First Prize

Fertilizers

INDIAN FARMERS FERTILISER

COOPERATIVE LIMITED
Phulpur Unit-II, Distt. Allahabad (Uttar Pradesh)

Unit Profile
Indian Farmers Fertiliser Cooperative Limited (IFFCO), globally acclaimed cooperative
in fertiliser production and marketing has been striving for socio-economic upliftment
of the rural population of India since inception. To ensure timely availability of
quality fertilizers to the farmers, IFFCO came into being on 3rd November, 1967.
Initially, IFFCO commissioned Kalol and Kandla plants in Gujarat in early 1975.
Due to increasing demand-supply gap of Urea in the country, Govt. of India has
given approval for expansion project at Phulpur site since basic infrastructure facilities
were available at Phulpur. The unit Phulpur-II was commissioned in December
1997 and consists of 1520 MTPD Ammonia Plant based on M/s. HTAS, Denmark
technology and 2620 MTPD Urea Plant based on M/s. Snamprogetti, Italy Technology.

155

Energy Consumption
Ammonia & Urea manufacturing is highly energy intensive and it contributes more
than 80% of the total cost of production Urea. Therefore, a slight change in energy
consumptions affects the cost of production in a big way. Apart from cost of
production reduction in energy saves the valuable fast depleting natural resources
such as Naphtha , Natural Gas, LSHS & Coal. Therefore, the Energy conservation is
a major corporate objective at IFFCO and it is a continuous process at its units.
IFFCO-Phulpur complex has become one of the lowest energy consuming units
amongst fertilizer plants in India. It has substantially reduced its energy consumption
during last three years. The details are highlighted below :
Plant

2006-07 2007-08 2008-09 2009-10

%Reduction
Over 2006-10

Ammonia-II

7.986

7.926

8.116

7.619

4.60

Urea - II

5.792

5.824

5.980

5.658

2.31

All figures are in Million kCal/MT

Performance At A Glance
UREA -II PRODUCTION

Production (MT)

1000085
1000000

924223
882600

900000

840584

800000

700000

Production (MT)

AMMONIA - II PRODUCTION

583507

600000
519949
506172
475913

500000

400000

2006 -07 2007 -08 2008 -09 2009 -10

2006 -07 2007 -08 2008 -09 2009 -10

YEAR

YEAR

AMM - II ENERGY CONSUMPTION

4.6%reduction over 2006 -10

UREA- II ENERGY CONSUMPTION

2.2 % reduction over 2006-10
8.30

8.12

5.90

5.98
5.79

5.82
5.66

5.70
5.50
2006-07

2007-08

2008-09

YEAR

156

2009-10

Overall Energy ( G
Cal/MT)

Overall Energy ( G
Cal/MT)

6.10

8.10

7.99

7.93

7.90
7.62

7.70
7.50
2006-07

2007-08

2008-09

YEAR

2009-10

Energy Conservation Commitment, Policy & Set-Up

IFFCO Phulpur Unit is playing a vital role in the national economy by providing
chemical fertiliser Urea to the Indian Farmers for prosperity and growth.
Manufacturing Process of Urea Complex is highly energy intensive and energy
contributes more than 80% of cost of production. Therefore, energy conservation
receives top priority at IFFCO Phulpur. IFFCO Phulpur Unit is committed to produce
good quality product with a mission to reduce the specific energy consumption 1%
every year.
IFFCO Phulpur is the first in fertilizer sector to receive Energy Management
Certification EN -16001.

Energy Conservation Achievements

Phulpur unit has always been a leader in adopting new developments in the field of
fertilizer production and number of modifications / revamp have been carried out
over the years which have resulted in substantial improvement in energy
consumption.

