First Prize () NATIONAL FERTILIZERS LIMITED Panipat () Unit Profile

The present installed capacity of National Fertilizers Limited (NFL) is 3.568 million tonnes urea per annum. It is the 2 nd highest producer of urea in the country.

NFL as a whole is also contributing ~16 % towards total production capacity of and total share of Panipat unit in Urea production from total NFL is also ~16%.

PANIPAT UNIT

• NFL Panipat Project was executed with the help of foreign contractor, M/s. Toyo Engg. Corporation, Japan and Indian consultant M/s. Ltd. • The cost of project was Rs. 2210 million with Rs. 550 million as foreign components. • Unit has a total area of 574 acres. Factory area is 442 acres and a beautiful township spread over an area of 132 acres • Urea plant was designed to produce 1550 TPD urea. plant was designed to produce 900 MT/day Ammonia based on partial oxidation of Residual fuel oil/LSHS by SHELL GASIFICATIION process. Commercial production of Urea was achieved in Sept. 1979. • A Captive Power Plant was also installed with 30 MW capacities at a cost of Rs. 1100 million in the year 1988. • In the year 2001-02, Unit introduced the concept of Neem coating on urea. After rigorous R&D the product was stabilized and test marketed. Seeing the overwhelming response from the farmers unit started large scale production. In view of this unit was awarded Golden Peacock Innovation Award by Institute of Directors, New Delhi in 2005 (till date unit has produced 963485.65 MT of Neem coated Urea).

Energy consumption in oil based plant was high. In view of this, announced a policy for revamp of the FO/ Naphtha based plants for changing feedstock from FO/LSHS to NG/RLNG in January 2004 with equity to debt ratio of 1:19.

In order to reduce the energy consumption under this policy, Unit has undergone for revamp of the plant by changing the feedstock from fuel oil to NG/RLNG based on proven process route of Steam Methane Reforming (AFCP). Zero date for the project was 29th Jan, 2010. Commercial production was achieved on 28.3.2013. Till date

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Panipat unit has produced 16059551 MT of Urea. Of this 927083 MT has been produced after the project of AFCP.

DESCRIPTION IN BRIEF OF AMMONIA FEEDSTOCK CHANGEOVER PROJECT UNDERTAKEN TO REDUCE ENERGY IS AS UNDER

FEED PREPARATION (HYDROGENATION AND DE-SULPHURISATION)

The natural gas feedstock contains minor quantities of sulphur compounds which have to be removed in order to avoid poisoning of the reforming catalyst in the primary reformer, and the low temperature shift catalyst in the CO converter. Particularly the low temperature shift converter is sensitive to deactivation by sulphur and sulphur bearing compounds. The sulphur contained in the natural gas will be reduced to a very low level, i.e. less than 0.1 ppm sulphur by weight.

REFORMING

The reforming of the hydrocarbon feed takes place in two stages, a direct fired primary reformer and an auto thermal catalytic secondary reformer. The hydrocarbon feed coming from the desulphurization unit is mixed with steam. The steam/carbon ratio is 3.0. The reaction mixture is preheated and taken to the primary reformer, where it is decomposed into hydrogen, carbon monoxide, and carbon dioxide over a nickel catalyst by heat supply.

In the secondary reformer preheated air is added, and the heat thus generated by burning of the gas decomposes the methane. The methane concentration in the outlet gas from the secondary reformer is 0.6 vol% (dry basis)

HIGH TEMPERATURE AND LOW TEMPERATURE CO SHIFT CONVERTER

The CO conversion takes place in two adiabatic stages. After reforming, about 12.7% CO is present in the gas (dry basis). In the high temperature CO converter, the CO content is reduced to approximately 3.1 vol%, and the temperature increases from 360 oC to 429 oC. It is then cooled to 205 oC and passed on to the low temperature CO converter, in which the CO content is reduced to approximately 0.3 vol%, while the temperature increases to 226 oC.

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CO 2 REMOVAL

For removal of the carbon dioxide, the activated MDEA process is used. Main equipment in the MDEA process is the CO 2 absorber and the CO 2 stripping column. CO 2 is removed from the process gas by counter-current absorption in two stages. In the lower part of the absorber, flash- regenerated solution is used for bulk CO 2 removal. In the upper part of the absorber, strip-regenerated solution is used for scrubbing. Thus, nearly a complete removal of CO 2 with only 0.05 vol % CO 2 (on dry basis) left in the treated gas.

