Date(s) - 16/02/2016
9:00 am - 5:30 pm
Indo Gulf Fertiliser
16 February, 2016, Jagdishpur, U.P : The 1st Fertilizer sector workshop for promoting exchange of “Best practices in Energy Efficiency in Fertilizer sector” under Knowledge Exchange Platform (KEP) initiative was hosted by Indo Gulf Fertilizers, on 16th February, 2016 at Indo Gulf Fertilisers, Jagdishpur, U.P.. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) for promoting energy efficiency through best practice transfer in industries covered under the Perform Achieve and Trade (PAT) scheme. KEP provides the institutional framework to catalyze the transfer of best practices within and across the industry sectors covered under PAT Scheme.
The workshop was inaugurated by Shri Rajendra Sankhe, Chief Operating Officer, Indo Gulf Fertilisers. In his inaugural address, he congratulated BEE and IIP for establishing the Knowledge Exchange Platform, which will assist the industries to share ideas and best practices such as selecting more efficient equipment, conducting regular energy audits and putting in place robust energy management systems to meet the challenges posed by rising manufacturing cost and changing climate.
Welcome address was delivered by Shri K K Chakarvarti, Expert Consultant Bureau of Energy Effieicny. He made a brief presentation on the rationale behind KEP, objectives and vision and the milestones achieved so far with the continued support of industries. He also highlighted the fact that although KEP although being in infancy stage, has undertaken commendable work since its inception in February 2015 . Five Best practices workshops for Aluminium, Cement, Paper and Pulp, Thermal Power and Textile sector have been successfully organized, attended by more than 1000 industry professionals. She also highlighted that cross sectoral knowledge transfer has also been high on KEP’s agenda and this was initiated by sharing of best practices in thermal power sector through a workshop and exposure visit for the benefit of other industry sectors having large captive power plants. 60 plants from all the PAT sectors have agreed to participate in Friendly Energy Efficiency Exchange Visits. Policy Roundtables on ESCerts Trading, Financing and Spent Pot Liners (SPL), a hazardous waste, generated from the aluminium sector and its gainful utilization in the cement industry, have been organized.
He also informed the participants KEP has launched an interactive website (www.knowledgeplatform.in) that facilitates knowledge transfer and discussion between stakeholder groups related to different PAT sectors and requested participants to give their feedback on different features to ensure that it met industry’s expectations and needs. While concluding his welcome address, he hoped that with these initiatives, KEP will be able to deliver significant energy efficiency benefits for the industrial sector and help sustain continuous improvement by promoting cost effective efficiency measures.
Vote of thanks was delivered by Shri Rakesh Jain, Senior General Manager, Indo Gulf Fertilisers. He conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop and assured the full support of Indo Gulf Fertilisers in future activities under KEP initiative.
Dignitaries at the inaugural session
The inaugural event was followed by two technical sessions and a panel discussion. The first technical session was Chaired by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The discussion in the session focused on Energy Conservation Act 2001, PAT Scheme, Trading mechanism proposed for Energy Saving Certificates (ESCerts) and Best Practices on energy efficiency. BEE made a presentation on the Energy Conservation Act and PAT Scheme wherein the participants were informed about the current status as well as next steps proposed with regard to PAT Scheme and M&V. The presentation also covered the methodology to be adopted for second PAT cycle and the new plants and sectors proposed to be added in second cycle of PAT.
Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included Fertiliser Association of India (FAI), Indo Gulf Fertiliser, Gujarat Narmada Valley Fertilizers & Chemicals Limited, Shriram Fertilisers & Chemicals, Rashtriya Chemicals & Fertilisers Limited, Thal Unit, National Fertilizers Limited, Vijaipur, Aditya Birla Management Corporation Private Limited and AMREC Group.
