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Coromandel International Ltd
Visakhapatnam Plant
K Sridhar – DGM – Mechanical
Sumit Roy – AGM – Power & Electrical
Amrendra Kumar – Manager - Operations
Commissioned in 1967
Fertiliser Products 1.0 MMTPA
Captive Raw Material Generation - 0.26 Phosphoric
Acid & 0.6 MMTPA Sulfuric Acid
0.025 MMTPA Specialty Nutrients Plants
5MW Captive Turbo Generator from Waste Steam
7.8% Power share of APGPCL gas based power plant
Connected Power Load 19 MVA
22 LIGPD Water from Tatipudi & Meghadrigedda
Reservoirs
DSIR approved R & D facility
Company Profile
ProcessPhosphatic Fertiliser with captive Sulphuric acid &
Phosphoric acid plants
Ownership Public - Private
Year of Establishment 1967
Turnover of the Unit 33863 (FY 2019-20) (INR Million)
Thermal Cost as % of Manufacturing Cost 0.23 %
Electrical Cost as % of Manufacturing Cost 2.03 %
Total Energy Cost as % of Manufacturing Cost 2.26 %
Thermal Energy Cost 9644 (INR / million kcal)
Electrical Energy Cost 5.46 (INR / kWh)
Process Flow Diagram
Sulphuric acid Plant – I - 1400 MTPD
Sulphuric Acid Plant – II – 350 MTPD
Sulphur Water Air
Sulphuric Acid
Phosphoric acid – I - 650 MTPD
Phosphoric acid –II - 350 MTPD
Water
Rock
Phosphate
By Product Gypsum
Evaporation
& Fluorine Recovery
Granulation Plant
1050 MTPD x 2
1800 MTPD X 1
By Product
Hydrofluorosilicic Acid
28-28-0
14-35-14
10-26-26
18-46-0
28% P2O5 Acid
48% P2O5 Acid
20-20-0-13
Products
Steam
Steam
Steam
Ammonia
Urea
Potash
24-24-0-8SBought out Sulf Acid
AFBC Boiler
45 MTPH
Coal
Diesel Generators
2 nos x 4 MW
1 nos X 6 MW
LSHS
Turbo Generator
1 nos X 5 MW
Bought out Phos Acid 20-20-0-13S
Turbo Generator
1 nos X 6.5 MW
Production & Energy Consumption
Parameters Unit of Measurements 2017-2018 2018-2019 2019-2020ProductionComplex Fertiliser MT 1066413 1072791 1079187Phosphoric Acid MT 194567 200025 243488Sulphuric Acid MT 546049 570945 581081EnergyAnnual Electrical Energy Consumption million kWh 105.8 102.1 115.5Annual Cost of Electricity Consumed million INR 434 421 492
Annual Thermal Energy Consumption million kcal 5669 6266 31067Annual Cost of Thermal Energy Consumed million INR 19.95 23.06 55.41
Specific Electrical Energy Consumption kWh/Ton of production 99 95 109Specific Thermal Energy Consumption Kcal/Ton of production 5097 5334 28788
Reason for increase in Specific Energy during 2019-20 :
Phosphoric acid Plant – II commissioning trials – Lower capacity utilisation
Energy Consumption 2019-20
Coal,
30943137349,
83%
LSHS,
5126432500,
14%
Kerosene,
544192715, 2%
LPG, 526062500,
1%
LDO, 75611559,
0%
Thermal Energy Consumption kcal
DG SETS,
63,161 , 0%
TG-II,
34,20,930 , 3%
TG-I,
357,94,600 ,
30%
Purchased,
786,17,600 ,
67%
Electrical Energy Usage kWh
Energy Consumption 2019-20
THERMAL,
3059, 12%
ELECTRICAL,
21600, 88%
OVERALL ENERGY CONSUMPTION,
MTOE
Specific Energy Consumption 2017-20
0.000
0.002
0.004
0.006
0.008
0.010
2017-18 2018-19 2019-20
Electrical 0.006 0.005 0.006
Thermal 0.001 0.001 0.001
▲2.6%
Intermediate Product Sulfuric Acid, MTOE/MT
Reason for Improved Specific Energy – Higher capacity utilisation (Achieved second highest ever Sulphuric acid production)
Specific Energy Consumption 2017-20
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
2017-18 2018-19 2019-20
Electrical 0.054 0.049 0.050
Thermal 0.003 0.003 0.013
11.9%
Intermediate Product Phosphoric Acid, MTOE/MT
