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Pre-Feasibility Report for Modification/ Revamping of Ammonia-Urea Plant at IFFCO Aonla

INTRODUCTION

Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production

and marketing of Fertilisers with the objective of helping the country to achieve self-

sufficiency in food grain production. IFFCO Aonla Unit – I was commissioned in May

1988 and Aonla Unit – II in December 1996. Ammonia Process of Aonla Unit-I & II is

based on technology from M/S Haldor Topsoe, Denmark with Natural Gas as main raw

material and Urea process is based on Snamprogetti, Italy.

Energy Consumption:

The average Sp. energy consumption of IFFCO Aonla Unit-I & II in last 3 years is as follows:

Unit Unit 2012-13 2013-14 2014-15 Average

Aonla-I Gcal/MT Urea 5.615 5.665 5.585 5.622

Aonla-II Gcal/MT Urea 5.372 5.498 5.359 5.410

As per revised energy norms under new Urea Policy-2015, the specific energy

consumption norms have been reduced w.e.f. 1st June, 2015 to 31st March, 2018 to

5.656 Gcal/MT Urea for Aonla-I and 5.505 Gcal/MT Urea for Aonla-II and for 2018-19,

5.5 Gcal/MT Urea for both Aonla-I & II.

Unit Energy Norms as per new Urea Policy 2015 for 2018-19

Present Average Energy

Difference

Aonla-I Gcal/MT Urea 5.5 5.622 - 0.122 Aonla-II Gcal/MT Urea 5.5 5.410 + 0.090

In view of the above, it is proposed to implement various Modification/ Revamping of

Ammonia-Urea Plant at IFFCO Aonla to implement the latest available proven

Technological solution to improve Reliability of Process / Equipments and to reduce the

Energy Consumption by 0.358 Gcal per MT Urea in Aonla-I and 0.396 Gcal per MT

Urea in Aonla-II.

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CHAPTER-I

Executive Summary

Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production

and marketing of Fertilisers with the objective of helping the country to achieve self-

sufficiency in food grain production. IFFCO Aonla Unit-I was commissioned in year 1988

& Unit-II in year 1996. Both Ammonia-I & II Plants are based on Haldor Topsoe

Technology, Denmark. Both Urea-I & II Plants are based on Process Technology of

Snamprogetti’s Italy. Total Urea Production Capacity of Aonla Unit is 6000 MTPD (21.90

lakh MT per annum considering 365 stream days). Natural gas is used as Feed & Fuel

at IFFCO Aonla which is supplied through the HBJ Gas Pipeline.

IFFCO Aonla Fertiliser Complex is spread over an area of 1383 Acres consisting 450

Acres Plant Area, 452 Acres Township Area & 110 Acres land for Railway siding.

Lay-out Plan of IFFCO Aonla Unit is enclosed as Annexure-1.

1. The actual production for last 3 years is given below:

Unit Year (2012-13)

Year (2013-14)

Year (2014-15)

Unit Qty Qty Qty Aonla-I Ammonia MT 634351 634254 609061

Urea MT 1091952 1103000 1046481 Aonla-II Ammonia MT 667295 623145 593082

Urea MT 1152829 1074173 1020855 Total Ammonia MT 1301646 1257399 1202143

Urea MT 2244781 2177173 2067336

2. The present Raw material Consumption:

Particulars Unit Aonla-I Aonla-II Urea Production MTPD 3000 3000 Feed NG to Ammonia plant Sm3/day 1056529 1052734 Fuel NG to Ammonia plant Sm3/day 430340 673059 Fuel to SG Sm3/day 108791 Fuel to CPP-I + CPP-II Sm3/day 463469 Purchased power MW 0.65 Ammonia energy Gcal/MT ammonia 7.859 7.575 Urea energy Gcal/MT urea 5.529 5.527

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3. The utilities (Water, Power & Steam) consumption:

Present Water requirement of IFFCO Aonla Unit 34200 m3/day is being met by 16

Nos. of Deep Borewells within premises of IFFCO Aonla. Around 5712 M3 per day

waste water is being generated which is stored in 2 nos of Guard Ponds of Capacity

85000 M3 each after treatment in the Effluent Treatment Plant. Most of the treated

effluent is utilized for irrigation and green belt development within IFFCO premises.

