WELCOME TO WELCOME TO

INDIAN FARMERS FERTILIZER COOPERATIVE LTD. INDIAN FARMERS FERTILIZER COOPERATIVE LTD.
PARADEEP UNIT PARADEEP UNIT
DATE: 19 DATE: 19- -20 AUGUST, 2013 20 AUGUST, 2013
VENUE: CII VENUE: CII- - HYDERABAD HYDERABAD
Kandla Kandla, , Gujrat Gujrat
Kalol Kalol, , Gujrat Gujrat
Aonla Aonla, UP , UP
Phulpu Phulpur r, UP , UP
Paradeep Paradeep, ,
Odisha Odisha
LOCATION OF IFFCO PLANTS
Year of Commissioning : 2000
Ownership of Plant upto 30-09-05 : OCFL
Take over by IFFCO : 01-10-2005
Product Capacity MTPD Technology
Sulphuric Acid 2 x 3500 Lurgi GMBH, Germany
Phosphoric Acid 1 x 2650 Jacobs Engg. USA
DAP/NP 3 x 2090 Jacobs Engg., USA
Captive Power Plant 2 x 55 MWH LMZ Energy, Russia
Annual Production 2.31 Million tonnes of Sulphuric Acid
0.875 Million tonnes of Phosphoric Acid
1.92 Million tonnes of Phosphatic Phosphatic fertiliser fertiliser
IFFCO PARADEEP UNIT A PROFILE
IFFCO PARADEEP UNIT - CERTIFIED FOR
ISO 14001: 2004 & BS OHSAS 18001:2007
ISO 14001:2004 ISO 14001:2004
BS OHSAS
18001:2007
ISO 50001:2011 ISO 50001:2011- -EnMS: EnMS: Documentation part, Internal audit Documentation part, Internal audit
and shadow audit have been completed. Certification work is and shadow audit have been completed. Certification work is
in progress. Certification expected by end of Dec. 2013. in progress. Certification expected by end of Dec. 2013.
Sulphuric
Acid
Plant
Phosphoric
Acid
Phosphoric
Acid
Plant
DAP / NP
Plants
DAP
Rock
Phosphate
Sulphuric Acid
NP
Sulphur
Process Diagram
Ammonia
NPK
Potash
Urea
Energy Management
in
IFFCO Paradeep Unit
S
N
Title of Energy saving project Energy savings per
Annum
Annual
savings
Invest
ment
made
Payback
Period
Electrical
!"
#$ermal
!# %uel
&s'
!illion
&s'
!illion
!ont$s
1 &emoval o( )oating drum (eed
conveyor * Product (eed
conveyor
0'++, - 0',4 .I/ Immedi
ate
2 &emoval o( polis$ing screens 0'101 - 0'40 .I/ Immedi
ate
+ &emoval o( coating drum 0'210 - 0'12 .I/ Immedi
ate
4 &eduction in po3er
consumption in A%4) coal (ired
boiler by running t3o nos'
4oiler (eed 3ater pumps
instead o( t$ree pumps'
+'+11 - ,'415 .I/ Immedi
ate
Energy saving pro6ects implemented in 2010-11
2011-12 * 2012-1+
S
N
Title of Energy saving project Energy savings per
Annum
Annual
savings
Invest
ment
made
Payback
Period
Electrical
!"
#$ermal
!# %uel
&s'
!illion
&s'
!illion
!ont$s
5 &eplacement o( product screen
(eeder 3it$ pan (eeders in 7AP
plant
0.333 - 0.833 1 14
6
!odi(ication o( 4all mill-) 8eig$
(eeder in P$osp$oric Acid Plant'
0'10+ - 0'252 2'01 04
7
&eplacement o( cooling to3er (an
blades 3it$ $ollo3 %&P blades in
P$osp$oric Acid Plant'
0'011 - 2'222 +'00 11
Energy saving pro6ects implemented in 2010-11
2011-12 * 2012-1+
S
N
Title of Energy saving project Energy savings per
Annum
Annual
savings
Invest
ment
made
Payback
Period
Electrical
!"