METHANATION

After the CO 2 removal, the gas contains

0.05% CO 2 and 0.3% CO (dry basis). These compounds are poisons to the ammonia catalyst and must be removed before the gas is taken to the synthesis section. This is done in the methanator,

where CO and CO 2 react with H2 to form

CH 4, which is harmless to the ammonia

catalyst. The content of CO + CO 2 is reduced to less than 5 ppm. The inlet temperature to the reactor is 300oC, and the outlet temperature is 323 oC.

AMMONIA SYNTHESIS

The synthesis gas after compression to 186 kg/cm 2 is taken to synthesis loop for recovery of Ammonia. In the synthesis loop, the make-up gas is sent directly to the ammonia converter (S- 300). The make-up gas contains about

1.04 % of inert gases (Ar+CH 4). The purge is taken from the outlet and is sent to the new ammonia recovery unit.

AMMONIA RECOVERY and STORAGE

Purge gas from the ammonia separator is sent to the purge gas absorber together with letdown gas from the product let-down tank. In purge gas absorber, ammonia

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is washed out of the gases with water. The aqueous ammonia from purge gas absorber is sent to the distillation column, where the ammonia is distilled off and added to the ammonia product drawn from the product let-down tank. The off-gas from the purge gas absorber is used as fuel in the primary reformer. Ammonia produced is stored in two Horton spheres having a capacity of 1500 MT each.

BAR CHART SHOWING SPECIFIC ENERGY CONSUMPTION / MT OF UREA

With the commissioning of Ammonia feed stock changeover project at the end of 2012-13, reduction in specific energy consumption/MT of Urea has been achieved from 10.097 GCal/MT Urea to 7.687 GCal/MT Urea.

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Second Prize Fertilizers (Urea) GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED Bharuch (Gujarat)

Unit Profile

Gujarat Narmada Valley Fertilizers & Chemicals Limited. (GNFC) is a joint sector enterprise promoted by the Government of Gujarat and the Gujarat State Fertilizer Company Ltd. (GSFC). GNFC started its manufacturing and marketing operations in 1982. Over the next few years, GNFC successfully commissioned different projects - in fields as diverse as chemicals, fertilizers and Information Technology.

Since beginning GNFC has embarked itself on the path of continuous modernization and technology up gradation for almost all the plants with the help of In house innovations as well as by incorporating latest technological advancements, not only for production enhancement but also to reduce energy consumption as well to improve environmental performance.

Production Performance (GNFC Bharuch)

2012-13 2013-14 Installed Product Units Capacity Capacity Capacity Actual Actual Utilization Utilization Ammonia MT 4,45,500 591,861 132.85% 608279 136.54 % Urea MT 6,36,000 708,795 111.29% 696428 109.35 % Methanol-II MT 1,88,100 130,456 69.35% 145347 77.27 % Formic Acid MT 10,000 20,153 201.53% 20492 204.92 %

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Acetic Acid MT 1,00,000 157,093 157.09% 155236 155.24 % Weak Nitric Acid-I MT 2,47,500 287307 116.08% 291183 117.65 %

2012-13 2013-14 Installed Product Units Capacity Capacity Capacity Actual Actual Utilization Utilization Weak Nitric Acid-II MT 100000 112,690 112.69% 123322 123.32 % Conc. Nitric Acid - I MT 33,000 29,784 90.26% 32871 99.61 % Conc. Nitric Acid - II MT 33,000 28,908 87.60% 35120 106.42 % Conc. Nitric Acid III MT 50000 49,408 98.82% 53504 107.01 % Amm. Nitro 188865 132.54 % phosphate MT 1,42,500 200,895 140.98% Aniline MT 35,000 41,717 119.19% 40473 115.64 % TDI MT 14,000 17,875 127.68% 16317 116.55 % Ethyl Acetate MT 50000 Under Under 52088 104.16 % Commissio Commissio ning till ning till October October 2012 2012