Rest is discharged to river Aril. The quality of treated effluent always meets the

prescribed standards. The Online monitoring system has been installed at Factory

Discharge for treated waste water quality & flow. Real time online data is being

transmitted to CBCB/SPCB server.

The Steam Generation facilities consist of 150 MT/hr SG Boiler, 2 X 80 MT/hr Waste

Heat Boilers (CPP), 120MT/hr Heat Recovery Unit (Ammonia-II) with total Steam

Generation capacity of 430 MT/hr. Power requirement of IFFCO Aonla Unit 31.7 MW

is met by 2 Nos. GTGs of capacity 25 MW (ISO) each.

The Offsites facilities include water De-Mineralisation plant, Effluent Treatment Plant,

Raw Material and Ammonia Storage Tanks, Inert Gas generation unit & Air

Compressors for Instruments and Plants.

4. Energy Consumption of Plants:





IFFCO Aonla unit is inherently committed to use the energy in the most efficient way.

"Energy Saving" is one of the major objectives of Aonla Unit. This effort has enabled

to run the old Ammonia and Urea Plants with better performance level even after 27

years of operation.

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5. Revamping / Modification of the Plants:

Urea business in India is covered under Essential Commodity Act (ECA) and same is

governed by Department of Fertilizer (DoF), Government of India. In the 2015, new

Urea Policy has been placed in effect reducing specific energy consumption to 5.5

Gcal/MT Urea for AONLA-I and AONLA-II. As per revised energy norms under new

Urea Policy-2015, the Specific Energy consumption norms has been reduced w.e.f.

1st June, 2015 to 31st March, 2018 to 5.656 Gcal/MT Urea for Aonla-I and 5.505

Gcal/MT Urea for Aonla-II and for 2018-19, 5.5 Gcal/MT Urea for Aonla-I & II.

Plant Unit Energy Norms as per new Urea Policy 2015 for 2018-19


Difference


In order to remain competitive, IFFCO has undertaken Modification/ Revamping of its

Ammonia–Urea Complex at Aonla to reduce the Specific Energy consumption of

Plant.

6. Proposed Modification / Revamping Schemes:

It is proposed to implement various Modification/Revamping of Ammonia-Urea Plant

at IFFCO Aonla Unit to implement the latest available proven technological solution

to improve Reliability of Process / Equipments and to reduce the Energy

Consumption by 0.358 Gcal/MT Urea in Aonla-I and 0.396 Gcal/MT Urea in Aonla-II.

The configuration of Ammonia Urea Complex of Aonla Unit along with proposed

Revamping/ Modification is enclosed as Annexure-2.

7. Scope of work of Engineering Consultant:

M/s CASALE, Switzerland was appointed for Basic Engineering Design package for

the proposed Revamping.

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8. Estimated cost of the Revamping:

Aonla-I

S. No.

Schemes under consideration Plant Estimated Cost (Rs. Lakh)

1

Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0, replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section and Replacement of one Semi-Lean Pump condensing turbine with new motor for less energy requirement.

Ammonia 13600

2 Replacement of HP boiler at downstream of High Temperature Shift Converter with new steam superheater

Ammonia 1600

3 New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge

Ammonia 1200

4 Replacement of existing sweet cooling water system using DM water as cooling medium for cooling of synthesis gas with new heat exchanger using cooling water as cooling medium

Ammonia 1500

5 Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency.