#$ermal
!# %uel
&s'
!illion
&s'
!illion
!ont$s
8
!odi(ication o( evaporator9s
barometric condenser by installation
o( single sieve type distribution tray
and removal o( steam e6ector
system'
- 22121
:)oal;
44'+5 ,'4, 2'+
9
Increase in <eig$t o( )-4 )onveyor in
coal (ired boiler
-
10
:7iesel;
4'14
2'00 1
10
Installation o( ,, numbers 008 /E7
%i=tures installed in place o( 1508
<PS> %i=tures
0.049
-
0.1215 0.992
0,
Energy saving pro6ects implemented in 2010-11
2011-12 * 2012-1+
958
833
806
718
620
616
568
400
500
600
700
800
900
1000
K
W
H

/

M
T

o
f

P
2
O
5

i
n

F
e
r
t

i
!
e
r
O"er# S$e%ifi% &on'()$tion of *e%tri%it+
,20
,1,
5,8
540
550
5,0
570
580
590
,00
,10
,20
2010-11 2011-12 2012-13
.
/
0
/
t
o
n
n
e

P
2
O
5
*e%tri%# *ner1+ &on'()$tion $er tonne of
&o)$e2 fertii!er P2O5
1.07
1.18
1.71
0
0.2
0.4
0.,
0.8
1
1.2
1.4
1.,
1.8
2010-11 2011-12 2012-13
3
%
#

/
t
o
n
n
e
P
2
O
5
T0er)# *ner1+ &on'()$tion $er tonne of
&o)$e2 fertii!er P2O5
Thermal Energy/MT P2O5 is higher due to stoppage of Sulphuric acid plant-1
from 13
th
Nov. 2012 to 7th Feb.2013 & Sulphuric acid plant-2 from 3
rd
Mar 2013
to 31 Mar 2013 resulted in more coal consumption and Lower production of
fertilizer due to all plant stoppage for 17 days from 20
th
May to 5
th
June 2013
due to very high price of raw material in international market , fluctuation in
price of Dollar vs INR, poor monsoon, high cost of phosphatic fertiliser etc.
Comparison with Global Norms/Benchmark data
S$e%ifi% *ner1+
%on'()$tion
4oM 2010-11 2011-12 2012-13 T#r1et
#$ermal ?cal@tonne P2O5 1'02 1'1, 1'21 A 1'02
Electrical k8$@tonne P2O5 120 111 51, A 51,
Road Map to achieve benchmark
Presently in fertlizer industry, in 1 Presently in fertlizer industry, in 1
st st
phase BEE has set SEC for phase BEE has set SEC for
UREA plants only. For Phosphatic plants BEE informed that SEC UREA plants only. For Phosphatic plants BEE informed that SEC
may be given in 2 may be given in 2
nd nd
phase starting from 2014 phase starting from 2014- -15. 15.
Implementation of ISO 50001:2011-EnMS with internal benchmark
& target to reduce energy and water usage
Internal & External Auditing to reduce Energy demand
Training on Energy conservation to all employees
Selection of Energy efficient technology & procurement
/ist o( pro6ects 3it$ savings
S.
N
Description of Scheme Energy
savings
Invest
Lakhs
6 Power savings due to provision of a Single cloth
wash tank in Phosphoric Acid Plant.
27.5 kw 10
7 Energy savings due to Conventional
GLS/Fluorescent/HPSV lamps replaced by
CFL/LED Lamps
172 kw 3.23
8 Energy savings due to Conventional HPSV lamps
replaced by Solar street Lights
65.52 kw 15.21
9 Replacement of Cooling Tower fan blades in
Sulphuric Acid Plant
105 kw 21
10 Replacement of Cooling Tower Fan blades in
Energy Center
114 kw
+0
1. Modification of Evaporator Barometric Condenser by by
installation of single sieve type distribution tray and installation of single sieve type distribution tray and
removal of steam ejector system. removal of steam ejector system.
Perforated single sieve tray has been
installed in barometric condenser in
place of baffles for six evaporators.
Vacuum is achieved without use of
MP Steam.
MP Steam saving of about 12 T/hr
( 2 T/hr per evaporator)
Yearly savings:Energy:63787 Gcal 63787 Gcal
(Monetarysavings: (Monetarysavings:Rs.355.82 Lakhs)
Investment: Rs. 84.894 Lakhs
Payback period: 3 months
Other Benefits : Equivalent CO Other Benefits : Equivalent CO
2 2
emission reduction. emission reduction.
