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Fertilizer

India is the world’s third largest producer of fertilizers and, as of 2013-14, it had an installed capacity of 127.67 lakh tonnes of nitrogen, and 62.08 lakh tonnes of phosphate nutrient. The actual quantities produced were 123.78 lakh tonnes of nitrogen and 37.14 lakh tonnes of phosphate. Production of nitrogen and phosphate fertilizers grew by 1.5% and 4.9%, respectively (against a production of 121.94 lakh tonnes and 35.41 lakh tonnes, respectively, in 2012-13).

The capacity utilization during 2012-13 was 101.2 % of nitrogen and 62.9% of phosphate, while corresponding figures for 2013-14 were 97.0% and 59.8%. The capacity utilization for urea plants was 108.8% in 2012-13, and 105.2% in 2013-14.

The fertilizer sector has made continuous efforts to improve the energy performance, and reduced the specific energy consumption from 8.24 Gcal/t of urea in 1990-91 to 6.00 Gcal/t in 2013-14. Most fertilizer manufacturing facilities have energy consumptions ranging between 5.25 and 6.0 Gcal/t. In terms of feed stock, natural gas-based fertilizer production is the most energy efficient, followed by naphtha-based fertilizers.
The sector is expected to achieve energy savings of 0.478 million tonnes of oil equivalent (toe) by the end of the first cycle of the Perform, Achieve and Trade (PAT ) scheme of the Bureau of Energy Efficiency. The energy savings target for the fertilizer sector will contribute 7.15% to the total national target assessed under the PAT scheme.

This section contains best practices in energy efficiency adopted by some of the progressive fertilizer industries in India. The case studies from KEP launch workshop and National Energy Conservation Awards, NECA 2012,2013 are presented here.

Resource Name:  Best Practice presentation by RCF, Trombay Unit

Abstract: The resource highlights 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.

Published by: Presented by Sh. V. K. Gupta, Senior Manager and Sh. P. P. Wad, Deputy Manager in Sector Level workshop for Fertilizer sector

 

Resource Name:  Best Practice presentation by Aditya Birla Management Corporation Private Limited

Abstract: The resource  highlights the the various options through which energy savings can be achieved in refrigerant system design, real time optimizer for Steam & Power and effective utilization.

Published by: Presented by Sh. Ilayaraja Palani, General Manager in Sector Level workshop for Fertilizer sector

Resource: Presentation by Aditya Birla Management Corporation Private Limited

 

Resource Name:  Best Practice presentation by National Fertilisers Limited, Vijaipur

Abstract: The resource  highlights 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

Published by: Presented by Sh. P. K. Jain, Assistant Manager(PE) in Sector Level workshop for Fertilizer sector

Resource: Presentation by NFL, Vijaipur

 

Resource Name:  Best Practice presentation by Rashtriya Chemicals & Fertilisers Limited, Thal Unit

Abstract: The resource  highlights 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.

Published by: Presented by Sh. A. J. Kalbande, Senior Manager in Sector Level workshop for Fertilizer sector

Resource: Presentation by RCF, Thal Unit

 

Resource Name:  Best Practice presentation by Shriram Fertilisers & Chemicals

Abstract: The resource  highlights 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.

Published by: Presented by Sh. K M Tandon, Senior Vice President (Fertiliser & Power) in Sector Level workshop for Fertilizer sector

Resource: Presentation by Shriram Fertilisers & Chemicals

 

Resource Name:  Best Practice presentation by Gujarat Narmada Valley Fertilizers & Chemicals Limited (GNFC)

Abstract: The resource  highlights 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.

Published by: Presented by Sh. M N Tekchandani, Additional General Manager in Sector Level workshop for Fertilizer sector

Resource: Presentation by GNFC

 

Resource Name:  Best Practice presentation by Indo Gulf Fertilisers

Abstract: The resource  highlights 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.

Published by: Presented by Sh. Tapas Bag, AGM, Unit-Technical Cell in Sector Level workshop for Fertilizer sector

Resource: Presentation by Indo Gulf Fertilisers

 

Resource Name:  Best Practice presentation by Fertiliser Association of India (FAI)

Abstract: The resource  focusses 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.

Published by: Presented by Sh. Manish Goswami, Dy. Chief (Technical) in Sector Level workshop for Fertilizer sector

Resource: Presentation by FAI

 

 Resource Name:  Energy Conservation Efforts at NFL- Vijaipur

Abstract: The resource presents concept and strategy of energy management in NFL, the major areas of technology interventions are cryogenic purge gas recovery, low grade heat recovery, utilization of C3 off gases in boilers, carbon dioxide recovery unit, synthetic coating over the pump casing inner surface, replacement of condensing turbine drives top electrical motor drives, use of FRP blades in cooling towers.

Published by: Presented by Sh. S.N.Sinha, NFL- Vijaipur in KEP launch workshop

Resource:Best-practices-case-study-IIP-NFL-Vijaipur_KEP03-01

 Resource Name:  Energy Conservation Efforts at GNFC, Bharuch

Abstract: The presentation highlights the energy management strategy adopted at GNFC, and also covers reliability improvement measures. Major technology inerventions discussed are, new catalyst basket S-50 installation , pre decomposer and pre evaporator concentrator in Urea Plant, replacement of  axial quench type reactor with isothermal rteactor, efficiency improvement of gas turbine based co-generation.

Published by: Presented by Sh. M.N Tekchandani, GNFC, in KEP launch workshop

Resource: Best-practice-case-study-IIP-GNFC_KEP03-02