Major Projects Implemented during the Year 2009-2010

1

Higher Load Operation, Maximization of on-stream days & optimization

of Process Parameters
Specific Feed, Fuel and Steam Consumption is monitored on daily basis. Based
on design data corrective measures are taken on day to day basis to run the
plant at optimum efficiency.
Other important parameters like, Turbine & Compressor Efficiency, proper
utilization of Turbine condensate, furnace stack temperature and Turbine exhaust
pressure are monitored to achieve the lowest overall plant energy. Due to
these measures, 5% reduction in the overall energy per MT of Urea has been
realized.
Yearly Saving (MTOE)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

23108.99
3471.22
NIL

Monitoring & Rectification of steam traps and leakages

Steam traps are installed in the steam lines to remove condensate from the
system. It is required to remove Condensate from the steam system, to avoid
heat loss and hammering in the line.
A survey was conducted to study the faulty traps and it was recommended to
replace those traps with new ones. Accordingly, all the faulty traps were changed.
Overall savings of 2 MT/Hr of HP steam has been realized with this measure.

157

Yearly Saving (MTOE)

Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)
3

:
:
:

1337.48
193.86
6.00

Absorber temperature improvement in Carbon Dioxide Recovery Plant

(CDR)
Carbon Dioxide Recovery Plant (CDR) has been installed to recover CO2 from
the Flue Gas of Primary Reformer of Ammonia-II Plant. CDR Plant mainly consists
of Wash Column, Absorber and Regenerator. Due to lesser CW supply pressure
to the coolers of Absorber, the design value of top temperature could not be
achieved. Due to higher temperature, low pressure (LP) steam consumption in
the Regenerator was more.
In order to increase the CW flow and bring down the absorber temperature to
design range, CW return line has been connected to the Mist Cooling water
sump. As Mist Cooling sump is located at ground level, due to pressure
differential CW flow increased, resulting in better performance of the Absorber.
Due to lesser temperature, LP steam savings in the regenerator section has
been achieved.
Yearly Saving (MTOE)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

91.72
13.29
8.00

Schematic Dig. of the Scheme

Bypass of Adiabatic Pre Reformer

Pre-Reformer was installed by the Process Licensor Haldor Topsoe at the time
of commissioning for the Naphtha feed. Pre-reformer adiabatically breaks the
higher hydrocarbons to lower hydrocarbons. After RLNG Conversion, in-house
study was conducted and it was decided to bypass Adiabatic Pre Reformer.
After by-passing Pre Reformer, pressure drop at the front-end reduced by 1.7

158

kg/cm2. Due to lesser pressure drop, Syn Gas Compressor suction pressure
increased by 1.7 kg/cm2 resulting in lower steam consumption in the Syn
Turbine.
Yearly Saving (MTOE)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

5445.93
793.63
NIL

Schematic Dig. of the bypass of Adiabatic Pre Reformer

Installation of Liquid Nitrogen Tank

Syn Gas is highly flammable mixture. Before doing any hot job, purging of Syn
loop is a must. During catalyst loading also N2 atmosphere is a must for Reduced
Fe catalyst. Total time required for purging and catalyst loading with existing
facilities like N2 Blower, Inert Gas Plant was atleast 3 days. Liquid N2 Tank has
been installed for storing the N2 brought through the tankers. With the help of
the stored N2 in the tank, purging and catalyst loading job was completed in
1.5 Days. Thus saving 1.5 Days shutdown time. Steam has been saved, as
steaming of Primary Reformer has been reduced by 1.5 Days.
Yearly Saving (MTOE)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

312.15
45.24
45.00

3 D view of Liquid Nitrogen Tank

159

CO2 Ejectors to prevent Seal losses

CO2 compressor is installed in the Urea Plant to compress the CO2 from the
Ammonia Plant from 0.5 kg/cm2 to 160 kg/cm2, before entering Urea Reactor.
CO2 from the seals of compressor escapes to the atmosphere. An ejector
system has been installed in the compressor. These ejectors were available in
Urea-II as discarded. The CO2 escaped from the system is trapped by the
ejector and sent back to the compressor suction. Total savings of 300 NM3 of
CO2 has been estimated. Earlier, this amount of CO2 was produced in the
Carbon Dioxide Recovery (CDR) Plant to keep up with the Urea Production.
With this scheme, load of CDR Plant has been reduced. Lower CDR Plant load
resulted in lesser low pressure steam consumed in the regenerator system.
Yearly Saving (MTOE)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

