Presented by :

M.N.Tekchandani

Chief Manager

GNFC Ltd.

Date : 26.02.2015

2/27/2015 GNFC Ltd

About GNFC Ltd.

2/27/2015 GNFC Ltd

• Joint sector enterprise promoted GOG & GSFC ltd, Public.

• Diversification :

Fertilizers such as ANP & CAN,

Industrial chemicals such as Methanol, Formic Acid, Acetic Acid, Nitric

Acid, Aniline, TDI, Ammonium Nitrate

Information Technology.

Certified Emission Reduction (CER) Company: 40,663 certificates for N2O

Abatement Project in Weak Nitric Acid (WNA) Plant, as well as 47,540 VER

for its 21 MW Wind Mill project in Kutch region of Gujarat.

CSR: Narmada Rural Development Society

Rs. 2001.57 lacs incurred in the year 2011 to 2014. Mobile medical van, Nutrition Project, Vocational training center, Model school project, safe drinking water for villages. Camps for Blood donation, eye donation, handicapped, Running School and College, Relief assistance during natural calamities

Gujarat Narmada Valley Fertilizers & Chemicals Limited.

Bharuch Gujarat

ENERGY CONSERVATION STRATEGY AT GNFC

10. Energy Cell

7. Energy Audits

3. Up gradation of Technology

8. Employee Suggestion Schemes

11. Awareness program 4. Monitoring of Consumption

1. Selection of Technology

6. Energy Saving Schemes

2. Reliability Improvement

5. In house capability

9. Renewable Energy

1. Selection of Technology

Plant Technology

Urea Saipem, Italy

Ammonia Linde Germany, Haldor Topsoe -Denmark, Texaco

Ammonium Nitrophosphat BASF, Germany

Calcium Ammonium Nitrate UHDE, Germany

Formic Acid Kemira OY, Finland

Acetic Acid B.P.Chemical,UK.

Con. Nitric Acid Plinke, Germany

Weak Nitric Acid/ Ammonium Nitrate

UHDE, Germany

Methanol Toyo,Japan

Identify equipment system limitation.

Sustained operation.

CO Shift section revamp.

Gasifier Quench ring modification.

Addition of one new chimney in Boilers.

Additional feed oil pump in Ammonia plant.

Refrigeration compressor modification to reduce speed

below MCS.

Addition of Third Gasifier

2. Reliability Improvement

A. New Catalyst basket S-50 Installation : Ammonia Plant Syn. Section for reducing steam consumption

B. Pre Decomposer and Pre Evaporator Concentrator in Urea Plant : For converting waste heat into steam

C. Isothermal Reactor : Improving energy Recovery in Methanol-II plant Reactor section by replacement of Axial Quench Type Reactor with of Isothermal Reactor

D. Revamp of Ammonia plant : for Feed stock conversion (Fuel Oil to Natural Gas).

E. Gas Turbine based Co-generation CPSU. : Heat rate reduced to around 2700 kcal/kWH

3. Up gradation of Technology

Installation of S-50 converter along with

additional waste heat Boiler and newly

designed BFW prehaeater: The synthesis

gas from existing Ammonia synthesis

convertor R-701 is feed to new waste heat

re-boiler E-703M for recovering heat of

reaction. It is subsequently charged to new

Ammonia Synthesis converter R702 (S-

50). Exit synthesis gas from R-702 is fed to

existing waste heat boiler E-703. BFW

prehaeater E704 redesigned and replaced

for higher heat recovery.

3. A: Installation of S-50 converter

Total investment, Rs. 5666 Lakhs

First year energy cost savings, Rs. 1924.6 Lakhs

Energy consumption before : 4.458 MT of HPSH Steam /MT Ammonia

Energy consumption after : 4.068 MT of HPSH Steam /MT Ammonia

Investment : Rs 2186 Lacs

Total Savings : Rs 468.14 Lacs/

Year

Urea Process was modified

with MP Pre Decomposer and

Urea Pre Evaporator

Concentrator installation for

converting waste heat into

steam.

3. B: Urea Revamp

MP Pre Decomposer

HP

Section

MP

Section

LP

Section

Vacuum

Section

Prilling

section

Pre evaporator concentrator

- Pre concentrator

- Urea solution pump

- Vacuum system

Modification

3. B: Urea Revamp Block Diagram

Pre decomposer

- MP pre decomposer

- Condensate collector

- Steam jet pump

Modification

Investment : Rs 9600 Lacs

Total Savings : Rs 220.29 Lacs/ Year

Improving energy Recovery in

Methanol-II plant Reactor section by

replacement of Axial Quench Type

Reactor with of Isothermal Reactor ,

resulting in 28 kg/cm²g - Saturated

Steam generation @ 23 - 24 MT/h at

full load of plant. Installation of energy

efficient 3 column distillation system

(Methanol Distillation Unit - MDU) to

save steam and electricity and

replacement of air preheater resulted

in overall saving of Steam, Power and

Natural Gas.

