IFFCO-Kalol Unit

(i) Unit profile

Kalol unit - the oldest unit of IFFCO is located at 26 km from Ahmedabad on the Ahmedabad
Mehasana highway. The Unit started commercial production in April, 1975 in an area covering
96 hectares. 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 Stamicarbon’s CO2
stripping process. Urea feed stocks i.e. ammonia and CO2 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.

(ii) Energy consumption

Kalol unit has produced 544518 MT of urea and 344326 tonne of ammonia during the year
2005-2006 attaining a capacity utilisation of 100.00 % and 94.86 % respectively. The ever
lowest specific energy consumption of 6.179 Gcal/MT and 8.967 Gcal/MT was achieved in the
year 2005-06 for Urea and Ammonia production respectively.

Energy Saving Project

IFFCO Kalol Ammonia plant is of early 70’s Kellogg technology and has limitations in
implementing new technologies. Space availability is another major problem. In spite of these
constraints Kalol unit is continuously putting efforts to reduce specific energy consumption.

Energy Saving Project (ESP) is one such measure which aims in reducing 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.
There is considerable reduction in Specific Energy Consumption of Ammonia and in turn,
Urea as a result of implementation of schemes under ESP.

The reduction trend in Specific Energy Consumption for the last three years is shown below.

Specific Energy Consumption: Ammonia

9.5
Specific Energy Consumption,

9.440
9.4
9.3
Gcal/MT

9.2 9.163

9.1
9.0 8.967
8.9
8.8
2003-04 2004-05 2005-06
 Specific Energy Consumption: Urea

Specific Energy consumption,

6.7
6.6 6.587

6.5

Gcal/MT
6.4 6.347
6.3
6.2 6.179
6.1
6.0
2003-04 2004-05 2005-06

Energy cost in terms of percentage of manufacturing cost.

With continuous efforts in energy conservation, there is tremendous reduction in the energy
cost and the same is illustrated below.

Particulars 2003-04 2004-05 2005-06

Energy cost (a) (Rs. Lakhs) 33915.65 36945.68 34964.78
Manufacturing cost of Bagged Urea
(b) (Rs. Lakhs) 39894.90 43689.14 46166.45
(a)/(b)*100 85.01 84.56 75.74

(iii) Energy Conservation Commitment, Policy and Organisational Set-up

Process Engg. Section, IFFCO Kalol carries out energy audit on regular basis. Plant operations
are studied in detail to identify the areas for reducing specific energy consumption and
minimizing losses.

Energy conservation is a continuous process with constant scope for further improvement. With
this objective and based on detailed study of energy audits, Ammonia plant Energy Saving
Project – Phase I and other energy saving schemes were successfully commissioned in June-
2005.

Energy Policy:

At IFFCO Kalol, optimum utilisation of energy and the total energy management are the
part of corporate mission and IFFCO is fully committed to reduce the specific energy
consumption in the production of nitrogenous fertiliser through:

• Conducting in-house energy audit and monitoring the energy consumption norms.
• Carrying out various minor and major modifications.
• Adoption of technological advancement befitting to the old plant.
• Development of human resources.
• Creating safe, healthy and energy conscious working environment.
• Better housekeeping in the plant.
 Organisation Chart of Process Engineering Section

DIRECTOR (TECHNICAL)

SR. EXECUTIVE DIRECTOR (TECH)

GENERAL MANAGER

CHIEF MANAGER (TECHNICAL)

CHIEF MANAGER (PROCESS)

SENIOR MANAGER

MANAGERS

DEPUTY MANAGER

ASSISTANT ENGINEER

(iv) Energy Conservation Achievements

• Ever lowest yearly specific energy consumption of 8.967 Gcal/ t of Ammonia.

• Ever lowest yearly specific energy consumption of 6.179 Gcal/ t of Urea.
• Ever lowest monthly specific energy consumption of 5.952 Gcal/ t of Urea in February-
06.
• Ever lowest monthly specific energy consumption of 8.728 Gcal/ t of Ammonia in
February-06.

Important schemes implemented for performance improvement during the year 2005-06

1 AMMONIA PLANT

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.

