IFFCO - PHULPUR UNIT

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This is a presentation from IFFCO, one of the finalists at the 5th CII-GBC National
Award for Excellence in Water Management in 2008

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

Published in: Education, Business, Technology
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IFFCO - PHULPUR UNIT

  1. 1. IFFCO‘ IFFCO‘S MISSION “To enable Indian farmers to prosper through timely supply of reliable, high quality agricultural inputs and services in an environmentally sustainable manner and to undertake other activities to improve their welfare" IFFCO- IFFCO-PHULPUR UNIT Honorable Members of Jury and Delegates IFFCO-PHUL PUR UNIT A Profile Phulpur-I Process Licensor Annual Ca pacity •Ammonia Plant MW Kellog, U.S.A 322400 MT •Urea Plant Snamprogetti, Italy 551100 MT FM 534418 ( ISO 90 01:2000 certified ) Phulpur-II Process Licensor Annual Ca pacity •Ammonia Plant HTAS, Denmark 501600 MT •Urea Plant Snamprogetti, Italy 864600 MT EM S 534419 •Com mercial Producti on ( ISO 14 001: 2004 certi fied ) •Phulpur-I Urea Mar. 28, 1981 •Phulpur-II Urea Dec. 22, 1997 ANNUAL UREA CAPACIT Y : 1415700 M T H9104243 (OHSAS18001:1999 cer tifie d) ( Design) ANNUAL TURNOV ER ( 07-08) : Rs. 1765 Crores ( Includi ng s ubsidy) 1
  2. 2. ISO 14001:2004 ISO 9001:2000 OHSAS 18001:1999 IFFCO-PHUL PUR PRO DUCTION O UTL INE POWER POWER COAL RLNG RLNG Co al - Base d RL NG/LS HS ( Support Fuel ) Boilers Boiler TG – I TG – II ( 3 X 125 MTP H ) ( 1 X 20 0 MTPH ) 12.5 MW H 18.0 MW H HIGH PRESS U RE STEAM AIR AMMONIA P LAN T ( 977 AN D 1 52 0 MTPD) ( N 2 + O2 ) (C+ H) CO 2 Synthes is Refor mi ng Shift N aphtha Co nvers io n Rem ova l N 2+ 3H 2 2NH 3 / R LNG CO 2 Am mo nia Flue Gas to C DR Pla nt for C O2 Recov er y (NH 3) Hig h Pr essur e POWER Secti on Med ium P ress ure Secti on UREA PL AN T (167 0 A ND 2 62 0 MTP D) Vacu um Co nce ntrati on (Designed) Prill in g 429 0 MTP D , 858 00 BAG S Trans port PER D AY UREA Bagging 2
  3. 3. Major Water Recycle /Reuse Schemes during 2004-2008 Phulpur Unit Sr. Water Recycle / Reuse Investment Annual Pay back no. Schem e (Rs. in w ater Lakhs) Saving (m 3) 1. Increase in C ycle of -- 603662 Im medi- C oncentration of C ooling ately Tower ( from 6.0 to 9.0) 2. Direct Recycling & Re use 0.92 23100 4.3 of Turbine C ondensa te in m onth Amm. – II Pla nt 3. Recycle of C DR effluent 0.44 118800 3.86 for process use as coo ling m onth Tower make-up through Water Sof tening Plan t Major Water Recycle / Reuse Schemes during 2004-2008 Phulpur Unit Sno. Water Recycle / Reuse Investment Annual Pay Schem e (Rs. in w ater back Lakhs) Saving (m 3) 4. Installa tion of Rain 13.14 3600 -- Water Harvesting System 5. C ollection and re use of 316.72 3900 -- rain wa ter in proces s throug h Mist C ooling System 6. Installa tion of Wa ter 5.50 32200 17.1 Spraying System in m onth Ammonical G uard Pond 3
  4. 4. RAW WAT ER CONSUMPTION FO R UREA PRO DUCTION Fresh water (Borewell) Industrial effluent Recycle Process & Turbine Condensate Treated Sewage Water Reuse 4% 24% 58% 14% Des cription Year 20 04-05 Year 20 07-08 Urea Produ ction, MT 14,29,078 15,53,980 Raw Water, M3 95,29,997 94,62,926 Raw Water Consu mpti on 6.67 6.00 per MT Urea Specific Raw Water Consumption 20 2 .0 18 18 CPCB Benchmark : 10 m3/MT Raw Water (M3 / MT of Urea) National Benchmark : 7.3 m3/MT 16 Raw Water Saving in Year 2007-08 : 10,41,0 00 m3 . 95 (as compared to year 2004-0 5) 13 14 12 .14 ` . 10 10 10 10 0 7.8 8 3 8 7.0 6.6 10 6. 00 6. 6 2 4 8 2 6 8 4 6 0 -9 -9 -9 -0 -0 -0 -0 -9 -0 93 97 05 91 95 99 01 03 07 4