Reason for higher Specific Energy consumption –
Phosphoric acid Plant – II commissioning trials – Lower capacity utilisation
Specific Energy Consumption 2017-20
0.000
0.010
0.020
0.030
2017-18 2018-19 2019-20
Electrical 0.0195 0.0185 0.0200
Thermal 0.0005 0.0006 0.0028
13.9%
Complex Fertiliser Plant, MTOE/MT
Consolidated
Reason for higher Specific Energy consumption –
Phosphoric acid Plant – II commissioning trials –
Lower capacity utilisation
0.000
0.003
0.006
0.009
0.012
0.015
2017-18 2018-19 2019-20
Electrical 0.010 0.009 0.009
Thermal 0.000 0.000 0.000
3%
Complex Fertiliser Plant, MTOE/MT
Stand alone
Reason for Lower Specific Energy consumption –
Higher capacity Utilisation
Benchmarking
Comments
Derived benchmark being sum total energy of Sulphuric
acid, Phosphoric acid & NPK complex plant
Source of InformationElectrical Thermal Total
Unit of measurement kWh/MT Kcal / MT MTOE/MT
Coromandel Specific Energy 109 28788 0.0228
Global Benchmark 88 870740 0.1124
Location of Unit Europe Europe Europe
Difference with Global Benchmark -21 865406 0.0896
Internal Target Specific Energy 109 6235 0.0219
1Page 58 Table A2, Best Available Techniques for Production of Sulphuric Acid, Booklet No 3 of 8, Year 2000
2EU IPPC - Reference Document on Best Available Techniques in Large Volume Inorganic Chemicals –Ammonia, Acids and Fertilizers Industries. December 2006
3Roger Heath, John Mulckhuyse and Subrahmanyan Venkataraman, Page 16, The Potential for Energy Efficiency in the Fertilizer Industry. World Bank Technical paper No 35, 11985
Benchmarking
Action Plans to Achieve Benchmark
Annual Specific energy consumption targets
Annual Energy efficiency improvement projects
with specific targets and allocated budget
Maximise Rail transport
Institutionalization of energy efficiency &
conservation awareness programs.
Institutionalization of internal incentive system to
promote & reward energy efficiency behaviors
Support technical training
2020-21
0.00219
MTOE/MT
2021-22
0.00217
MTOE/MT
2022-23
0.00215
MTOE/MT
Activities:
Installation of capacitor banks at motor control centers
SCADA & IIOT for real time monitoring
Installation of LED lights for general illumination
Installation of Variable Frequency drives
Installation of Roof top solar plant
Modernisation of age-old electrical drives & switchgear
Maximise day light savings using translucent roof
sheets and optimization of auto light sensors
Optimisation of process plant loads
Maximise Planned shutdown
Maximise utilisation of waste heat
Avoid Diesel Power & Coal Fired Boiler Generation,
Maximize internal storage & avoid multiple material
handling
Deploy best available technologies in manufacturing
Planned ENCON 2020-21
Title of Project
Annual Electrical
Saving
Annual
Thermal Saving Investment
(Million kWh) (Million Kcal) Rs Million
Optimisation of Plant Layout - 35000
MT internal raw material storage 0 2405 96
Modernisation of age old Motor control
switchgear 0.05 10
Covid – 19
Several Project Plans deferred complying to state restrictions. Site activities being restored
ENCON 2017-18
Sl No Project Details Investment Savings Payback
Rs million Rs million Months
1 Scrapped Energy Intensive 6 MW Diesel Generator set III 0 0 0
2Phase I - Installation of 25000 MT Sulf Acid Storage Tanks at
Wharf & Laying of 5 Kilometer Long Pipeline36 0
0
3 Solar energy power tie up with Visakhapatnam Port Trust 0 0.89 1
