This document discusses modifications made to an incinerator plant at an IFFCO fertilizer unit in Phulpur, India. The plant previously had issues with loose jaw contacts causing downtime and the inability to independently operate motors. The implemented solution added modified spacers to address loose contacts and interfacing to allow independent motor operation. This resulted in annual savings of over 1.97 crore rupees from reduced downtime and lower energy costs. The author was recognized and awarded for their suggestions through IFFCO's creativity program.

1. Modification in Incinerator
Plant
Satyajeet S. Naib
Asst. Manager (Electrical)
IFFCO Phulpur Unit

2. Contents…
1. Introduction
2. Problem Faced
3. Implemented Suggestion
4. Tangible Benefits
5. Calculations
6. Rewards & Recognition

3. Introduction
IFFCO Phulpur Unit Phase-II has a Carbon Di-Oxide recovery
unit installed in 2006 based on the proprietary KS1 solution.
This provides auxiliary supply of CO2 to boost the urea production
in the plant.
KS1 Solution is an Amine based CO2 solvent that can absorb CO2
at atmospheric pressure.
To dispose of the used/waste KS1 solution we burn it in an
incinerator which is based on RLNG burners.
In this plant & MCCs of other plants also had one common
problem of loose jaw contacts.

4. Problems faced – Part 1
There were certain
motor in the Incinerator
Group that need to
operated independently
without starting the
other motors.
But there was only a
provision to run all the
motors in the incinerator
group at once along with
the RLNG gas burners.
This caused a loss of Rs
1 lac in cost of RLNG
and Rs 5 lacs in cost of
Electricity every year.

5. Problems faced – Part 2
Feeder Trolley
Incoming Bus bar
Outgoing Bus bar
Incoming Jaw Contact
Outgoing Jaw Contact

6. Problems faced – Part 2
Feeder Trolley Burnt Feeder Trolley

7. Total Problems Faced…
Plant downtime
due to flashoversLoss of energy
and
inconvenience
Great
inconvenience
Increase
in
Downtime
Plant downtime of
6 days a year =
Loss of 1.97 Crore
Rs
No provision
to run motors
independently
Loose jaw contacts
No control
drawings
existed
Mistakes in old rough
control drawings

8. Implemented Solution Part 1
Interfacing
details added
Now
chattering
contactors
wont cause
damage
Motor can now run
independently

9. Implemented Solution Part 2
 There was loose contact in the jaw contacts of feeder trolleys resulting in frequent
flashovers.
 This problem was innovatively solved by adding modified spacers as shown above.
 This resulted in reduction in downtime of 6 days in a year causing huge savings.

10. Implemented Solution Part 2
This is the jaw contact before and after the said modification

11. Tangible benefits
Due the facility to run motors independently there is a huge
savings in RLNG burners.
The electricity used to run motors that are not used while a
particular required motor is running is also saved.
The flash overs caused due to loose jaw contacts have been
avoided permanently and this has caused a reduction in
plant downtime of about 6 days of Phulpur Unit 2 which
manufactures 3030 TPD of urea at profit of Rs. 1050
rs/Tonne

12. Tangible benefits calculation….
Savings in RLNG Rs. 1,00,000
Savings in Electricity Rs. 5,37,000
Total Savings in 2014-15 Rs. 6,37,000
Total Profit in Selling Urea Rs. 1050 per Metric Tonne
Savings of days in Downtime Up to 6 days every year
since 2014-15
Total Savings per day of
downtime in 2014-15 =
1050x(3030 tons/day)x6
Rs. 1,90,89,000
Total Yearly Savings Rs. 1,97,26,000

13. Rewards & Recognitions
 I was awarded 2nd Prize at
INSSAN Creativity Meet in
November 2015 at IFFCO
Phulpur.
 As recognition for my effort
and successful implementation
of my suggestion, I will be
awarded by Hon. M.D. of
IFFCO on 26th Jan-2016.
 I have been considered for
award of flat 1% of the
savings due to my suggestion
as prize money as per new
IFFCO Norms.