1.2 BASF aMDEA two stage CO2 removal system

The conventional aMDEA CO2 removal system was consuming energy of 30,000 kcal/kg
mole of CO2. BASF aMDEA two stage CO2 removal system is installed to reduce energy
consumption to about 10,000 kcal/kg mole of CO2. 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 energy for regeneration of the solution and improves the
quality of the CO2 product. New absorber has both lean and semi lean absorption.

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.

2.0 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 non-galling
advantages, which will improve pump reliability.

2.3 Installation of smaller capacity low head surface condensate pump in urea plant

52.5 m3/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 m3/h (design: 52.5 m3/h).

30.0 m3/h normal capacity (Rated: 35.0 m3/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 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.
2.5 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.

(v) Energy Conservation Plans and targets

IFFCO Kalol unit is committed to further improve its energy performance by finding out new
avenues on continuous basis. Kalol unit is working on the following proposals as a part of its
future plans for energy conservation.

Anticipated Savings Project

Energy Conservation Measures Investment completion
GCal/Annum Rs.lakhs/Annum (Rs. Lakhs) year

Installation of S-50 radial flow 102400 947.6 1840 2006

Synthesis converter and MP
Boiler
Synthesis gas compressor LP & HP 57600 533.6 1288 2006
case internal replacement
Drying of make-up gas (Ammonia 25600 239.2 552 2006
wash) and synthesis loop re-piping
Installation of new BFW Coil in 9600 87.4 138 2006
Waste Heat Section of Primary
Reformer
Performance improvement of LP 1065 10.0 2 2006
absorber
Installation of New Atmospheric 6676 60.0 54 2006
Scrubber for ammonia recovery
Preheating of LNG fuel in BHEL 1417 13.1 2 2006
Boiler
(vi) Environment & Safaty

Environment:

Kalol Unit has also been certified for ISO 14001 for environmental management system
adopted since August-2000. The system was upgraded to meet the requirements of ISO
14001 -2004 version and the same was audited and certified by BVQI during October 2005
audit.

There is highly evident “continual improvement” on EMS front at Kalol as the scrap disposal
has become an ongoing exercise with optimum realization of residual value of items disposed
off and clean and orderly scrap yards. Not only the environmental parameters are well
maintained in the plants there is a
sizeable reduction in the consumption of natural resources, quantifiable in terms of specific
consumptions like energy, water and other process inputs.

House keeping of the plants is appreciated by all the visitors and the unit has received
running trophy for the best maintained gardens, institutional category from Gujarat
Horticultural Association for the third year in succession.

Safety:

Several Motivation measures are adopted for safe practices. Some of them are as under:

• Awards for safety suggestion scheme, good house keeping scheme are distributed to the
winners/runners on the eve of national safety day celebration and various competition are
being conducted for Employees & their family members such as safety essay, safety
poster, safety slogan, safety quiz etc. during safety week celebration.
• Shop floor safety committee, central safety committee & Joint Management Council are
constituted for monitoring safety performance of the employees.
• The State & National level Safety competitions are participated by workers. Employees
are getting Awards in various categories. Management also encourages workers by
suitably rewarding them.
• Corporate policy for using personal protective equipment is strictly enforced failing this by
employee suitable actions are initiated.

Safety Awards from Gujarat Safety Council

• Kalol Unit has won second prize “RUNNER-UP from NATIONAL SAFETY AWARDS
2003" under Scheme No.II (Manufacturing of Chemicals & Fertiliser Industries
Group) at National Level. This is the highest award in Industrial Safety in India being
given by Government of India.
• IFFCO Kalol Unit has received “Certificate of Honor” for working more than one million
man-hours without lost time accident during the year 2004 (Manufacturing of Chemicals &
Fertilizer Industries Group) from Gujarat Safety Council.
• IFFCO Kalol Unit has received “Rotating Shield (Winner Award) with certificate for the
lowest Disability Injury Index (DII)” from Gujarat Safety Council.

The unit also achieved the longest accident free period of 1168 days (from 19th January 2003 to
31st March 2006) and the record continues.