2. 2. Installation of Steam Air Heater in place of Furnace Oil Installation of Steam Air Heater in place of Furnace Oil
(Fuel oil) fired heater for drying of fertilizer in Train (Fuel oil) fired heater for drying of fertilizer in Train- -A, B & C. A, B & C.
)ombustion
)$amber
<ot Air duct
&otary 7ryer
%uel oil 5+0 Bgs
@ $r 20
0
)
Cuenc$ air (an
cap' 150000
m+@$ 100 mm
3'g'
Solid material
4urner
112 11+ m+@$r at
1,0
0
) * -2 mm 3'g' in
2400 mm O'7 10 mm
t$ick duct re(ractory
lined
102,2+ m+@$
amb' air at +1
0
)
amb' air at +1
0
)
Air (or %O
atomiDation
*
combustion
cap'
40000
m+@$ +00
mm 3'g'
Before: Before:
To evaporate the To evaporate the
moisture of fertilizer moisture of fertilizer
hot gases is supplied hot gases is supplied
into the dryer through into the dryer through
a duct which is lined a duct which is lined
with refractory. The with refractory. The
hot air is generated hot air is generated
by by firing fuel oil firing fuel oil
through a burner and through a burner and
a combustion a combustion
chamber with supply chamber with supply
of inlet air of inlet air
System after System after
modification: modification:
System was retrofitted System was retrofitted
with steam heated air with steam heated air
system by connecting the system by connecting the
hot air duct of this new hot air duct of this new
steam air heater to the steam air heater to the
existing discharge duct of existing discharge duct of
combustion chamber. combustion chamber.
This will enable This will enable
changeover to changeover to
conventional fuel firing conventional fuel firing
mode as and when mode as and when
required. required.
2. 2. Installation of Steam Air Heater in place of Furnace Oil Installation of Steam Air Heater in place of Furnace Oil
(Fuel oil) fired heater for drying of fertilizer in Train (Fuel oil) fired heater for drying of fertilizer in Train- -A, B & C. A, B & C.
Investment : Investment : for 3 trains = for 3 trains = Rs. 6.78 Crores Rs. 6.78 Crores
Monetary Savings: Monetary Savings:
a). FO savings : 12151 KL/year x Rs. 53770 per KL= Rs. 65.34 Cr a). FO savings : 12151 KL/year x Rs. 53770 per KL= Rs. 65.34 Cr
b). Yearly HP steam cost: 217800 MT x Rs. 648 = Rs. 14.11 Cr. b). Yearly HP steam cost: 217800 MT x Rs. 648 = Rs. 14.11 Cr.
c). Yearly Monetary savings ( a c). Yearly Monetary savings ( a- -b)= Rs. 51.22 Cr. b)= Rs. 51.22 Cr.
Payback period: Payback period: 48 days. 48 days.
2. 2. Installation of Steam Air Heater in place of Furnace Oil Installation of Steam Air Heater in place of Furnace Oil
(Fuel oil) fired heater for drying of fertilizer in Train (Fuel oil) fired heater for drying of fertilizer in Train- -A, B & C. A, B & C.
3. Modification of Ball mill-C Conveyor in
Phosphoric Acid Plant.
Brief description:
In Ball mill-C, Rock was
being fed to Ball mill through
02 nos. of conveyors
delivering in series.
Dust was generated during
transferring the material from
one conveyor to another.
It has been modified by
putting a single conveyor
Modification:
The present feed conveyor was extended up to ball mill feeding
point diagonally to avoid spillages and an additional drive.
Investment : Rs. 20, 16,418 /-
Operating cost before modification:
Power rating of the feed conveyor : 3 kw
Power rating of the transfer conveyor : 14.5 kw
Total power consumed : 17.5 kw
Operating cost after modification:
Power rating of the feed conveyor : 4.5 kw
Savings:
Saving in power consumption : 13 kw
Unit cost of power (Rs/kwh) : 3.19
Total energy saved in year (13X24X330) : 102960 kw
Yearly savings : Rs 3, 28,442
Pay back period : 74 months
Above modification has also reduced generation of dust due to
decrease in number of multiple handling and transfer points and reduce
maintenance activity.
3. Modification of Ball mill-C Conveyor in
Phosphoric Acid Plant.