4Deployment of higher capacity trucks 25 MT trucks replacing
19 MT trucks0 5.2
1
5 Install Variable Frequency Drive 0.4 0.9 6
6Plant Layout Improvement - Install internal storage – 30000 MT
Rock godown86 6.6
156
7 Installed Sieve Tray Condenser in Fluorine Recovery Unit 3.1 2.83 13
8 Energy Efficient Lighting - Phase II 0.84 0.59 17
ENCON 2018-19
Sl No Project Details Investment Savings Payback
Rs million Rs million Months
1Turbo Generator Surface Condenser Online Tube Cleaning
System 3.6 8.88 5
2Plant Layout Improvement - Installed internal Sulphuric acid
storage & Piping system 288.5 4.67 742
3Installation of Online Silica Analyser in Demineralised Water
Plant 1.38 1.44 11
4 Replacement of old rewound Motors 2.1 0.63 40
5 Modernisation of High Tension switchgear 2.5 0.26 113
6 Lower Temperature suction to Air compressor 0.1 0.05 24
7 Energy Efficient Lighting, Phase III 2.1 1.19 1
ENCON 2019-20
Sl No Project Details Investment Savings Payback
Rs million Rs million Months
1 Installation of Combined Heat & Power Plant 500 100.3 60
2 Demineralisation Plant upgradation with Mixed bed & Ultra filtration Units 47 12.2 46
3 Waste Utilisation – Installed 4no’s evaporators 183 74.2 30
4 Variable Frequency Drive Phos Acid plant - II & AFBC boiler 14 1.8 92
5 Modernisation of Low Tension switchgear 10 1.1 113
6 Energy Efficient Lighting 7 6.8 12
7 Modernisation of Air Conditioning Units 2 0.167 144
8 Belt Conveyor travel length Optimisation 0.000 0.039 0
Year No of Proposals Investment Savings
Summary Rs Million Rs Million
2017-18 8 126 17.01
2018-19 7 300 17.11
2019-20 8 762 197
Innovative Projects 2019-20
1 Installation of 45 MTPH AFBC Boiler & 6.5MWH Combined Heat & Power Plant
2 Installed 6.5 MW non condensing steam turbine. Exhaust steam utilised for process heating.
3 Replication Higher thermal efficiency over Turbo Generator I which is a condensing turbine. Also, the cost of installation is lower than condensing turbine! Hence finds wide replicability
Impact Higher thermal efficiency due to Utilisation of exhaust steam for process heating4
Innovative Projects 2019-20
1Installation of Mixed Bed Ion exchange systems along with Ultra Filtration Units for meetings stringent silica & TDS norms for high pressure boiler
2
To bring down Total dissolved solids of Boiler Feed Water from 0.5 ppm to 0.02 ppm & employ 0.02 microns ultra-filtration to remove 98% of colloidal silica with molecular weight cut off of 10000 daltons. This results in lower steam turbine specific steam consumption
3 Replication DM Plant with mixed bed and ultra-filtration units is a viable option for meeting quality parameters of high-pressure boilers
Impact 1) Lower scaling & higher thermal efficiency of turbines 2) Lower boiler blowdown heat loss
4
Innovative Projects 2019-20
1 Installed Additional 4 no’s Evaporators for waste steam utilisation
2 Low Pressure waste steam is better utilized for concentrating Phosphoric acid otherwise being lost in turbine condenser
3Replication Best Practice where waste Low Pressure steam is available for concentrating Phosphoric acid
Impact
Waste Energy Low Pressure steam Utilisation
Byproduct Fluorine recovery
Concentrated Phosphoric acid production
4
Utilisation of renewable energy sources
Replacement of Electrical
Energy with Renewable
Energy
Installed
Capacity
(MW)
Annual
Energy
Generated
in 2017-18
%
Share
Annual
Energy
Generated
in 2018-19 % Share