275.16
39.88
NIL

Sketch before modification

Sketch after modification

Stoppage of Service Water Pump

Water requirement of Phulpur Unit is full-filled by borewell water. Earlier, borewell
water was stored in the raw water storage and water for Softening Plant was
transferred by Service Water Pump.
Now, the feed water for Softening Plant is taken directly from the borewell
header, resulting in stoppage of 122 KW service water pump.
Yearly Saving (Lakh kWh)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

Sketch before modification

160

:
:
:

10.69
117.56
NIL

Sketch after modification

Stoppage of RO Feed Water Pump

Reverse Osmosis Plant has been installed to treat effluent water. Earlier effluent
water from the plant was stored in a Feed Tank and transferred to the RO feed
with the help of RO Feed water pump.
As a energy saving initiation, effluent water is fed directly to the RO feed. This
has resulted in the stoppage of 45 KW feed water pump.
Yearly Saving (Lakh kWh)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

3.94
43.36
NIL

Sketch before modification

Sketch after modification

Installation of Solar Power Pack

A Solar Photo Voltaic Power Plant of 1.5 kW has been installed at R&D building
in plant premises. The power generated is being utilized for fan and lighting
application of the R&D building.
There are total 20 Nos. of Solar Photo Voltaic modules of 75 W each. The
energy generated by these Solar Photo Voltaic modules is stored in rechargeable
batteries and this energy is consumed as per the desired application.
Yearly Saving ( kWh)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

1460
0.16
5.23

Picture / Sketch of Solar Power Pack

161

10 Installation of Solar Street Lights

6 Nos. of 22 W stand alone Solar Street Lights have been installed in the
premises.
Each system contains, 2 CFL bulbs of 11 W each, Solar Photo Voltaic modules
of 100 W, rechargeable batteries. The energy is saved in the batteries during
day time and consumed during night. The CFL gets ON automatically during
darkness.
Yearly Saving ( kWh)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

:
:
:

385
0.04
2.50

Picture of Solar Street Lights

11 Output Voltage Reduction of Lighting Transformer

Power saving by reducing the supply voltage in lighting system has been carried
out by lowering the tap of the lighting transformer. Supply voltage has been
reduced from 414 V (3 phase) to 404 V (3 phase). Total power reduction is
13.9 KW.
Yearly Saving ( kWh)
Yearly Saving (Rs. Lakhs)
Investment (Rs. Lakhs)

162

:
:
:

60882
6.70
NIL

163

Environment and Safety

IFFCO Phulpur Unit is totally committed for maintaining an eco-friendly environment.
For controlling air pollution, plants have been provided with Bag Filters, Electro
Static Precipitators, Dust Extraction Systems, etc. A lush green belt with about 3
lakh trees has been developed all around the factory premises which is a natural
means of air purification. To overcome the problem of fly ash disposal, generated
in the Captive Power plant, a dense phase dry fly ash disposal plant has been
installed which directly fills the fly ash in closed tankers for transportation of the
ash to the cement plants manufacturing Portland Pozzolana cement.
Phulpur Unit has always put its best efforts for conserving water. The effluent
generated in the plant is recycled back after purification in Reverse Osmosis Plant.
Even the sewage water generated in the township is reused in the plant after
treatment in sewage treatment plant. The plant is running on zero effluent discharge
and total recycle basis. The present specific water consumption is the lowest among
the fertiliser industry in the country. Plant and its township have ISO 14001
certification which speaks volumes about its environmental commitment.

164

Second Prize

Fertilizers

RASHTRIYA CHEMICALS AND

FERTILIZERS LTD.
Trombay Unit, Mumbai (Maharashtra)

Unit Profile
Rashtriya Chemicals and Fertilizers Limited, Trombay, a Govt. of India Undertaking
is one of the largest integrated Fertilizer and Industrial chemicals complexes in the
country. It was incorporated on 6th March'1978 during reorganization of the erstwhile
Fertilizer Corporation of India Ltd. into Hindustan Fertillizer Corporation Ltd., and
National Fertilizers Limited. It has two industrial complexes located at :
Q
Q

Trombay in Mumbai
Thal in Raigad district of Maharashtra

165

Trombay Unit manufactures a vast range of products ranging from Complex Fertilizers
to Industrial Chemicals. These plants were installed phase wise under various
schemes such as expansion, de-bottlenecking, revamping etc.