45 He#t 6e%o"er+ S+'te) in S($0(ri% A%i7 P#nt
Fir't ti)e i)$e)ente7 in 89:8A
Pro;e%t &o't : 6'. 100 %rore'
&o)$etion 7#te: 15
t0
<(+= 2013
>e#r+ S#"in1': 348480 3%# ? 6'. 25 &r5
P#+@#%.: 4 +e#r'
Ot0er Benefit' : &O Ot0er Benefit' : &O
2 2
e)i''ion e)i''ion
re7(%tion re7(%tion':126998 &*6' $er #nn()5 &*6' $er #nn()5
Without HRS at Present Without HRS at Present
Sulfuric acid Sulfuric acid
plant plant
Heat Input by Heat Input by
Burning sulfur Burning sulfur
HP steam 175 MT/hr HP steam 175 MT/hr
14 !"al/hr 14 !"al/hr
#aste heat t$ "$$ling #aste heat t$ "$$ling
t$%er t$%er
&' !"al/hr &' !"al/hr
Sulfuric acid Sulfuric acid
plant plant
14 !"al/hr 14 !"al/hr
(P steam &)*5 MT/hr (P steam &)*5 MT/hr
44 !"al/hr 44 !"al/hr
#aste Heat t$ #aste Heat t$
"$$ling t$%er "$$ling t$%er
1+ !"al/hr 1+ !"al/hr
H,S H,S
Heat Input by Heat Input by
Burning sulfur Burning sulfur
-.$ change in input heat/ -.$ change in input heat/
With HRS Proposed With HRS Proposed
HP steam 175 MT/hr HP steam 175 MT/hr
45 He#t 6e%o"er+ S+'te) in S($0(ri% A%i7 P#nt
STEAM AND POWER BALANCE OF THE COMPLEX
IN PRE HRS-I
SAP SAP - - I I SAP SAP - - II II
AFBC AFBC - - I I
AFBC AFBC - - II II
155 155 155 155 57.5 57.5 57.5 57.5
425 425
188 188
PAP PAP
(Evap. , Reac. & (Evap. , Reac. &
Filt.) Filt.)
SAP SAP
(BFW, CWP & (BFW, CWP &
BLOWER ) BLOWER )
DAP DAP
(Air Heater, (Air Heater,
Ammon. heating Ammon. heating
& flushing) & flushing)
84 84
30 30
10 10
AFBC AFBC
(De (De- -areator) areator)
171 171
Power Power
Plant Plant
45.0 MW 45.0 MW
For internal For internal
consumption consumption
0 MW 0 MW
Power Power
export export
PRDS PRDS PRDS PRDS PRDS PRDS
Sulphur Sulphur
Melting Melting
21 21 26 26 113 113
25 25
16 16
15 15
Legend Legend
HP Steam, 61 kg/cm HP Steam, 61 kg/cm
2 2
and 480 and 480
0 0
C C
MP Steam, 16 kg/cm MP Steam, 16 kg/cm
2 2
and 210 and 210
0 0
C C
LPS LPS
1 1
Steam, 6.5 kg/cm Steam, 6.5 kg/cm
2 2
and 168 and 168
0 0
C C
LPS LPS
2 2
Steam, 3.6 kg/cm Steam, 3.6 kg/cm
2 2
and 155 and 155
0 0
C C
Hourly steam balance in MTPH
Turbine Exhaust Turbine Exhaust
20 20 SAP SAP De De- -areator areator
71 71
STEAM AND POWER BALANCE OF THE COMPLEX
IN POST HRS-I
SAP SAP - - I I SAP SAP - - II II
AFBC AFBC - - I I
AFBC AFBC - - II II
155 155 155 155 62.5 62.5 0 0
372.5 372.5
188 188
PAP PAP
(Evap. , Reac. & (Evap. , Reac. &
Filt.) Filt.)