Annual
Energy
Generated
in 2019-20 % Share
(Million
kWh)
(Million
kWh)
(Million
kWh)
Solar (PV) - Offsite Gen. 0 0.989 0.93 0.682 0.67 0.945 0.81
Others – Offsite Gen. 0 1.479 1.4 1.363 1.33 1.512 1.29
Waste Utilisation
2017-2018 2018-2019 2019-2020
Generation, MT
Waste Steam from Sulphuric acid Plant, MT 655479 691210 696965
Heat Value (GCV 634 kcals/kg) mkcal 415574 438227 441876
Disposal, MT
Utilised for Process Heating 449191 488433 488095
Balance for Power Generation 206289 202777 208870
Commissioned 4 nos evaporators in Phosphoric acid Plant for utilisation of waste
steam (Alternative fuel usage) during 2019-20 at an investment of Rs 183 million
GHG Inventorisation
Absolute Emissions 2017-18 2018-19 2019-20
Thermal (Scope 1 - Direct) 2090 2336 2355 Ton CO2
Power (Scope 2 - bought out power) 60282 57508 64466 Ton CO2
Scope III - Employee commuting 3177 3177 3177 Ton CO2
Total 65548 63021 69998 Ton CO2
Emission Intensity 2017-18 2018-19 2019-20
Production 1066413 1072791 1079187 MT
Carbon Intensity 0.0615 0.0587 0.0649 Ton CO2 / MT
Disclosure of Emission data Publicly – Yes Partial disclosure
GHG Inventorisation
Minimising Power consumption
Maximise turbo power generation from waste
Steam
Install energy efficient lighting using LED bulb
Install Rooftop solar power plant of 95 kWp
capacity
Modernisation of age-old low-tension
switchgear
Power factor improvement by installing
capacitor banks
Minimising Thermal energy consumption
Replacement of defective insulation
Improve condensate recovery
Action PlanEmission Ton CO2/MT
Target Short Term 0.064
Target Long Term 0.058
Achieved 2019-20 0.0649
1
2
3
4
5
6
7
8
9
Green Supply Chain Management
Green purchase policy ( if, any) : Yes
In all purchases, preference to local suppliers
All packaging materials used to be made of recyclable materials
Transport charges determined considering fuel efficiency
1
2
3
Projects Implemented
Investment Made (Rs In
Million) Description
Captive Generated Raw
Material Phosphoric
acid supply to sister
concerns
1
As part of Make in India initiative, Captive Generated Raw
material phosphoric acid plant capacity augmented, resulting
in self-sufficiency. Excess raw material produced is supplied to
sister concerns through truck transport, limiting import &
saving in transport fuel costs
Captive Raw Material Generation &
supply to sister concerns
Monitoring
Daily Monitoring – Daily Target Vs Actual Specific Energy Consumption compared & corrective actions undertaken
Review Meeting Chaired By - Unit Head
Typical Report
Encon budget & Training
126
300
762
106
0
100
200
300
400
500
600
700
800
900
2017-18 2018-19 2019-20 2020-21
Encon Investment, Rs million
All proposals are evaluated for performance and
economic viability and then implemented.
Proposals with quick payback are prioritised.
There is no limit of funds for taking up energy
conservation activities
Training
Plant personnel regularly participate in CII
Webinars, Encon training programs conducted by
CII and Other Institutions & Internal training
programs
Walkathon conducted on the beach on world
environment day, world earth day, world water
day etc. to raise public awareness on
conservation of resources
Plant Underwent CII Energy Audit of Visak Unit in
2014
Baseline verification audit was carried on 8th
August 2016 as per guidelines issued by Bureau of
Energy Efficiency, Ministry of Power, Govt of
India.