Energy Consumption
Year

Electrical Energy consumed

Lakhs kWh

Thermal energy consumed

Lakh SM3

2008-2009

2097.20

1949.17

2009-2010

2713.98

2996.84

Energy Conservation Commitment, Policy & Set-Up

Considerable efforts have been made to reduce energy consumption of age-old
plants making use of latest technology.
An Energy Cell with an Energy Manager and qualified engineers has been set up to
analyze the day to day energy consumption levels in various process plants in the
factory. Energy Conservation Opportunities are identified based on energy audits,
case histories of successful conservation measures implemented by other plants
and through suggestions received from the operating and technical personnel etc.

Major Projects Implemented during the Year 2009-2010

1. Provision of capacitor banks on 11KV system fed from
Ammonia-1
After provision of capacitor banks on 11 KV system fed the power factor has improved
to the tune of 0.999. Thus reducing the losses in electrical network and saving
almost Rs. 90 Lakhs in electricity bill.
Energy cost savings
Total investment

=
=

Rs. 90.01 Lakhs

Rs. 35.00 Lakhs

2. Scheme to use Benfield condensate in place of DM water in

Ammonia-V plant
The above scheme of using Benefield Condensate in place of DM water for purpose
of sealing in Benefield solution pump has lead to saving in electrical power as one
DM water pump (P313) is stopped. The Benefield condensate is connected at
discharge line of DM water pump (P313).
Energy cost savings
Total investment

166

=
=

Rs. 4.78 Lakhs

Rs. 4.00 Lakhs

3. Conventional 125 Watt HMPV light fittings have been replaced

with 70 Watt Metal halide light fittings
Total 100 no. of Conventional 125 Watt HMPV light fittings have been replaced with
70 Watt Metal halide light fittings leading in electrical energy saving of 0.5 lakh
kWh.
Energy cost savings
Total investment

=
=

Rs. 2.51 Lakhs

Rs. 4.50 Lakhs

4. Installation of new modified SL Saturator in ANP Plant

The above scheme has lead to savings in steam of 0.5 MT/hr due to stopping of
steam leakage. Thus leading to reduction in fuel consumption.
Energy cost savings
Total investment

=
=

Rs. 7.16 Lakhs

Rs. 17.30 Lakhs

5. Installation of new AN surface condenser in ANP plant

The above scheme has lead to Saving of electrical energy due to stoppage of 2 no.
Vacuum pump motors (140 kW) which were earlier required to operate with the
old surface condenser.
Energy cost savings
Total investment

=
=

Rs. 29.38 Lakhs

Rs. 53.40 Lakhs

6. Replacement of 240 Nos of old A/Cs by new energy efficient

A/cs
Replacement of 240 Nos of old A/Cs by new energy efficient A/Cs leading to saving
of electrical energy
Energy cost savings
Total investment

=
=

Rs. 9.52 Lakhs

Rs. 27.10 Lakhs

7. Installation of Fan less cooling tower in Sulphuric acid plant

Fan less cooling tower is installed in place of two induced draft cooling towers in
Sulphuric acid plant.
Reduction of power consumption:
Energy cost savings
Total investment

=
=

Rs. 15.50 Lakhs

Rs. 14.05 Lakhs

167

8. Installation of Capacitor Banks in Sulphuric Acid Plant

Installation of Capacitor Banks in Sulphuric Acid Plant has lead to reduction in
electrical energy consumption.
Energy cost savings
Total investment

=
=

Rs. 6.29 Lakhs

Rs. 7.00 Lakhs

9. Installation of Air Handling Unit for SAP-CNA Control Room

Installation of Air Handling Unit in Sulphuric Acid Plant leading to saving of electrical
energy by stopping Air Conditioners in Control room.
Energy cost savings
Total investment

=
=

Rs. 1.68 Lakhs

Rs. 6.50 Lakhs

10. Provision VFD for 2 No. of aerator motors in Sewage Treatment

Plant
Installation of VFD in for 2 no. aerator motors leading to saving of electrical energy.
The operation of VFD is linked with online Dissolved Oxygen measurement. By
monitoring the DO value the speed of aerators can be controlled, thus leading to
saving of electricity.
Energy cost savings
Total investment