Ammonia 4000

6 Replacement of existing condensing turbine with electric motor drive for BFW pump

Ammonia 200

7 Replacement of existing combustion Air type pre-heater with new plate type exchanger in Ammonia-I.

Ammonia 1000

8 Installation of Fuel gas expander with power generator

Ammonia 3200

9 Replacement of existing CO2 Compressors by new higher efficiency compressors

Urea 8000

10 Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors achieving higher conversion

Urea 1000

11 Installation of Ammonia Preheaters Urea 900 12 Sub Total 36200 13 Contingency (3%) 1100 14 Total 37300

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Aonla-II

S. No.

Schemes under consideration Plant Estimated Cost (Rs. Lakh)

1 Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0, replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section and Replacement of one Semi-Lean Pump condensing turbine with new motor for less energy requirement.

Ammonia 13400

2 New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge

Ammonia 1200

3 Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency

Ammonia 3600

4 Installation of Vapour Absorption Machine for the cooling of inlet air to Process Air Compressor

Ammonia 900

5 Running of one BFW pump with motor in place of turbine whereas another BFW pump shall be run by turbine

Ammonia

1000

6 Replacement of existing combustion Air type preheater with new plate type exchanger

Ammonia

7 Installation of Fuel gas expander with power generator

Ammonia 3200

8 Replacement of existing CO2 Compressors by new higher efficiency compressors

Urea 7800

9 Installation of Vapour Absorption Machine for the cooling of inlet CO2 gas to CO2 Compressor

Urea 800

10 Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion

Urea 900

11 Installation of Ammonia Preheaters Urea 700 12 Sub Total 33500 13 Contingency (3%) 1000 14 Total 34500 15 Grand Total Aonla-I + Aonla-II 71800

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9. Raw Material and Utilities:

Basic purpose of implementation of Revamping Schemes is to conserve the Raw

Materials i.e. Natural Gas. There will be over all saving of Natural Gas in Aonla Unit.

No additional Raw Materials will be required.

10. Project Implementation Plan & Time Schedule:

The Revamping Schemes will be implemented in two Phases. The Schemes which

are having high energy savings potential and required relatively short lead time will

be implemented in during 2016 turnaround and while the complete project will be

completed in 2017 turnaround.

11. Estimated Capital Cost

The estimated capital cost of proposed Energy Saving Project is as under

(Rs. Crore):

Sr. No

Units Equipment Cost (including 3% Contingency)

BEDP DEDP Total

1. Aonla-I 373 16 4 393

2. Aonla-II 345 16 4 365

3. TOTAL 718 32 8 758

BEDP : Basic Engineering Design Package

DEDP : Detailed Engineering Design Package

12. Financial Analysis of project:

The overall saving in Urea specific energy at each Unit and payback period be as

under:

Particulars UNIT Aonla-I Aonla-II Total

Urea Plant Capacity MTPD 3000 3000 6000

Energy Saving Gcal/MT 0.358 0.396 0.377

Estimated Investment Rs. Crore 393 365 758

Monetary Savings /Year Rs Crore 90 99 189

Payback Years 4.4 3.7 4.0

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13. Consumption of Raw Material and Utilities after Revamp:

Although power consumption of IFFCO Aonla Unit will increase by 4.8 MW due to

change of turbine driven pumps to motor driven pumps being more energy efficient;

but overall consumption of Natural Gas is expected to reduce by 258,000Sm3 par day

after revamp at same production level.

The Water consumption of IFFCO Aonla Complex will not increase after Revamp and

there will be reduction of wastewater generation.

Further, there will be reduction in daily consumption of NG which will reduce the over-

all pollution load in the surrounding environment.

14. Emission Load- Before and after Revamp:

The present emission load of CO2 is around 144 MT/hour considering the present

Fuel consumption. After revamp the emission load of CO2 would be 127 MT / hour

considering the projected Fuel consumption maintaining the same production level.

Further, the emission level of SOx & NOx is expected to reduce due to reduction in

NG consumption of 258,000Sm3 par day at same production level as explained

above.