Sharing and discussing their innovative best practices, the presentation by Fertiliser Association of India (FAI), focused on benefits achieved by implementing energy saving schemes in Ammonia-Urea plants particularly in reforming section, CO shift conversion, CO2 removal section, and synthesis conversion. The presentation by Indo Gulf Fertilisers highlighted the energy savings achieved by upgrading synthesis gas compressor train, CO2 removal section to reduce the steam consumption, replacement of steam turbine drive of primary reformer ID fan with motor, modification in combustion air duct in primary reformer furnace for uniform distribution of air in burners, VAM for suction air chilling of gas turbine to increase power generation and VAM for suction CO2 chilling of CO2 compressor which led to annual energy savings of 0.133 MkCal/MT Urea. The presentation by Gujarat Narmada Valley Fertilizers & Chemicals Limited highlighted the energy savings achieved by revamping Urea plant and Methanol-II plant, which led to an annual monetary savings of Rs. 468.14 Lakhs and Rs. 220 Lakhs respectively. The presentation by Shriram Fertilisers & Chemicals highlighted the energy savings achieved by changing the process control instrumentation of Urea plant from pneumatic to DCS, introducing an advanced process control system for ammonia plant and commissioning of Benfield (CO2 removal) system revamp. The presentation by Rashtriya Chemicals & Fertilisers Limited, Thal Unit highlighted the energy savings achieved by installing S-50 converter for L1 & L2, modifications in MP condensate stripper, revamping of single stage Benfield (CO2 removal system) to 2stage GV system in Ammonia -1and replacement of MP turbines with LP turbines for cooling tower and BFW pumps, which led to an annual energy savings of 0.13 Gcal/MT, 0.16 Gcal/MT, 0.15Mcal/MT and 0.12 Gcal/MT. The presentation by National Fertilisers Limmited, Vijaipur highlighted the energy savings achieved by replacing condensing turbine of cooling water pump in Ammonia-I plant with motor, replacing condensing turbine of cooling water pump in Urea-II plant with motor, recovery of heat from C-3 off gases and revamping of Ammonia I & Urea I plant, and revamping of Ammonia- II & Urea II plant, which led to an annual savings of 30250 Gcal, 22500 Gcal, Rs. 5.12 crores, 140000 Gcal, and 53000Gcal respectively. The presentation by Aditya Birla Management Corporation Private Limited highlighted the various options through which energy savings can be achieved in refrigerant system design, real time optimizer for Steam & Power and effective utilization. The session also had technology presentation on the energy efficient jet-type fan less cooling towers by AMREC Group.
Shri K K Chakarvarti with the panelists of first technical session
The second technical session was focused on sharing of experience of the industry on implementation of innovative best practices and energy efficient technologies for the Fertilizer sector, was Chaired by Shri K M Tandon, Sr. Vice President (Fertiliser & Power), Shriram Fertilisers & Chemicals.
The presentation by RCF, Trombay Unit, highlighted the energy savings achieved by installing Electronic governing system, Over-speed protection and Anti-surge control system for PAC compressors in Ammonia-V plant, replacing old stripper in Urea-V plant with new stripper with improved design, replacement of combustion air preheater to reduce ID fan suction temperature from 270 Deg C to 220 Deg C in Ammonia-V plant, installing new ammonia feed pump in Urea Plant –leading to saving in electrical energy and improving reliability, commissioning of new MP stripper in place of LP Stripper in
Ammonia-I plant, replacing Primary reformer, High Temperature, LT Guard & LT main catalyst in Ammonia-V Plant and reversal of Over-head condenser in WW section leading to saving of Ammonia loss to atmosphere in Urea-V plant, which led to annual monetary savings of Rs. 200 lakhs, Rs. 169 lakhs, Rs. 144 lakhs, Rs. 141 lakhs, Rs. 334 lakhs and Rs 249 lakhs respectively.
The session also had presentations on technologies available for various operating areas viz. solutions to improve upon energy efficiency in compressed air system for textile sector by Atlas Copco (India) Limited, case studies on energy saving solutions in fertiliser industries by GE and automatic tube cleaning system for shell and tube type heat exchangers for prevention of scaling by CQM-RAJ India.
Shri K M Tondon with the panelists of the second technical session
Technical sessions was followed by a panel discussion on future strategies to be adopted and need for promoting innovative, new and cutting edge technologies and cross-sectoral best practices. The panelists were the members of Sector Learning Group. The panelist briefly explained the key discussion points of the SLG meeting, which was held a day before the workshop (15th February, 2016) and concluded that KEP can play an important role in facilitating policy discussions around PAT, particularly, as it is moving in to the next cycle where the fertiliser industry is expected to have new targets and more plants are expected to come under the ambit of PAT. Panelist also felt that KEP will be in a position to assist the industries to meet the new targets by bringing in international best practices and technologies.