3. C: Methanol-II Revamp

Review of Specific energy consumption at top management level.

Addressing Energy issues :

Fuel management.

Operation of boilers and other furnaces.

Performance of steam and condensate system.

Performance of compressed air network.

Cooling Towers Performance evaluation and monitoring.

Performance of rotating machines.

Electrical load management system and lighting load.

Continuity in plant operation.

4. Monitoring of Consumption

Software Application Sr No. Software Purpose

1 Aspen Simulation 2 Chemcad Simulation 3 HTRI Heat Exchanger Design 4 HTFS Heat Exchanger Design 5 Hysis Simulation 6 Sinet Simulation 7 Auto CAD Drawing & Engg.

5. In house capability

Infrastructure

Technical Services group Process Design and Simulation

Design & Construction Group Piping ,Mechanical, Electrical, Instrumentation and Civil Design,

Construction

PMG Group S/D schedule, production budget, Hazop, Safety, Lube oil, plants performance review.

Aniline/TDI Plant: 6" line from utility plant to ANI/TDI complex is installed to stop air venting by stoppage of one compressor.

• Power saving : 1460 MWh/Year. • Total investment : Rs. 41 Lakhs

CNA Plant: Provision of Variable Speed Drive for 50K060 blower.

• Power saving : 222000 kWh/Year • Total investment : Rs.6.0 Lakhs

6. Energy Saving Schemes

Ammonia plant: Improvement in Fan

Operating Efficiency by Revising Fan

specifications to match actual

operation.

• Power saving : 39 kW

• Investment : Rs 3.82

6. Energy Saving Schemes

Ammonia plant: In Ammonia plant,

power saving achieved by removing

one of the impeller from MP BFW

multistage pump P-1302.

• Total investment : Rs. 1.0 Lakhs

• Power Saving : 514800 kWh

Urea Plant: Additional small

capacity Pump P-2 C was installed to

save energy at higher plant load.

Total investment : Rs. 350 Lakhs

Power Saving : 10.32 Lakh kWh

6. Energy Saving Schemes

Ethyl Acetate Plant : With the help

of change in blade angle of Cooling

Tower Fans, one of the cooling water

pump was stopped .

Total investment : Rs. Nil

Power Saving : 556910 kWh

Hazardous Plant: Total 71 defective traps/valve /fittings/

coupling and line leakages were indentified. 10 traps

replaced with new one, reduction in steam consumption of

LP steam @ 1 MT/Day in Hazardous plant

6. Energy Saving Schemes

Internal Audits & Surveys

Walk Through Audit

External Audits- Legal and Voluntary

7. Energy Audits

Internal Audits and Surveys

Fans/Blowers

Steam Traps

Compressed Air

Cooling Towers

Cooling Water Pumps

Process Pumps for Possible Impellers trimming and Resizing

Insulation Surveys: steam piping & Boiler Insulation

Thermography of Boilers

Cooling Towers

Walk through Survey

Steam Trap

Energy audit of GNFC complex

Energy audits of GNFC complex by External Auditors

Year of Audit

2002

2005

2009

2013

Its various recommendations implemented.

8. Employee Suggestion Schemes

Installed capacity of Wind Power Generation 21 MW

9. Renewable Energy

Solar System is installed and working satisfactory at the

following locations.

Corporate Building:150 KW Presently Guest House Solar system feeding 125 KWH / Day,

School solar System 625 KWH / Day and Corporate Solar

system 600 KWH / Day in the Electrical system.

9. Renewable Energy

• Forming of Energy Cell in 2001

• Framing of Energy Policy

• Energy efficient Purchase guide line

• Mandatory Compliance (BEE,PAT)

• Identification of Energy saving

potential

• Energy Audit Support

10. Energy Cell

Guideline for purchase of energy efficient items

• Electric Motors

• Electric Transformers, Heaters, Vibrators etc.

• Criteria for Purchase of Rotating Machinery like

Compressors, Pumps, Blowers, Fans etc

• Electrical Appliances like Lighting, Fans, Split and

Window Air Conditioners, Refrigerator, Coolers,

Geysers etc.

Awareness program from employee as

well near by school children

11.Awareness program