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.

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Thank You
13