SAP SAP
(BFW, CWP & (BFW, CWP &
BLOWER ) BLOWER )
DAP DAP
(Air Heater, (Air Heater,
Ammon. heating Ammon. heating
& flushing) & flushing)
84 84
30 30
8 8
AFBC AFBC
(De (De- -areator) areator)
169 169
Power Power
Plant Plant
44.35 MW 44.35 MW
For internal For internal
consumption consumption
0 MW 0 MW
Power Power
export export
PRDS PRDS PRDS PRDS PRDS PRDS
Sulphur Sulphur
Melting Melting
21 21 26 26 68 68
25 25
16 16
15 15
Legend Legend
HP Steam, 61 kg/cm HP Steam, 61 kg/cm
2 2
and 480 and 480
0 0
C C
MP Steam, 16 kg/cm MP Steam, 16 kg/cm
2 2
and 210 and 210
0 0
C C
LPS LPS
1 1
Steam, 6.5 kg/cm Steam, 6.5 kg/cm
2 2
and 168 and 168
0 0
C C
LPS LPS
2 2
Steam, 3.6 kg/cm Steam, 3.6 kg/cm
2 2
and 155 and 155
0 0
C C
Hourly steam balance in MTPH
HRS HRS - - I I
65 65
Turbine Exhaust Turbine Exhaust
26 26 SAP SAP De De- -areator areator
65 65
Sulphuric Acid Plant
On-line SO2 analyzer in SAP stack has been installed for continuous
monitoring and control of SO2 emission through stack. Facility for Facility for
transmitting data to OSPCB server is in progress. transmitting data to OSPCB server is in progress.
Phosphoric Acid Plant
Installation of Bag filter De Installation of Bag filter De- -dusting system in Phosphoric acid plant dusting system in Phosphoric acid plant
rock phosphate reclaiming conveyors no. 105 & 106 rock phosphate reclaiming conveyors no. 105 & 106
Utilization of TG Cooling tower blow down water in filter conden Utilization of TG Cooling tower blow down water in filter condenser ser
and as Vacuum pump seal water. and as Vacuum pump seal water.
Power Plant
Boiler Boiler - - 1 & 2 F.D. Fans suction duct extended vertically up to 10 mtr. 1 & 2 F.D. Fans suction duct extended vertically up to 10 mtr.
Thus improved fan performance and quality of combustion air and Thus improved fan performance and quality of combustion air and noise noise
level from 109 db to 82 db. level from 109 db to 82 db.
List of major Environmental
improvements made
List of major Environmental
improvements made
Utility & Offsites
Revamping of 60,000 m3 guard pond with new HDPE and RCC Revamping of 60,000 m3 guard pond with new HDPE and RCC
lining. lining.
30 meter setback has been provided all along the periphery at 30 meter setback has been provided all along the periphery at
the top of phosphogypsum stack, for enhacement of stability of the top of phosphogypsum stack, for enhacement of stability of
stack. This was done by deploying earth moving equipments. stack. This was done by deploying earth moving equipments.
To minimize dust emission in Coal Handling plant, dry fog water To minimize dust emission in Coal Handling plant, dry fog water
spray nozzle system provided for coal crushers, screens and spray nozzle system provided for coal crushers, screens and
hoppers hoppers
Installing of Online ambient air monitoring station with facilit Installing of Online ambient air monitoring station with facility of y of
transmitting data to OSPCB server transmitting data to OSPCB server
STP revamp and Green belt development STP revamp and Green belt development
8niti#ti"e' t#.en for *n"iron)ent Prote%tion A
i)$ro"e)ent in :AP/9PK $#nt
1' Sc$eme : Installation o(
additional dust scrubbing
system in 7AP plant to increase
dust and (ume scrubbing
e((iciency'
2' Investment : &s +00 /ak$s
+' 4ene(it: Improvement in dust
scrubbing e((iciency'
4' 4' Particulate matter reduced Particulate matter reduced
(rom150 mg@.m+ to 100 (rom150 mg@.m+ to 100
mg@.m+ mg@.m+
The unit recovers fertilizer
dust from various transfer
points in bagging plant.
The system was designed
in-house & installed using
discarded equipment &
material thus saving around
Rs. 1 crore investment.
This has resulted in
keeping the area dust free.
Spray nozzle Spray nozzle
Scrubber Scrubber
Exhaust fan Exhaust fan
Circulating pump Circulating pump
De De - - Dusting system at Bagging plant Dusting system at Bagging plant
Initiatives taken for Environment Protection & Initiatives taken for Environment Protection &
improvement improvement
O"er# S$e%ifi% &on'()$tion of Pro%e'' W#ter
Sp. Consumption of process water is higher during 2012 Sp. Consumption of process water is higher during 2012- -13 due to less 13 due to less
fertilizer production because of plant stopped due to very high fertilizer production because of plant stopped due to very high price of raw price of raw
materials in international market & fluctuation in price of D materials in international market & fluctuation in price of Dollar vs INR . ollar vs INR .