=
=

Rs. 6.24 Lakhs

Rs. 4.35 Lakhs

11.Solar water heater for providing 6000 liter per day of hot water
(70 0C) Sewage Treatment Plant
Installation of Solar water heater for providing 6000 liter per day of hot water (70
0C) Sewage Treatment Plant. This has lead to stopping of two electric heaters (24
kW each) and thus reducing power consumption

Energy cost savings

Total investment

168

=
=

Rs. 6.83 Lakhs

Rs. 9.88 Lakhs

12.Provision of High Capacity C.W. Pump

for Methylamine Plant
Provision of High Capacity C.W. Pump for MAP has
resulted in saving of electrical energy (25 kWh).
Earlier two less capacity pumps were operated. These
pumps are now stopped and new high capacity pump
is installed leading to stoppage of two lesser capacity
pumps.
Energy cost savings
Total investment

=
=

Rs. 7.33 Lakhs

Rs. 2.00 Lakhs

Environment and Safety

In line with motto of sustainability, The plant is Environment Management System
(EMS) ISO-14001:2004 compliant.

169

Certificate of Merit

Fertilizers

GUJARAT STATE FERTILIZERS &

CHEMICALS LIMITED
Vadodara Unit, Distt. Vadodara (Gujarat)

Unit Profile
Gujarat State Fertilizers & Chemicals Ltd. (GSFC), a unit promoted by the
Government of Gujarat is leading manufacturers of fertilizers & chemicals. GSFC is
spread over 648 hectare with 220 (34%) hectare of green belt.
On February 15th 1962, GSFC was incorporated as Joint Sector Company with
determination of the Government of Gujarat to offer quality products and services
to the farmers. The first latency of GSFC's fertilizer rolled out of its production unit
in 1967.
During the years 1974 to 1982 with serene policies of alteration, GSFC turned into
manufacturing of Caprolactam, Nylon-6, Melamine and Argon. Subsequently,
capacities were enhanced in Caprolactam and Melamine. Initially all the power was
drawn from state grid. GSFC installed three nos. of Cogeneration plants in phase
wise manner.

170

Manufacturing facilities / products range

Installed capacity / Actual production / Capacity utilization for the last three years
are presented below:
Product

Unit

Installed

Actual production / (Capacity utilization %)

capacity
2007-08

2008-09

2009-10

Urea

MT

367200

277008
(75.44%)

280500
(76.39%)

326300
(88.86%)

Ammonium
sulphate (AS)

MT

196000

292935
(149.46%)

265710
(135.57%)

271580
(138.56%)

Diammonium
sulphate (DAP)

MT

108000

79300

43770

00

APS

MT

120120

207500

293600

Caprolactam

MT

70000

79716
(113.88%)

70913
(101.3%)

81151
(115.93%)

Melamine

MT

15000

14741
(98.27%)

13655
(91.03%)

13735
(91.57%)

Nylon-6

MT

8000

8638
(107.98%)

8751
(109.39%)

8688
(108.6%)

MEKO

MT

4450

4083
(91.75%)

3400
(76.4%)

2780
(62.47%)

Energy Consumption
Energy consumption at GSFC is monitored on regular basis during day to day
production meeting, fortnightly Operation division meeting (ODC) and monthly
Technical Monitoring Committee (TMC) meetings.
Consumption of NG, power and LSHS for last three years is as given below:
YEAR

NG

Power Power
own generation purchased
units * 1000
units * 1000

LSHS MT

Total
energy
consumed
Gcal

2007-08

153265

169056

424786

4088

3044065

2008-09

145039

162029

392605

5412

2875911

2009-10

551946

140989

446118

6916

3201640

171

Total Energy consumption at GSFC

3400000
3200000

Energy, Gcal

3000000
2800000
2600000
2400000
2200000
2000000
2007-08

2008-09

2009-10

Year
Energy Gcal

Energy Conservation Commitment, Policy and Set-Up

GSFC has energy conservation as major corporate objective. General Manager
(also designated Energy Manager) coordinated the activities of energy conservation
and cost reduction. GSFC has dedicated energy cell comprising members from
Operation, Electrical, Maintenance and Technical Services. Energy conservation
ideas are also received from all employees in form of suggestion through Suggestion
Appraisal Committee. Also a dedicated Energy management team comprising of
16 members is formed to discuss, evaluate and encourage energy conservation
ideas from each plants and departments.
GSFC has also implemented Energy Management system BS - EN-16001 to have
energy conservation approach in systematic, uniform and continuously monitored
parameter by one and all, including higher management. Various energy
conservation schemes are initiated under the Energy management system adopted
and targets set for implementation of the same at faster rate. Special attention is
given for purchase of energy efficient items.