  5. 5. SPECIFIC EFFLUENT DISCHARGE Zero discharge since 1994-95 1 7.0 CPCB Ben chmark: 5.0 m3 /MT of Urea 6. 3 Effluent discharge, M3/MT Urea 6.3 5.6 Nati onal Ben chmark:0.6 m3 /MTof Urea 1 4.9 4. 3 4.2 4 2. 9 3.5 2.8 9 2 1.8 1.8 2.1 1.4 0 0 0 0 .0 0 0 0.00 0 0 0 0 0 0 0 0.7 0.0 0.0 0.0 0 0.0 0. 0 0. 0 0 .0 0.0 0. 0 0. 0 0. 0 0.0 0.0 92 02 03 04 05 06 07 08 98 99 00 01 90 91 93 94 95 97 6 95 - 9 01 - 02 - 03 - 04 - 05 - 06 - 07 - 91 - 89 - 90 - 92 - 93 - 94 - 96 - 98 - 99 - 00 - 97 - EFFLUENT DISCHARGE PER MT OF UREA Per capita Domestic Water consumption Industrial Colony water consumption Year Consumption Average Per capita Consumption No of Per capita m3 / day No. of consumption m3 person consumption emplo yee (Ltr per (Ltr per per day person per person per day) day) 2004- 05 350 1185 295 3800 4000 950 2005- 06 350 1118 313 3800 4000 950 2006- 07 300 1063 282 3800 4000 950 2007- 08 300 1967 281 4100 4500 911 5
  6. 6. INNOVATIVE PROJECT No.-1 ETP cum Recycle Plant based on Steam Stripper Off-spe cification Ammonical effluent and deoiled water from Am monia and Urea Plant is treated in stripper of ETP vEarlier treate d wate r was dischar ged into Gu ard Po nd. vPresently this effluent water is recycled and reused in pr ocess as Cooling Water make-up. This sav es 742 M3/day of Raw water. Year of Implementation: 2004-0 5 Water Quality ( mg/l) Paramet er Before After (Designed). Treat ment Treat ment Amm. - N 2000 < 50 Effluent Treat ment Plant Cost : Rs. 203 Lakh Tr eated Wat er R ec yc led as C W make-u p INNOV ATIV E PROJ ECT No.-2 Blo w-do wn re duct io n due w- to im proved COC from 6 to 9 Cooling Blow-dow n Blow -dow n Cooling Evaporation, Make up Make up Pl ant Water fl ow, COC = 6 , CO C = 9 , Range, deg.C m3/ hr COC = 6 CO C = 9 m3/hr m3 /hr m3/ hr Ammonia C. T- I 13000 12 279 334 313 56 35 Urea C.T. - I 10000 10 179 214 201 36 22 Power C. T. - I 3200 5 29 34 32 6 4 Ammonia C. T- II 20000 7 250 300 281 50 31 Urea C.T. - II 17000 7 213 255 239 43 27 COC = 6 Power C. T. - II 4800 5 43 51 48 9 5 Total 68000 991 1189 1115 198 124 Benefits: v Reduction in Blow-down = 1776 m3/day v Ye arly Raw water saving = =60 366 2 m3 v Reduction in Hydrated lime consumption in Cold lime softening process due to reduced make up water requirement. COC = 9 vYear of Implementation: 2004-0 8 6
  7. 7. INNOVATIVE PROJECT No.– 3 Recycle of CDR Effluent Water in to Plant Process Year of Implementation: 2006-0 7 Raw Water Saving (1188 00 m3 per year) Cost : Rs. 0.44 Lakh. v Reduction in quantity of the effluent Paybac k: 3.86 months (1188 00 m3 per year) vSaving of Electrical energy (39204 KWH per annum) S.N. Composition Design Value CDR Fresh Effluent Raw Water Actual 1. Na 2SO3 0.02 –0.03 0.012 % - Wt% 3. Na 2CO3 0.04 –0.05 0.10 % - Wt% 5. pH 7.0 7.80 7.6 6. Colour None None None 7. Total Amm.-N 0 25.0pp nil (as N) m 8. TKN (as N) <50 mg/L 29.5 nil ppm 10. COD <50 mg/L 55 ppm - 14. TDS 800 360 ppm INNOVATIVE PROJECT No.– 4 Recycle of Turbine Condensate in Ammonia Plant -II Year of implementation :2006-0 7 Cost : Rs. 0.92 Lakh Benefits: v Raw Water Saving (23100 m3per year) v Reduction in quantity and improvement in quality of the effluent (2310 0 m3per year) vSaving of required chemical (HCl – 100 MT per Annum and NaOH – 89 MT per annum) for regeneration of condensate Polisher Unit for this condensate water. vSaving of Electrical energy (8075 0 KWH per annum) 7
  8. 8. INNOVATIVE PROJECT No.– 5 Water Spraying System in Guard Pond Year of Implementation: 2007-08, Cost – Rs. 5.5 Lakh Benef its: vRaw Water Saving (2800 0 m3 per year) v Reduction in quantity of the effluent 28000 m3 per year) Rain Water Harvesting System (Central School & Guest House Ghiyanagar Township) Roof Area : 4340 Sq. mtr. (excludi ng gr ound area) Cost : Rs. 13.14 Lakh Annual Water Sav ing : 3700 m3 per year 8
  9. 9. Conversion of Ash Pond in to Rain Water Harvesting Pond Rain Water Collection : 2,20,000 m3 per year Water Monitoring Report A. Total Raw w ater Consumption. 15.11.2008 28787 KL B. Raw Water Consumption per M.T. of 15.11.2008 5.49 KL Ur ea. C. Effluent Water Reuse/ Recycle Effluent 1 2 3 4 Recycle pump Running at Guard Yes No Pond. Yes No 1. R.O. Plant. Yes No 2. Bottom Ash Deashing to Old Ash Pond. Yes No 3. Fly Ash Deas hing to New Ash Pond. 4. Old Ash Pond through 6” dir ect line Yes No from Guar d Pond. 5. Coal Yar d Spray. Yes 6. Cordet Yes Continued 9