*n"iron)ent Pro;e%t' in.in1 /it0 &#r@on
e)i''ion re7(%tion ?4n7er 8)$e)ent#tion;
Sl
No
Title of project
implemented
Year of
Implementation
Total CO
2
Reduction
Total
Annual
Savings
Invest.
Made
Payback
Years
No of
CERs per
annum
Rs Million Rs Million
1 Heat recovery
system in
Sulphuric acid
plant
Project Started
in 2011 and
Commissioned
on 15
th
July,
2013
126998 Rs. 250
million
per
annum
Rs. 1000
million
4 years
4tii!#tion of W#'te 0e#t fro) $ro%e''
No Type of
Waste Fuel
used
Quantity of waste
steam used,
tonnes
Total energy used
in complex, Gcal
Waste fuel as
% of total
energy
1.
Steam
generated
from
Sulphuric
Acid Plant
waste heat
Recovery
Boiler by
burning of
Sulphur
1549704 tonnes
of HP Steam
generated during
the year 2012-13
(61.2 kg/cm2.g
pressure and 480
Deg centigrade
Temp.)
(Equivalent to
1248131 Gcal)
1875404 Gcal for
the year 2012-13
66.5%
4tii!#tion of W#'te @+-$ro7(%t'
No Type of
Waste By-
product
Quantity of waste
by-product
Generated (Tons)
Cuantity o( 3aste
by-product Sold
:tonne;
"tiliDation
E
1
Fluorosilicic
Acid from
Phosphoric
Acid plant
4219.81 41!."1
#$ale to %&s.
Alufluoride'
Visa(hapatnam
1)) *

Gypsum from
Phosphoric
Acid plant
2724132.66 +""14.,
# sale to local
-endors.
1.)/ *
+
Fly Ash
generation
from AFBC
Coal Fired
Boiler
157992 1,/!!
#own 0and 1illing.
1))*
Involvement o( employees *
E=tent o( team 3ork in Encon'
Awareness & Training to Engineers, Supervisors & Work men
Periodic Energy Audits, Continuous Monitoring, Review Of Targets
& Bench Marks For Energy Consumption Done By Top
Management.
Identification of Potential Areas & Equipments For Energy
Conservation.
Encouraging Employees for giving Suggestions towards Energy
Conservation.
Looking For Latest Technologies & Implementation.
Continuous Study of Operating Parameters to avoid deviation.
Time-To-Time Technology Up gradation.
Regular In Plant Training For The Employees.
Employees suggestion sc$eme is in place and is very e((ective' A lot
nos' o( energy saving suggestions $ave been selected and a3arded'
Employees are very muc$ encouraged' %or t$is a (ull (lagged
suggestion committee is t$ere (or revie3 and selection o(
suggestions (or a3ard'
Suggestions received and a3arded %rom 1
st
Fuly 2012 to +0
t$
.ovember 2012
Total no. of Suggestion
Received
Suggestion Accepted No. Of Suggestions
Awarded
909 572 59
Employees suggestion scheme Employees suggestion scheme
Employee Training Employee Training
Year Total mandays covered
2010-11 1627
2011-12 1712
2012-13 2759
2013-14 (till July) 1779
Year wise total number of employee trained(Mandays) Year wise total number of employee trained(Mandays)
during (In during (In- -House + Corporate + External) Training House + Corporate + External) Training
Programme Programme
Energy manager head energy conservation cell, which
comes under technical cell headed by GM (Technical).
Technical cell helps in monitoring process parameters for
various equipment.
Technical cell make energy conservation proposal duly
authenticated by data & the same is being submitted to Unit
Head for approval.
Once the proposal is approved modifications are
implemented.
Frequency of review of energy consumption is Daily /
Monthly / Quarterly / Half yearly / & Yearly.
