ENERGY EFFICIENCY IN

THE SHOP FLOOR-GSFC’S

EXPERIENCE
SHRI DS PRADHAN
GENERAL MANAGER
SHRI GN DESAI
ADDL.GEN. MANAGER
GSFC, VADODARA

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AM Chemicals Ltd.
 Corporate Policy of Energy
Management Adopted at GSFC
1 Considerations to Energy and Low
Environmental impact during Selection
of Technology
2 Process Integration
3 Energy Conservation through
Modernization/Retrofit/Cogeneration of
Steam/Power.
4 Energy Conservation measures in
operating plants
5 Monitoring Energy Cons. & Efficiency
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AM Chemicals Ltd.
 GROWTH OF GSFC
Ammonia-I, 1967 Urea-I, 1967
DAP,1967 Amm.Sulph.-I,1967
Ammonia-II,1969 Urea-II,1969
Capro-I,1974 Amm.Sulph.-II,1974
Ammonia-III,1980 PGR,1980
Sul.Acid-III,1981 Melamine-I,1982
CoGen-I,1989 CoGen-II,1990
APS,1992 Amm.Sulph-III,1993
Sul.Acid -IV,1993 Capro-II,1993
CoGen-III,1995 MEK-Oxime,1997
Melamine-II,1997 Ammonia-IV,1998
Nylon-6-1981, Re,2000
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AM Chemicals Ltd.
 FERTILIZER INDUSTRY
z Fertilizer Industry is highly energy and
Capital Intensive.
z Ammonia is the building block for all
nitrogenous & complex fertilizers.
z Steam & power are other major energy
inputs in Fertilizer industry.
z About 90% of the variable cost is
energy in ammonia production. This
makes it very obvious to concentrate on
energy conservation in ammonia plants.
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AM Chemicals Ltd.
 FERTILIZER INDUSTRY

z Continuous upgradation in the plants and

technology has resulted in reduction in
specific energy consumption during last
about 15 years - ~ 25% reduction in
energy consumption
¾ for Ammonia from 10.22 GCAL to ~7 GCAL
¾ for Urea from 8.87 GCAL to 6.67 GCAL

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AM Chemicals Ltd.
 Technological Upgradation at GSFC
z Primary Reformer efficiency increased to
93%, by improved heat recovery by reducing
Flue gas temp. up to 110 0C compared to
normal value of ~ 150OC resulting in yearly
NG saving of 27 lac SM3 equivalent to Rs 145
Lacs.
z Reduced S/C ratio resulting in annual saving
of 1.01 Lac MT steam which is used to
generate 20300 MW more power equivalent
to Rs 425 Lacs.
z Use of Flash gas & Tail gas in Reformer saving
~ 19 lac Sm3 equi. NG per year. (Rs103 Lacs)
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AM Chemicals Ltd.
 Technological Upgradation at GSFC

z Low energy based MDEA - CO2

recovery system.
z Use of Pre-Reformer designed for
Naphtha for NG reforming to reduce
energy consumption by ~ 0.2 Gcal
/MT of NH3 is under engineering.

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AM Chemicals Ltd.
 Process Integration at GSFC
z Supply of pure O2 from A-IV to
CEP:
¾ Pure O2 generated from ASU was being
vented. 2 Kms. Pipeline installed to
supply O2 to Caprolactam-II plant
resulting in stoppage of one no. of air
compressor at ASU plant of Capro.-II.
Power saving = 6928 MW/Year
equivalent to Rs 145 Lacs.
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AM Chemicals Ltd.
 Process Integration at GSFC
z Vapour ammonia supply from A-IV plant
to DAP plant:
¾ NH3 vapours were supplied to DAP from old
Ammonia plants.
¾ Subsequent to stoppage of old plants, Vap.
NH3 generated through chilling of process
fluid to be transferred to DAP plant to
reduce Refrigeration compressor load at A-
IV plant.
Annual Power saving (anticipated)
= 1400 MW (Rs 29 Lacs)
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AM Chemicals Ltd.
COGENERATION OF POWER AND STEAM
at GSFC
z Total installed power generation capacity -
115 MW. (90 MW as per steam balance)
z Actual avg. Power generation based on steam
requirement - 55 MW -- Optimized to have
minimum steam condensation.
z Full load power requirement - 66 MW
z Balance power obtained as share from GIPCL.
z Total steam consumption - 5000 MT/Day.
z Steam requirement met by extraction steam
from TG & Waste Heat Recovery in the ratio of
2:1.
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AM Chemicals Ltd.
 N.B.: FIGURES IN BOXES SHOW STATUS AT 08:45 HRS ON 01-10-2004 (TODAY)