  10. 10. Water Monitoring Report 7. Treated Sew age Water from STP Yes No w ater softening Plant. Yes No 8. Law n Irrigation in Tow nship. Yes No 9. Ex tra Pump Running. No 10.. Hydr olysed Water from Urea- I. CPU Hydrolysed Water from Urea- II. CPU 11. In effluent Holding pit from Urea- I /II, Yes No Amm.- II. 12. Leakage / Water Loss U/G Raw Water Leakage 1. Near Ur ea-2 silo under maint. Salient features of Environment Awareness Programme Natural resource conservation & aw areness am ong the em ployees and com m unity are an integral p art of our Environm ental Policy . A lot of w ork regarding these is being done in IFFCO Phulpur to increase aw areness am ong the people v Display of Ho ardings and Banners,Display of Slog an/film regarding w ater conservation on CCTV in tow nship,Lectures on Im portance of w ater conservation regularly, Distribution of Circulars & leaflets am ong the com m unity v In house training program m es on natural resource conservation, Com m unity aw areness programm es organised in nearby villages, Aw areness lectures organised at nearby schools & colleges to m otivate students. vEmployees are inv olv ed through suggesti on sche me. Technicall y suitable suggesti ons are impleme nte d and em ployees are rew arded. v Water leakage / ov erflow from pi pe lines / tanks observ ed in tow nship & plant of imme diatel y informe d by tow nship reside nts / employees to EP C group for correc tiv e action. vTow nship reside nts (e mpl oyees ) optimize w ater uses in their houses by re ducing the w astage of w ater in da y to da y w ork. 10
  11. 11. AWARENESS CAMPAIGN ENVIRONMENT AND SUSTAINABILITY Zero Liqui d Effluent Discharge Reverse Osmosis Plant For Effluent Recycle Of Sewage Water For Process Use Hydrolysed Water Being Used As BFW Through CPU On Continuous Basis Household Waste Disposal using Vermi-Composting Fly Ash for Usar land reclamation and ash disposal in Eco-friendly tankers Ground water Recharge by Water Harvesting Bio-Methanation Plants from waste 11
  12. 12. Recognition on Environmental Performance Year 2007-08 •Best over all performance Award for Nitrogenous ( Ammonia & Urea ) plant – From Fertiliser As sociation of India, New Delhi • National Energy Conserv ation Aw ard – 2007 ( First Prize in the Fertiliser Sector ) – From Ministr y of Pow er •National Energy Conservation Award – 2007 ( First Prize in the Fertiliser Sector) – From Ministry of Power • Best Produc tion Per for mance Aw ard in Nitr oge nous Fertiliser Plants – From Fertiliser Associati on of India, New •National Aw ard for Excellence in Energy Mana gement – 2007 from CII, Hyderaba d Year 2006-07 • Indira Gandhi National Award-Best Pollution Implementation Gold Award from Public Sector Today, Hyderabad •Prestigious National Energy Conservation Award – 2006 in Fertiliser sector from Bureau of Energy Efficiency , Ministry of Power , Government of India. Recognition on Environmental Performance Year 2006-07 •Best Chief Executiv e Gold Aw ard to Uni t Head of I FFCO-P hul pur from Public Sector Today, Hydera bad. • Best Technical Paper Aw ard by FAI on the Pa per - “Im plementati on of Ener gy Sav ing Proj ect at IFFCO Phulpur Unit " . Year 2005-06 • Innovative Project Implementation Award 2005 in the field of Water Manage ment by Confederation of Indian Industry (CII), GBC, Hyderabad. • National Award for “Excellence in Energy Management-20 05” by CII- Sohrabji Godrej Green Business Centre – Chennai • National Award for “Efficient Water Managem ent-20 05” by CII- Sohrabji Godrej Green Business Centre – Chennai • Rajiv Ratna National Gold Award for “Best Pollution Control Implementation (2004- 05)” (2004- 05)” from Public Sector Today, Hyderabad Year 2004-05 • National Energy Conservation Award ( awarded in Dec. 2004) - from Ministry of Power 12
  13. 13. Thank You 13

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