*9*63> MO98TO6893 A9: 6*PO6T893 S>ST*M
7aily Energy report
Energy saving & Renewable Energy projects
for next three years
Installation of Heat Recovery system in Sulphuric Acid Plant Installation of Heat Recovery system in Sulphuric Acid Plant- -II ( CDM II ( CDM
project) costing around Rs. 100 Cr. (For generating extra 65 t/h project) costing around Rs. 100 Cr. (For generating extra 65 t/hr steam from r steam from
waste heat) waste heat)
Installation of Sulphuric Acid dilution cooler to reduce Reactor Installation of Sulphuric Acid dilution cooler to reduce Reactor temparature temparature
in Phosphoric acid plant in Phosphoric acid plant
Replacement of old conventional motors with energy efficient mot Replacement of old conventional motors with energy efficient motor or
Replacement of conventional GLS/Fluorescent/HPSV fittings with I Replacement of conventional GLS/Fluorescent/HPSV fittings with Induction / nduction /
LED fittings. LED fittings.
Providing Green Bay induction fitting along the plant main roads Providing Green Bay induction fitting along the plant main roads to counter to counter
global warming. global warming.
Using natural daylight in storage sheds & new buildings by insta Using natural daylight in storage sheds & new buildings by installing Light lling Light
pipe. pipe.
Installation of Solar street lights, Solar Photo Voltaic modules Installation of Solar street lights, Solar Photo Voltaic modules and Solar and Solar
water heaters. water heaters.
Sl.No. MP
No:
Objective Budge
t
Key
respon
sibility
Remarks/
Present
status
Completion
date
1 EHS
GE:M
P 02
To recover 20-
25% of energy
in SAP in the
form of LP
steam by
installing Heat
recovery
system
Rs.
10000
Lakhs
GM
(Techn
ical)
Completed 15.07.2013
2 EHS
PE:MP
01
Installation of
Steam Air
heater instead
of Furnace Oil
fired heater
Rs 680
Lakhs
GM
(Techn
ical)
Completed Dec 2012
Energy saving projects from
ISO 14001
70 Nos. Conventional HPSV 70 Nos. Conventional HPSV
lamps replaced by 12W Solar LED lamps replaced by 12W Solar LED
street lights street lights
Electrical savings/ year: 0.285Lakh Electrical savings/ year: 0.285Lakh
kWh kWh
Yearly saving : Rs. 0.713 Lakh Yearly saving : Rs. 0.713 Lakh
Investment : Rs. 15.21 Lakhs Investment : Rs. 15.21 Lakhs
Replacement of Conventional HPSV Replacement of Conventional HPSV
Lamps Lamps by 12W Solar LED street lights by 12W Solar LED street lights
2. 2. Installed 3 Nos. Solar water heaters for hot water generation Installed 3 Nos. Solar water heaters for hot water generation
Electrical savings : 4380 kWh ( 2 kW x 2 hrs x 3 nos. x 365 days Electrical savings : 4380 kWh ( 2 kW x 2 hrs x 3 nos. x 365 days) )
Yearly saving : Rs. 10950 (considering Rs. 2.5 per unit) Yearly saving : Rs. 10950 (considering Rs. 2.5 per unit)
Investment : Rs. 141000 (Rs. 47000 x 3) Investment : Rs. 141000 (Rs. 47000 x 3)
1. 1. Installed 3 x 10 kw = 30 kW Photovoltaic Installed 3 x 10 kw = 30 kW Photovoltaic
Solar pack to generate power for Solar pack to generate power for
Administrative building. Administrative building.
Electrical savings per year: 131400 kwh (30 Electrical savings per year: 131400 kwh (30
kw x 12 hrs x 365 days) kw x 12 hrs x 365 days)
Yearly saving Rs. In Lakhs : Rs. 328500 ( Yearly saving Rs. In Lakhs : Rs. 328500 (
considering Rs. 2.5 per unit) considering Rs. 2.5 per unit)
Investment = 2295000 x 3 = Rs. 6885000 Investment = 2295000 x 3 = Rs. 6885000
Renewable Energy Renewable Energy
Renewable Energy Purchase Obligation
of IFFCO Paradeep
2011-12 RPO Compliance(5.0%):
2011-12 yearly RPO compliance has submitted to OREDA along with .
cogeneration certificate received from GRIDCO. Letter received form
OREDA that there is no penalty for IFFCO for the year 2011-12.
2012-13 RPO Compliance(5.5%)
The yearly RPO compliance for the financial year 2012-13 has been
submitted to OREDA. Cogeneration certification for the year 2012-13 is yet
to receive from GRIDCO.