SG PLANT
COGEN- I COGEN - II 0
COGENERATION - III

COG – I 80 80 COG – I I BOILER-4 BOILER-5 GTG

BOILER BOILER 45 TPH 45 TPH 30 MW
130 TPH 130 TPH
0 0
105 ATA
105 ATA 105 ATA
13. 0
HRSG STEAM
5
TG2 0
TG1 43 SG Plant
15 MW 25 MW Int. Cons
14 14 ATA PRDS - I 0
37
AT 37
ATA
A 0 0
BFW
CO 5
G ATA 14 ATA
21 37 ATA EXT.
HE STACK
AD 10 ATA
SA -III STG 3
ER 19
17. To Grid 20 MW
20
5 TO UREA PLANT 43 00
40 14 ATA SA-IV
Internal Consumption
5 ATA 50 0
(14 ATA & 5 ATA)
13
PRDS - FROM 37 ATA
A-IV
4 III GRID
37 ATA SG HEADER STG 00
4
EXP. 0 IMP. 16 22 MW 37 K STEAM
OF A-IV
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AM Chemicals Ltd.
 Modernization/Retrofit at GSFC
z Debottlenecking of PA, DAP plants.
¾ Capacity of PA increased from 165
to 280 MTPD.
¾ Improvement in Grinding capacity
from 30 MTPH to 45 MTPH reducing
specific power consumption by ~33%
¾ Installation of Belt Filter--Improved
P2O5 recovery.
¾ Increased circulation through Flash
Cooler
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AM Chemicals Ltd.
 Modernization/Retrofit at GSFC
¾ Capacity of DAP 340 to 600 MTPD
¾ Bigger Neutralizer
¾ Dedusting to Recover 4 MTPD DAP
¾ Improved Ammonia sparger design for
Granulator
¾ Elimination of Ammonia flow limitation
in Granulator
¾ Result --Reduction in specific from 90
kWH to ~50 kWh power
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AM Chemicals Ltd.
 NH3 flow limitation to granulator
FCV Globe Globe
2”φ
valve valve Granulator
* *

Original flow with new Control valve

= 1000 Kg/Hr
Revised flow by replacement of Globe valves by
Gate valves = 1300 Kg/Hr
This enabled us to feed 10% more
slurry to granulator and hence
increased production rate.
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AM Chemicals Ltd.
 Modernization/ Retrofit at GSFC
z Installation of Vapour Absorption Heat
Pump (VAHP)
¾ Use of low level steam which otherwise was vented.
¾ Reduction in Refrigeration compressor load by ~
325 kWh.( Rs 54.6 Lacs)
z Use of Magnetic Resonators in CoGen-I / II
& III plants:
¾ To reduce NG consumption at Ph-I / II boilers is
under consideration.
¾ Less NG consumption= 8 lacs SM3/Year
( Rs 42.88 Lacs)

