Energy Saving schemes at IFFCO- Kalol unit Kalol unit - the oldest unit of IFFCO is located at 26 km from Ahmedabad

on the Ahmedabad Mehasana highway. The unit consists of plants to produce 910 t/d ammonia based on MW Kellogg USA natural gas steam reforming process and 1200 t/d urea based on Stamicarbons CO stripping process. Urea feed stocks i.e. ammonia and CO are supplied from ammonia plant. Capacity of ammonia plant at IFFCO Kalol was uprated from 910 tpd to 1100 tpd in August, 1997 with installation of Pre-reformer unit using naphtha as feed stock. R-LNG which is the main feedstock is presently supplied by GSPCL. The fuels natural gas (NG) and associated gas (AG) are supplied by ONGC/GAIL from nearby gas wells and LSHS & Naphtha are from ONGC. Water is supplied by GIDC from 15 borewells around the Unit. The unit also has plants to produce 6 tpd Dry Ice and 12 tpd Liquid CO2 along with necessary offsite facilities. Ammonia Plant Important schemes implemented for performance improvement during the year 2005-06 Several Schemes in phased manner under Energy Saving Project (ESP) were implemented in the year 2005 and 2006 to reduce specific energy consumption by 0.915 Gcal/t of ammonia at an estimated cost of Rs. 125.30 crores. ESP Phase-I was implemented and commissioned in May-June 2005. ESP Phase-II was implemented and commissioned in April-May 2006. 1.1 LTS Guard Bed and BFW Pre Heaters A new LTS guard reactor is installed at upstream of existing LT Shift Converter with the provision for replacing the catalyst during plant operation. In this way, it is possible to keep a low CO-slippage during the entire life of the LT shift converter catalyst. A guard bed with 11.6 m3 catalyst along with two BFW preheaters is installed. Furthermore the constraint for decreasing the steam/carbon ratio during normal operation with old LTS catalyst is removed
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1.2 BASF aMDEA two stage CO removal system

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The conventional aMDEA CO removal system was consuming energy of 30,000 kcal/kg mole of CO . BASF aMDEA two stage CO removal system is installed to reduce energy consumption to about 10,000 kcal/kg mole of CO . The system includes a two stage absorption, low pressure and high pressure flash and stripping. The introduction of LP and HP flash vessels reduces the
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energy for regeneration of the solution and improves the quality of the CO product. New absorber has both lean and semi lean absorption.
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1.3 Change over of ID Fan Drive Turbine from back pressure to condensing type For closing steam balance, back pressure ID fan turbine is modified to more efficient condensing one with a provision of atmospheric venting during plant startup. MP steam consumption reduces from 10.0 t/h to about 5.0 t/h and LP steam generation stopped.

UREA PLANT 2.1 CO2 recovery with installation of ejector/separator system for CO2 centrifugal compressor About 237 kg/h of CO2 from CO2 centrifugal compressor seal leak off gases of HP&LP cases is recovered by installing an ejector/separator system. The CO2 recovery from vent gases is equivalent to additional urea production of 7 t/day. The net financial saving is Rs. 38 lakhs per annum.

2.2 Removal of last stage impeller and providing ARLON-1555 case wear rings for hydrolyser feed pump As an energy saving measure, the original SS 316 wear ring of the hydrolyser feed pump is replaced by Greene Tweede Make ARLON-1555 ring. The pump clearance has reduced from about 0.8 mm to 0.5 mm and the leakages across the seal system reduced resulting in increase of pump discharge pressure to 30.7 kg/cm2g as against the original normal pump discharge pressure of 24.0 kg/cm2g. With installation of ARLON-1555 wear ring and reducing one stage in hydrolyser feed pump, there is saving of 23.0 kWh power. Annual monetary saving will be Rs. 10 lakhs. In addition to above, ARLON-1555 case wear rings material imparts non-seizing and nongalling advantages, which will improve pump reliability.

2.3 Installation of smaller capacity low head surface condensate pump in urea plant 52.5 m /h capacity with 120 m head surface condensate pump was used to pump condensate from surface condenser to the utility deaerator. The actual required operating capacity is about 30 m /h (design: 52.5 m /h). 30.0 m /h normal capacity (Rated: 35.0 m /h) with 85 m head surface condensate pump is installed in place of the higher capacity surface condensate pump. About 17 kW power is saved by installing smaller capacity and low head surface condensate pump. The cost of new pump installation is about Rs. 2,00,000/-(rupees two lakh only). The monetary saving is Rs.7,30,000/.per annum. The pay back period works out to be about three months. 2.4 Provision of bigger size second evaporator steam control valve to reduce pressure drop in steam system. The 3 control valve with Cv of 70 was designed for normal flow of 4.5 t/h with pressure drop of 3.0 kg/cm2. During high prilling load operation, it is required to supply 9.0 ata steam to second evaporator more than 4.5 t/h. It was causing limitation and the control was getting almost full open to maintain
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second evaporator outlet temperature. To keep the control valve in some operating range for operational flexibility, it was required to increase the 9 ata steam drum pressure to about 10.5 kg/cm2g. 9.0 steam system pressure loss survey was carried out & appreciable pressure loss was found across the control valve. As per the study, to keep control valve in operating range with lower delta P across the control valve, higher Cv of the control valve (= 170) was required. As an energy saving measure, bigger size control valve is installed in June-2005 at cost of Rs.2.25 lakhs. With implementation of the scheme, the pressure drop across control valve has reduced, control valve supply full flow at desired 9.0 ata steam drum pressure i.e. at about 7.0 to 8.0 kg/cm2g instead of 10.5 and control valve remains in operating range instead of wide open at full prilling load.It is now possible to maintain 9.0 ata steam drum pressure at 7.0 to 8.0 kg/cm2g. Due to this, about 1.0 t/h more 9.0 ata steam is generated from flashing of 23 ata steam condensate. The monetary saving works out to Rs.40 lakhs/annum. The pay back period is less than a month.

Single urea solution pump operation by installing bigger size urea solution flow control valve During normal plant operation, with one urea solution pump in operation, urea solution flow control valve to first evaporator was remaining about full open. To meet the flow requirement, it was required to operate both the urea solution pumps in parallel operation and about 12 kW additional power was consumed in pumping system. To reduce the pressure drop in the control valve, the scheme is implemented as under. New 6 globe type control valve having CV:312, class 300 # RF is installed in place of existing control valve of CV:187. The cost of modifications was around Rs.6,70,000/- (rupees six lakhs seventy thousand only). With bigger size flow control valve, the flow control valve is remaining in operating range with one pump in operation. This has saved about 11.7 kWh of electric power equivalent to annual monetary saving of about Rs.5.09 lakhs. The pay back period is about of one and half year.

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