Energy Consumption

At GNFC Ltd., Steam was generated mainly from 3 pulverized Coal fired Boilers, each having capacity of 180 MT/hr of HPSH steam and HRSG of GT unit. The fourth Boiler is gas based and was operated only in case of requirement. Required Power is generated with the help of 2X25 MW Steam Turbines and a 35 MW Gas Turbine based Co-generation unit. Natural Gas and LSHS were used as feed stocks in Feed Stock Conversion Unit (ASGP Plant) and FO based Ammonia plant respectively. Natural Gas was used as Fuel for Turbo generators and as well as Feed Stock in Methanol / SGGU plants. Small quantity of Natural Gas is also used as fuel in some of the plants. GNFC has also installed Wind Turbo Generators (WTG) having total capacity of 21 MW, in Kutch District of Gujarat state in the years 2007 and 2008 and operative since then. A 300 kW PV Solar plant was added to renewable portfolio and commissioned in April 2014.

Energy Saving Achievements during 2013-2014

Ammonia Plant Feed stock conversion Unit (ASGP Project) began its commercial production from 1.10.2013. This has significantly reduced energy consumption for Urea Production.

Over and above, following energy saving measures/ schemes are implemented

FO based Ammonia plant • Three pump impellers were trimmed in Rectisol unit of, which resulted in power saving of 1,98,000 kWh.

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• MP Boiler feed water transfer pump impeller was trimmed, resulted in power saving of 5,14,800 kWh.

Urea Plant • Installation of small additional HP Carbamate pump, resulted in power saving of 10,32,294 kWh and steam saving of 10,936 MT. • Condensate transfer pump’s 110 kW motors were replaced with 90 kW high efficiency & increased safety motors, resulting in power saving of 79,440 kWh.

Formic Acid Plant • Use of condensate in place of DM water for steam pressure reduction station, resulted in saving of 473 MT steam.

Ethyl Acetate Plant • Subsequent to the change in angle of the cooling tower fans’ blades, one of the cooling wat er pump was stopped, resulting in power saving of 5,56,910 kWh.

Aniline/TDI Plant • With the increase in the size of supply pipe, one hot well pump was stopped, resulting in power saving of 1,16,640 kWh.

Utility Plant • Replacements of raw water supply pump to demonstration farm with lower capacity pump resulting in power saving of 42,522 kWh. • Two pumps handling effluent discharge were replaced with energy efficient pumps resulting in power saving of 23,400 kWh. • Installation of 90 kW VFD at Filter water pump MP- 1701C, resulted in power saving of 77,280 kWh.

Electrical System • On account of following actions, power saving of 2,82,657 kWh was achieved • Replacement of old lighting fixtures with energy efficient ones in various Plants and Buildings. • Provided contactor and push button to keep normal lighting OFF and to make it ON as per the requirement in CNA-II plant. • Replacement of Split AC and fans with star rated AC and fans in Township area. • Replacement of 6 nos. of Air Handling Unit motors in the Corporate Building.

Use of Solar Energy • Total 300 kW Solar Photo Voltaic power generation systems installed at (i) Company Guest house building having capacity of 25 kW (ii) School building having capacity of 125 kW and (iii) Corporate building is having capacity of 150 kW.

Steam traps management • Steam trap survey was carried out in various plants for identification of defective traps and corrective actions initiated.

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Certificate of Merit Fertilizer s (Phosphate) THE FERTILIZERS AND CHEMICALS TRAVANCORE LIMITED UDYOGAMANDAL COMPLEX-FERTILIZER PLANT Ernakulam (Kerala)

Unit Profile

The Fertilisers and Chemicals Travancore Limited (FACT), one of the first large-scale fertilizer plants in India located at Kochi in Kerala was incorporated in the year 1943. FACT became a Public Sector company in 1960 and the Government of India became the major shareholder in 1962. FACT has business interests in manufacturing and marketing of fertilizers, Caprolactam, Engineering Consultancy and Fabrication of equipment.

FACT’s mission is to be a market leader in Fertilisers / Petrochemicals and a significant player in all its other businesses including engineering/ technology services, providing maximum customer satisfaction and reasonable reward to shareholders adhering to business ethics and professionalism with adequate concern for the community and the environment.