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AM Chemicals Ltd.
 Energy Conservation Schemes at
GSFC
Major areas of Focus:
z Replacement of Energy inefficient
Machinery by efficient ones
z Look for reduction in capacity/head
where throttling is done
z Elimination of heat energy going to
cooling water
z Elimination of leakage in compressed
air system
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AM Chemicals Ltd.
 Energy Conservation Schemes at
GSFC
z Replacement of motors operating
below 50% load.
z Star-Delta changeover for under
loaded motors.
z Reduction in Lighting Voltage.
z Rescheduling of Transformer Loads.
z Recovery Of Flash Steam
z Utilization of low level Heat.
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AM Chemicals Ltd.
 Energy Conservation Schemes at
GSFC
zInstallation of small capacity pumps,
better efficiency pumps and
optimization of running hours.
¾ Saving realized through schemes
implemented = 1390 MW/Year
(RS 29 Lacs)
¾ Saving envisaged through schemes
under implementation= 410 MW/Year
(Rs 8.6 Lacs)
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AM Chemicals Ltd.
 Energy Conservation Schemes at
GSFC
z Trimming of impellers:
¾ Pressure drop in terms of valve throttling
reduced by impeller trimming of various
process and CW pumps.
¾ Saving realized through schemes
implemented = 1870 MW/Year
(RS 39 Lacs)
¾ Saving envisaged through schemes under
implementation= 850 MW/Year
(RS 17.8 Lacs)
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AM Chemicals Ltd.
 Energy conservation Schemes at GSFC
z Pre heating using process heat
¾ Feed pre heaters installed after identifying area
to recover process heat which was being
rejected to Cooling water.
¾ Total saving in terms of steam
= 7200 MTPY(Rs 61 Lacs)
z Installation of Desuperheaters in Urea plant:
¾ Desuperheating of High temp. steam at exhaust
of turbine to generate more steam, to reduce
process limitation.
Steam saving realized = 20000 MTPY
(Rs 170 Lacs)
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AM Chemicals Ltd.
 Energy Conservation Schemes at GSFC
z Supply of 5 ata steam in place of 14 ata
steam to deaerator of CoGen-III:
¾ 5 Kg steam for deaeration purpose was let
down from 14K steam .
¾ TG-I (15 MW) uses 105K steam and
Extraction of 14 K, 10 K, and 5 K steam.
¾ 5K steam to be extracted more from TG-I
and to be supplied to deaerator.
¾ Additional Power generation=2800 MW/Yr
(Rs 59 Lacs)
¾ Cost of Implementation =Rs 15 Lacs
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AM Chemicals Ltd.
 Comparison of Power consumption value

3500

3000
kWh / M T Product

2500
Design
2000 2003-4

1500

1000

500

0
Capro-1 CEP Urea Mel-I Mel-II DAP
Design 2900 2400 210 1975 1600 117
2003-4 2345 1616 169 1769 1368 56
Plants
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AM Chemicals Ltd.
 Comparison of Steam consumption value
16.00

14.00
MT steam / MT product

12.00
Design
10.00 2003-4

8.00

6.00

4.00

2.00

0.00
Capro-1 CEP Urea Mel-I Mel-II
Design 13.70 7.00 1.55 8.00 7.50
2003-4 7.48 5.35 1.42 6.08 5.11
Plants
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AM Chemicals Ltd.
 Reduction in Energy consumption - GSFC
complex
160000 2600

140000 2500

Energy Kcal * 10^9

120000
2400
Production MT

100000
2300
80000
2200
60000
2100
40000

20000 2000

0 1900
2001-02 2002-03 2003-04
Years
Fertilizers MT*10 Industrial MT Energy Kcal/Yr*10^9

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AM Chemicals Ltd.
Monitoring Energy Consumption &
Efficiency at GSFC
z Plant report generation:
¾ inclusive of daily, monthly, yearly
energy consumption figures.
¾ inclusive of daily, monthly, yearly
specific consumption figures.
¾ Special task of Tech. Deptt.
¾ Yearly reports by each plant - ISO
procedure.
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AM Chemicals Ltd.
Compliance to Statutory requirements at
GSFC
z As per requirement of Energy Conservation Act,
¾ Energy Manager nominated
¾ Energy Cell formed
Energy Cell comprises of members from various
disciplines- Technical Services, Operation,
Mechanical, Electrical and Instrumentation
¾ Energy policy declared.
z During last 5 years two energy audits- one by
M/S Saket and one by M/S ERDA carried out.
z Next energy audit will be completed by Dec-
2004.
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AM Chemicals Ltd.
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AM Chemicals Ltd.