In light of significant Judgment by Applette Electricity tribunal in the case
of Vedanta Aluminium Vs. Orissa Electricity Regulatory Commission (59 of
2012), our consultant M/s. Reconnect suggested IFFCO Paradeep Unit not
to purchase RECs. Accordingly we have stopped purchasing RECs during
FY 2013-14.
In the above circumstances, It is decided not to purchase RECs till further
OERC order or SC hearing (if OERC filed counter against APTEL
judgement).
S.N Description Of Scheme Source of
Idea
1 &emoval o( coating drum )oating drum (eed conveyor * Product
(eed conveyor polis$ing screens and cooler (eed conveyor
I%%)O BA/O/
2 &eduction in po3er consumption in A%4) coal (ired boiler by
running t3o nos' 4oiler (eed 3ater pumps instead o( t$ree pumps'
I%%)O
P$ulpur
+ &eplacement o( product screen (eeder 3it$ pan (eeders in 7AP
plant
Suggestion
Sc$eme
4 !odi(ication o( 4all mill-) 8eig$ (eeder in P$osp$oric Acid Plant' Suggestion
Sc$eme
5 &eplacement o( cooling to3er (an blades 3it$ $ollo3 %&P blades
in P$osp$oric Acid Plant'
I%%)O Aonla
6 !odi(ication o( evaporator9s barometric condenser by installation
o( single sieve type distribution tray and removal o( steam e6ector
system'
Suggestion
Sc$eme
7 Increase in <eig$t o( )-4 )onveyor in coal (ired boiler I%%)O
P$ulpur
, Installation o( ,, numbers 008 /E7 %i=tures installed in place o(
1508 <PS> %i=tures
I%%)O
P$ulp$ur
4est practices implemented among associates
ACCOLADES & AWARDS ACCOLADES & AWARDS
National Award for Energy National Award for Energy
Conservation & Water conservation Conservation & Water conservation
)II )II- -E=cellent Energy E=cellent Energy
E((icient "nit A3ard E((icient "nit A3ard - -
2011 2011
4EE 4EE- -.E)A 2000 .E)A 2000
4EE 4EE G G.E)A 2010 .E)A 2010
)II )II- -8ater E((icient "nit 8ater E((icient "nit
A3ard A3ard- -2012 * 2011 2012 * 2011
?reentec$ ?reentec$- -2011: 2011: ?old; ?old;
?reentec$ ?reentec$- -2010: Silver 2010: Silver; ;
?olden peacock ?olden peacock- -
201+:8inner 201+:8inner; ;
?reentec$ ?reentec$- -2012:Silver 2012:Silver; ;
National Award for National Award for
Environment Management Environment Management
89SSA9 A/#r7
I.SSA. I.SSA.
A8A&7 A8A&7- -201+ 201+
I.SSA. I.SSA.
A8A&7 A8A&7- -2011 2011
Fertii!er A''o%i#tion of 8n7i# A/#r7' Fertii!er A''o%i#tion of 8n7i# A/#r7'
%AI %AI- -Improvement in Overall Plant Improvement in Overall Plant
per(ormance * 4est tec$nical per(ormance * 4est tec$nical
Innovation Aa3rd Innovation Aa3rd- -2000 2000
%AI %AI- -4est 4est
#ec$nical #ec$nical
Innovation Innovation
Aa3rd Aa3rd- -2011 2011
%AI %AI- -4est 4est
#ec$nical #ec$nical
Innovation Innovation
Aa3rd Aa3rd- -2012 2012
CSR Award: CSR Award: Sri S.K. Sri S.K.
Gandhi, Executive Director, Gandhi, Executive Director,
IFFCO Paradeep unit IFFCO Paradeep unit
receiving Kalinga CSR receiving Kalinga CSR
Award Award- -2012 from Honorable 2012 from Honorable
Governor of Odisha. Governor of Odisha.
Best Importer Award: IFFCO
has received the HSecond Best
ImporterI award from Paradip
Port Trust (PPT) during the
financial years 2012-13, 2011-
12, 2010-11, 2009-10 and
HBest ImporterI award during
2007-08 & 2008-09
&S6 A/#r7 A Be't 8)$orter A/#r7 &S6 A/#r7 A Be't 8)$orter A/#r7