Major Projects Implemented during the Year 2009-2010

GSFC implemented following schemes at Vadodara unit.
1.

Installation of small capacity Make up water pump at Co-Generation -III plant.

Due to low load operation requirement, make up water pump was operating
at low capacity. Small capacity, low head pump installed in place of high
capacity, high head pump to reduce power consumption by 2.4 lacs

172

equivalent to Rs. 6.03 lacs/Yr. Cost of installation of small capacity small head
pump is Rs. 3.17 lacs/Yr with payback period of about 7 months.
2.

Power saving by stopping continuous operation of high capacity Caustic pump

(P-1046) in Capro-II plant. A high capacity caustic pump common for
continuous and occasional consumers is provided which runs on continuous
basis. Small capacity pump for continuous supply to consumers, installed. It
resulted in to stoppage of higher capacity pump except for occasional running.
It resulted in to annual power saving by 0.48 lacs units/Yr, equivalent to Rs.
1.81 lacs/Yr. Cost of installation of small capacity pump is Rs. 1.65 lacs/Yr
with payback period of less than a year.

173

3.

Changing of CT fan blade from Aluminium to FRP-Hollow blades at Ammonia

storage plant. Existing Aluminium blades replaced by hollow FRP blades to
reduce power consumption. It resulted in to annual power saving by 0.32 lacs
units/Yr, equivalent to Rs. 1.21 lacs/Yr. Cost of installation of is Rs. 1.0 lacs/Yr
with payback period of 10 months.

Savings and payback period for Energy conservation schemes at

GSFC.
12

10

0
1

NO. of Schemes
Eletricity conservation, Lacs/kWh
Savings, Rs. (lacs/Yr)
Cost of Implementation, Rs. (lacs) Payback period, months

174

Environment and Safety

175

Certificate of Merit

Fertilizers

INDIAN FARMERS FERTILISER

COOPERATIVE LIMITED - PARADEEP UNIT
Distt. Jagatsinghpur (Orissa)

Unit Profile
Indian Farmers Fertiliser Cooperative Limited (IFFCO) took over OCFL's Phosphatic
Fertiliser Complex at Paradeep in October 2005

The plant consists of two streams of Sulphuric Acid Plant, one stream of Phosphoric
Acid plant and three streams of Complex fertilizer plant. In addition to these various
offsite and utilities facilities are also present inside the complex to fulfill various
requirements.

176

Energy Consumption
Production Performance
During the financial year 2009-10, IFFCO Paradeep unit have produced 15.00 lakhs
metric tonnes (MT) of complex fertilisers, 14.28 lakhs MT of Sulphuric Acid and
4.62 lakh MT of Phosphoric Acid (as 100% P2O5).
Specific consumption of Energy

1.2
S p. Cons. (Gcal/M T)

1
0.8
0.6
0.4
0.2
0
2006-07

2007-08

2008-09

2009-10

Year

Specific consumption of Power

1.000
S p. C ons .(M W H /M T)

0.900
0.800
0.700
0.600
0.500
0.400
0.300
0.200
0.100
0.000
2006-07

2007-08

2008-09

2009-10

Year

177

Energy Conservation: Commitment, Policy & Set-Up

178

Major Projects Implemented during the Year 2009-2010

1.

Replacement of cooling tower fan blades: The cooling tower blades of

Energy Center cooling tower & Sulphuric Acid Plant (SAP) cooling tower were
replaced with energy efficient FRP hollow blades as an energy savings scheme
measure. The modification led to savings of 15kWh per fan.