1
2
3
4
Encon Kaizens & Team work
Modernisation of Air conditioning system Right sizing belt conveyor
Projects taken up by workers & supervisors
Implementation of ISO 50001 / Green Co / IGBC rating
28
Ours integrated management system encompasses standards of Quality - ISO 9001:2015, Environment
- ISO 14001 : 2015 & Occupational Health & Safety - ISO 45001:2018.
The level of integration with energy management is
ISO14001:
Cost savings through improved efficiency and productivity.
Minimize waste and improve energy efficiency in order to reduce operating costs.
Continual improvement based on Plan – Do –Check-Act
Our Annual Energy Consumption is average 24659 MTOE , also as we are not a designated consumer
as our energy consumption is less than 30000 MTOE for fertiliser sector.
Hence we have not opted for ISO50001 additional certification
Encon Investment on Turnover
29
2017-18 2018-19 2019-20
Investment in Encon 126 300 762 Rs millionTurnover 25770 31387 33863 Rs million% Investment for Encon on Turnover 0.49% 0.96% 2.25% %
Other Innovative technologies implemented
30
a. Roadmap for digital enablement Developed b. Automation projects
1) Level transmitters installation on Major acid tanks 2) Manless Gypsum weigh bridge 3) Online moisture analyser Gypsum 4) Stack Opacity Monitor5) Real time monitoring
6) CEQMS & CAAQMS-Online Connectivity to CPCB/APPCB
Real time Monitoring DCS Training CentreManless Gypsum
weighbridgeStack Opacity Monitor CEQMS & CAAQMS -
Automation projects – Benefits achieved
1. Real time process monitoring
2. Ambient air & Emission monitoring
3. Manless operation
4. Product quality monitoring
1
2
3
4
Long term vision on Energy Efficiency
31
Long Term target of Energy Efficiency
1. 6% Renewable energy utilisation
2. 90% Capacity utilisation
3. 1% increase in Planned shutdown every year from current 35% to 40% by 2025
Support required
1. Suppler engagement –
a. Wagons availability during peak season
b. Priority berthing for Fertiliser materials
2. Financial support
a. External - Regular Subsidy payment by Government
b. Internal - Funds for implementing latest technology
3. Technical support
a. Latest technology IOT, Robotics, AI, Analytics implementation
b. Training
Energy Management Awards
32
2014 2015 2016 2017
2018 2019
Accolades
33
Award Awarded By Year
SAFETY & ENVIRONMENT
“One of the Top 10 Greenest Companies in India” TERI & Business Today 2001
Safety, Health & Environment Performance Award CII - SR 2003, 2004
Environment Protection Award FAI 1996, 2009, 2017
5 Star Rating British Safety Council 1999, 2011
Safety Award National Safety Council 1998
WATER & ENERGY CONSERVATION
Excellence in Energy Conservation & Management CII 2000,2001,2002,2014,2015,2016,2017,2018, 2019
Certificate of Merit Energy Conservation BEE 2002-03, 2003-04, 2005-06 & 2006-07, 2011-12
Excellence in Energy Conservation NREDCAP –Govt of AP 2009-10,2011-12,2012-13
Excellence in Energy Conservation AP Productivity council 2006-07
Excellence in Water Management CII 2009-10, 2010-11, 2011-12
PRODUCTION
Best overall performance of Fertiliser Plant FAI 1994-95
Best Operating Phosphoric Acid Plant FAI 1994-95,1995-96,1996-97,97-98,2000-01,2001-02, 2003-04,2004-05,2005-06,2006-07,2009-10, 2011-12,2013-14,2014-15,2015-16,2016-17, 2017-18
INDUSTRIAL RELATIONS
Best Management Award Labour Dept – AP Govt 2000, 2005, 2013, 2015,2016,2017
Energy Management
For further information please contact
Vice president - Manufacturing
Thank you