The main products of FACT are complex fertiliser NP 20:20:0:13 (FACTAMFOS), Ammonium Sulphate and Caprolactam.

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FACT has two manufacturing divisions (Udyogamandal Complex and Cochin Division), a consultancy unit (FACT Engineering and Design Organization - FEDO), a fabrication division (FACT Engineering Works – FEW) and Marketing Division.

FACT Udyogamandal Complex – Sections

FACT Udyogamandal plant, which started production of Ammonium phosphate in 1947 using fire wood gasification process, has undergone several stages of expansion and diversification, giving up old and obsolete technology and installing new and sophisticated plants. Apart from fertilizers like Ammonium Sulphate and Ammonium Phosphate Sulphate (Factamfos) FACT Udyogamandal plants also manufacture chemicals like Sulphuric acid, Ammonia, Sulphur Dioxide, Oleum etc. As a replacement to the high energy consuming old ammonia plants at Udyogamandal, a new 990 TPD capacity Ammonia plant at a cost of 642 Crore was put up in March 1998.

Energy Management and Production Performance

FACT achieved an important landmark during 2013 – 14, by converting the feed and fuel for Ammonia production from Naphtha to RLNG. The changeover was done online - without stopping the plant - at 80% load and it was the first time in India, a conversion of this kind was carried out without stopping the plant.

Specific energy consumption of Ammonia, with this conversion, improved from 9.626 GCal/ MT in 2012 - 13 to 9.511 GCal/ MT in 2013 – 14, in spite of the fact that the plant run for just 4 months on RLNG.

The production figures for Ammonia and the Products for the year 2013 – 14 are as below.

Installed Item 2013 - 14 Capacity Ammonia 3,26,700 MT 1,41,056 MT Factamfos (NP 20:20) 1,48,500 MT 1,65,432 MT Ammonium Sulphate 2,25,000 MT 1,78,792 MT

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Energy Conservation Measures Implemented

Particulars Description Major Benefits Use of RLNG The feedstock in 990 MT/ day • Better energy as feedstock in Ammonia Plant was changed over efficiency Ammonia from naphtha to Re-gasified LNG • Reduction in carbon- Plant dioxide gas emission & lesser pollution • Capacity enhancement Use of RLNG The fuel used for boilers (5 X 60 T/ hr • Cost reduction in for fuel in Capacity) was changed over from FO steam production Boilers to RLNG by replacing burners and • Lesser pollution associated control system

Particulars Description Major Benefits Condensate Replacement of thermodynamic type • Better energy Recovery steam traps with Twin Orifice Float efficiency of Acid System in traps and installation of flash vessel Plant Sulphuric Acid with steam operated pump so as to • Cost recovery Plant recover steam condensate Operational Conducting Energy Audit and • Better energy changes in implementing audit efficiency Plants, recommendations. The following • Cost saving improved programmes, without incurring any maintenance considerable expenditure, were programmes carried out. etc. a) Providing saturated steam for heat exchangers in Ammonia Plant b) Energy saving by reducing exit flue gas temperature by adjusting air-inlet damper c) Replacing/ Cleaning of suction filter in Main Air Blower in Acid Plant d) Proper maintenance of Air Compressor for increased efficiency e) Lighting improvements

Specific Energy Consumption of Products

Specific energy consumption of major products viz. Factamfos and Ammonium Sulphate for the last three years is as below:

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The specific energy consumption of Ammonia improved from 9.626 GCal/ MT in 2012 - 13 to 9.511 GCal/ MT in 2013 - 14 due to RLNG conversion of feedstock and fuel.

Energy Policy

FACT Udyogamandal Complex is committed to responsible energy management and will ensure utilization of all forms of energy in most efficient, cost-effective and environment-friendly manner in all our activities, products & services. The Company will implement effective energy management programmes for continual improvement in energy performance and ensure a safe and comfortable working environment to all.

To accomplish this we shall:

1. Monitor closely and control the consumption of various forms of energy through an effective Energy Management Information System 2. Implement effective programmes for increasing energy conservation awareness throughout the organization 3. Conduct regular management reviews to ensure continual improvement 4. Reduce specific energy consumption of products by 2 % (from the present average values) by the year 2016 5. Generate/ purchase 1% of our energy use from renewable sources by the year 2022

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