Investment in SAP cooling tower : Rs. 21,00,000 /Savings in energy due to replacement SAP cooling tower blades with hollow
FRP blades :Rs.246600/year
Investment in TG cooling tower : Rs. 30,00,000 /-Savings in energy due to
replacement TG cooling tower blades with hollow FRP blades : Rs.65,26,000
per year
2.

Trimming of filter water pumps: The filter water pumps are used to pump
process water to different plants inside the complex. Each of the three pumps
was designed to give a flow of 1800 m3/hr at a discharge pressure of 6.9 kg/
cm2. After an in-house study as per the requirement of the plant it was observed
that the impeller of one pump can be trimmed for lower flow without any
change in the discharge pressure. The impeller dia. of the pump was trimmed
form 520 mm to 490 mm. After the trimming the performance of the pump
was observed and tabulated below.

Description

Before trimming

After Trimming

Dia. of the Impeller

520 mm

490 mm

Flow of the pump

1800 m /hr

1500 m3/hr

Discharge Pressure

6.9 kg/cm2

6.9 kg/cm2

Current

42 amp

36 amp

Power consumption

411 kW

338 kW

Savings

73 Kw

Monetary Savings

17.96 Lakh rupees

Investment

NIL

3.

Use of Liquid ammonia instead of vapor ammonia: In the DAP/NP plant it

was designed to use vapor Ammonia to react with Phosphoric acid to produce
the complex fertiliser (DAP/NP). So steam was used to vaporize liquid ammonia
as the ammonia is received and stored in the liquid state. After an in-house
study it was considered to use liquid ammonia in place of vapor ammonia
which saves energy in terms of steam being used for vaporization.

179

A.

Savings of energy in DAP/NP plant due to liquid ammonia feeding

I. Energy savings from Steam pre-heater

Consumption of steam in Preheater =

Heat content of the LP steam =

Energy savings per hour =
Total energy savings for 2009-10 for three trains =
(considering stream hours for three trains 18878 Hrs)

2360
2.360
661.300

kg/hr
MT/hr
Kcal/kg

1.561

Gcal

29462.291

Gcal

II. Energy savings from ammonia vaporiser

Steam requirement during the start up =
Heat requirement per startup =

10.250

MT/startup

6.778

Gcal

Assuming one startup each day (330 days)

2236.847

Gcal

energy savings for three trains due to ammonia vaporiser =

6710.542

Gcal

Total savings per year (I + II) =

36172.832

Gcal

Steam savings per year =

(converting to HP steam, 805.9 Kcal/kg)

44879.444

MT

Price of steam per MT =

500.00

INR

Total savings per year =

22439722

INR

13598.472

MT

Coal savings per year =

(considering sp. Cons. Of 0.3030 per MT of steam)

B.

Investment: Rs. 30,00,000 /-

C.

Payback period: 0.133 Yrs

4.

Reduction of MP steam pressure in DAP/NP Complex fertiliser Plant:

2 MT of Medium Pressure steam at 15 kg/cm2g was being used in combustion
chamber of Dryer for atomization of furnace oil, flushing of slurry pumps and
slurry lines. After an in-house study it was observed that MP steam at 10 kg/
cm2g can be used for the above purpose. Accordingly the pressure was reduced
as per requirement and the savings are as following.

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A.

Investment: NIL

B.

Savings due to reduction of pressure in MP steam

Quantity of MP steam used in DAP

TPH

Enthalpy of steam at 15kg/cm2g, 220 OC

679.9

Kcal/kg

Enthalpy of steam at 10kg/cm2g, 200 OC

674.1

Kcal/kg

Savings in energy per hour

11600

Kcal/Hr

Savings in energy per year

218984800

Kcal/Yr

Enthalpy of HP steam (61 Kg/cm2g, 480 OC)

805.4

Kcal/kg

Savings in terms of HP steam per year

272

MT

Cost of HP steam

500

INR

Monetary savings

135948

INR

Coal savings per year

82

MT

Energy savings in Coal Handling Plant (CHP): In the old CHP total eleven nos.
of conveyors were present for conveying coal inside the plant. When it was planned
to construct the new present CHP it was considered to reduce the no. of the belts
which in turn reduces the energy consumption as the no of drives were reduced.

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