SLG members as the Panelists at the Panel discussion
On behalf of Bureau of Energy Efficiency and Institute for Industrial Productivity, Shri K. K. Chakarvarti thanked the top management of Indo Gulf Fertilisers, in particular, Shri Rajendra Sankhe, Chief Operating Officer, Shri Rakesh Jain, Senior General Manager, Shri Tapas Bag, AGM, Unit-Technical Cell and the entire team of Indo Gulf Fertilisers for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also thanked all the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.
The workshop had participation from over 60 eminent industry leaders of fertiliser sector, energy auditors and energy managers, industry association, research associations, technology providers and senior Industry professionals amongst many others.
Participants at the 1st Fertilizer Sector Workshop under Knowledge Exchange Platform initiative
Alongside to the Best practice workshop, a visit to the Indo Gulf Fertilisers plant was also organized. Delegates of the workshop were taken around the control room of urea plant, ammonia plant, captive power plant and other plant areas. The workshop was successful from every aspect as it was able to secure diverse stakeholder participation, active exchange of best practices and technology exhibition.
Delegates during the plant visit
Best Practices in Energy Efficiency in Fertiliser Sector
INAUGURAL SESSION (9.30 AM- 10.00 AM)
Lighting of Lamp
Welcome Address, introduction and expectations from the workshop Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Inaugural Address Shri Rajendra Sankhe, Chief Operating Officer, Indo Gulf Fertilisers
Vote of Thanks Shri Rakesh Jain, Senior General Manager, Indo Gulf Fertilisers
TEA BREAK (10.00 AM -10.15 AM)
TECHNICAL SESSION I (10.15 AM - 1.00 PM): Best Practice Presentation by Industry Representatives
Chairman Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Energy Conservation Act and PAT Scheme by Bureau of Energy Efficiency Shri K. K. Chakarvarti, Expert Consultant
Energy Saving Efforts in Indian Ammonia-Urea Plants by Fertiliser Association of India (FAI) Shri Manish Goswami, Dy. Chief (Technical)
Best Practices adopted by Indo Gulf Fertilisers Shri Tapas Bag, AGM, Unit-Technical Cell
Best Practices adopted by Gujarat Narmada Valley Fertilizers & Chemicals Limited Shri M N Tekchandani, Additional General Manager
Best Practices adopted by Shriram Fertilisers & Chemicals Shri K M Tandon, Senior Vice President (Fertiliser & Power)
Best Practices adopted by Rashtriya Chemicals & Fertilisers Limited, Thal Unit Shri A. J. Kalbande, Senior Manager
Best Practices adopted by National Fertilizers Limited, Vijaipur Shri P. K. Jain, Assistant Manager(PE)
Best Practices adopted by Aditya Birla Management Corporation Private Limited Shri Ilayaraja Palani, General Manager
Energy Efficient Cooling Towers by AMREC Group Shri Shailesh Harani, Managing Director
LUNCH BREAK (1.00 PM - 2.00 PM)
TECHNICAL SESSION- II (2.00 PM - 3.15 PM) : Best Practices adopted and Energy Efficient Technologies for Fertilizer Sector
Chairman Shri K M Tandon, Sr. Vice President (Fertiliser & Power), Shriram Fertilisers & Chemicals
Best Practices adopted by RCF, Trombay Unit Shri V. K. Gupta, Senior Manager
Shri P. P. Wad, Deputy Manager
Energy Efficiency in Compressed Air Systems by Atlas Copco Shri Phanendra Kumar, Sr. Sales Engineer- North
Automatic Tube Cleaning System (ATCS) by CQM-RAJ India Shri Aashish Sharma, Dy. General Manager- Sales & Business Development
Shri Sameer Gaur, Head Business Development
Case study on Energy Saving Solutions for Fertilizer Plants by GE Shri A.S. Lokesh, Engineering Technical Leader
Ms. Paromita Bhattacharya, Lead Engineer
PANEL DISCUSSION (3.15 PM - 3.30 PM) : SLG MEMBERS
Future Strategies to be adopted; need for promoting innovative, new and cutting edge technologies and identify the areas for sharing of Cross- Sectoral Best practices.
CONCLUDING REMARKS (3.30 PM - 3.45 PM)
Shri Rajendra Sankhe, Chief Operating Officer, Indo Gulf Fertilisers,
Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
TEA BREAK (3.45 PM -4.00 PM)
PLANT VISIT: 4.00 PM ONWARDS