in Ammia-II Plant. Replacement of CO 2 Compressor 31 Unit of Urea –II with new efficient CO 2 Compressor. Installation of 450 KWp Solar Power Panels at different locations in Phulpur- I Plant. Replacement with LED Street Light fixture in Township in lieu of 120 & 220 W HPSV tube. 2 3 4 Elect. Energy Fuel Saving (Lakhs Saving Kwh) (MTOE) Investment (in Lakhs) - 6755. 90 22586. 00 - 2852. 43 3134. 00 1. 60 - 237. 92 1. 36 - 11. 42

Major energy Saving Schemes Implemented during 2016 -18 Replacement of 2 nd Stage Intercooler of Process Air Compressor in Ammonia –I Plant : Yearly Saving (Gcal) : 20026. 7 Yearly Saving (Rs. Lakhs) : 239. 68 Investment (Rs. Lakhs) : 62. 55 2 nd Stage Intercooler of Process Air Compressor

Installation of VAM System for CO 2 cooling in Urea-I Plant: Vapour Absorption Machine (VAM) is installed to generate chilled water required for suction CO 2 chilling of CO 2 Compressor in Urea-I Plant. By this modification, the suction temperature of CO 2 at the suction of CO 2 Compressor is reduced resulting in saving of HP Steam consumption. The heating medium in VAM machine is waste heat of condensate from Ammonia-I Plant. Yearly Saving (GCal) : 8867. 2 Yearly Saving (Rs. Lakh) : 106. 12 Investment (Rs. Lakhs) : 833. 0

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 GTHRSG. 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. Yearly Saving (Gcal) : 39772. 5 Yearly Saving (Rs. Lakhs): 934. 1 Investment (Rs. Lakhs) : 2175. 0

GTG-HRSG PACKAGE 24

GTG-HRSG PACKAGE 25 Vendor Gas Turbine : M/s MHPS, Japan • • Model ISO Rating : H 25 : 30. 02 MW (@ 15 °C, 1013 mbar Atm. Press, 60% RH) • Guaranteed Power : 22 MW (@ 45 ° C Temp. , 973 mbar Atm. Press. , 60% RH) : M/s MHPS India Ltd. HRSG : M/s Thermax, India • Capacity : 60 MTPH (@ 115 Bar, 515 °C) 4 Nos. Supplementary Firing Burners • Power Generator : M/s Brush, Netherlands Capacity : 28. 125 MVA P. F. : 0. 80 Performance Guarantee Test carried out on 25 th Nov. 2016.

PG TEST OF GTG-HRSG Guaranteed Value Test Result 22. 0 22. 33 8946. 0 8624. 17 116 Bar(a) 520 +/-5 Deg C 60. 0 60. 45 NOx SOx 50. 0 0. 4 18. 93 NT Parameter Net Power Output (MW) Total Fuel Consumption (NM 3/Hr) HRSG Steam Generation at B/L (MT/Hr) Emission Guarantees at stack (ppmvd @ 15 % O 2) Condition Guarantee Condition (45 ° C Temp. , 973 mbar Atm. Press. , 60% RH) Guarantee Condition at 23 MW Net Power Output (35 ° C Temp. , 973 mbar Atm. Press. , 100% RH) 26

GTG-HRSG PACKAGE 27 Savings Achieved : Particular Unit Before After Savings Total Urea Production MTPD 5362 5145 (2115+3030) Complex Urea GCal/MT Energy 5. 978 5. 658 0. 32 R-LNG 000 SM 3/Day 3423 3363 60 Coal MT/Day 823 684 139

Installation of 800 KWp Solar Power Panels at different locations: 800 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. Solar Power Panel Supplier : M/s Lanco Solar Energy Pvt. Ltd. Gurgaon Cost : Rs. 404. 0 Lakhs Yearly Saving (KWH) : 284543 Yearly Saving (Rs. Lakhs) : 17. 07

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: 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 32184 KWH per year. Yearly Saving (KWH) : 32184 Yearly Saving (Rs. Lakhs) : 1. 93 Investment (Rs. Lakhs) : 3. 93 BEFORE AFTER REPLACEMENT

Replacement of 400 Nos 30 W LED Street Light fixture in Township branch road in place of 120 W high pressure sodium tube : To reduce the energy consumption, 400 Nos. of 120 W High Pressure Sodium Fixure has been replaced with 400 Nos of 30 W LED Street Light fixtures in Branch Road of Township. Annual saving comes 59417 KWH per year. Yearly Saving (KWH) : 59417 Yearly Saving (Rs. Lakhs) : 3. 57 Investment (Rs. Lakhs) : 3. 73 BEFORE AFTER

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: 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 24427 KWH per year. Yearly Saving (KWH) : 24427 Yearly Saving (Rs. Lakhs) : 1. 47 Investment (Rs. Lakhs) : 1. 97

Modification in CO 2 Recovery Process- a. MDEA Process in place of GV Process in Ammonia-I and Ammonia-II Plants : A new Bulk Absorber in addition to existing CO 2 Absorber is used to absorb CO 2 in a. MDEA solution from process gas. CO 2 rich a. MDEA solution is regenerated in three stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO 2 Stripper. The source of regeneration energy is only process gas which has got reduced due to pressure reduction at different levels. CO 2 separated is sent to Urea plant for the production of urea. Regenerated a. MDEA solution is again sent to CO 2 Absorber to absorb CO 2 from process gas. CO 2 Stripper (HP) CO 2 Absorber CO 2 Stripper (LP) BEFORE MODIFICATION

Bulk Absorber CO 2 Lean Absorber LP Flash Tower CO 2 Stripper HP Flash Tower AFTER MODIFICATION Yearly Saving (Gcal) (Rs. Lakh) Investment (Rs. Lakh) Ammonia-I 17236 404. 8 20773 Ammonia-II 67559 1586. 6 22586

Replacement of CO 2 Compressor from M/s Hitachi, Japan in 31 Unit & 41 Unit of Urea –II Plant with new efficient CO 2 Compressor: To reduce the specific energy consumption, Old inefficient CO 2 Gas Compressor has been replaced with new high efficiency CO 2 Compressor under Energy Saving Schemes. The Specific Steam consumption in Steam Turbine drive CO 2 Compressor has been reduced. Yearly Saving (Gcal) Yearly Saving (Rs. Lakh) Investment (Rs. Lakh) 31 Unit 41 Unit 28524 34619 670 813 3134 2051

AWARDS RECEIVED BY IFFCO PHULPUR FOR ENERGY CONSERVATION National Energy Conservation Award -2017: IFFCO Phulpur Unit-II received the Certificate of Merit for Energy Conservation Award-2017 from BEE on 14 th December, 2017 in New Delhi.

UP State Energy Conservation Award -2017: IFFCO Phulpur-II Unit has won "UP State Energy Conservation Award -2017: First Prize" in Fertiliser Sector by Uttar Pradesh New and Renewable Energy Development Agency. The Award was conferred by Hon’ble Minister of Additional Energy Resources, Govt. Of U. P. , Shri Brajesh Pathak, on 14 th December, 2017 in Lucknow.

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