Due to reduction in water consumption by 500 m3/day, reduction in waste water

generation & discharge is expected.

15. Capacity of the Plant after Revamp:

The production Capacity of Urea for the Aonla Unit (Aonla -I & Aonla -II) will remain

the same as 6000 MTPD (21.90 lakh MT per annum considering 365 stream days).

Similarly, the production Capacity of Ammonia for the Aonla Unit (Aonla -I & Aonla -II)

will remain the same as 3450 MTPD (12.60 lakh MT per annum considering 365

stream days).

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CHAPTER-II

SITE ANALYSIS

IFFCO Aonla-I Unit was commissioned in the year 1988 and Aonla-II Unit in year 1996

and running successfully since then. Several modernization schemes have been

implemented successfully in past. The prime factor with respect to connectivity plays an

important role in successful implementation of the project as per schedule.

.

IFFCO Aonla is located at Aonla Tehsil in Bareilly District of Uttar Pradesh. The site is

located at a distance of about 7 kms from State Highway No. 33 (connecting Bareilly to

Badaun) on Lucknow Delhi Highway. Aonla, which is tehsil headquarter, is at a distance

of about 11 km and Bareilly town is at a distance of about 28 kms from IFFCO Aonla.

Aonla railway station is at a distance of about 14 kms and Bareilly railway station is at a

distance of about 27 km from Aonla fertilizer complex. IFFCO Aonla Unit is spread over

an area of about 1273 Acres of land owned by IFFCO Management. The proposed

energy saving schemes shall be implemented within plant premises of existing Aonla-I

& II Units.

Since the project shall be implemented within existing plant premises, there would no

change in existing land use pattern.

Eco-sensitive Areas

The project is limited to revamping/modernization of Ammonia & Urea Plants of Unit-I &

II without any change in production profile. There will be reduction in natural resource

and energy per capita of finished production.

It is envisaged that there is no Wild Life Sanctuary, National Park and Reserved Forest

within 10 km radius of the project area.

Topography

The site has natural gradient from north to south. The land within plant premises is

almost flat. The soil of the project site is alkaline in nature with a pH value in the range

of 8.0 to 9.0. The soil contains fine clay which is compact and non-porous. As water

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logging due to rain takes place in the area, grade leveling has been and adequate

drainage facilities have been provided within plant premises.

The site area is not prone to inundation. However, pile foundation may be required for

major equipment and structure foundations. The depth of piles and the related aspects

will be decided appropriately based on soil investigations. However, the area is

predominantly covered with fine clay soil, which is compact and non-porous in nature.

Existing Facilities

IFFCO Aonla Unit is a well established fertilizer complex spread over an area of 1383

Acres of land (including 110 Acre land for railway siding) owned by IFFCO

Management. IFFCO Aonla-I was commissioned in 1988 and Aonla-II in 1996.

Capacity enhancement/ Debottlenecking of IFFCO Aonla Unit was done in 2008 with

the increased capacity of 3450 MTPD Ammonia & 6000 MTPD Urea production.

In addition to industrial activities, there exists residential area for providing

accommodation to its employees. The residential accommodations are well furnished

and well connected with metallic road with water supply and electricity. Water is being

supplied to the residential colony through underground pipelines. Source of power is

own power generation plant. All the other infrastructural facilities like school, play

grounds etc are well maintained. The colony has a good sewerage system and sewage

treatment facility. The treated sewage is used as irrigational water.

Soil texture

Soil texture is an important soil characteristic that could influence water retention

capacity, aeration, drainage, and susceptibility to erosion which drives crop production

and management. The textual class of soil is determined by the percentage of sand, silt

and clay. Soils can be classified into one of four major textural classes including sands,

silts, loams and clays. Broadly speaking, three textural classes are identified in the

state. Clayey and loamy types are predominant in the state under fine and medium

textured soils.

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The soil of the project area is clayey and the load bearing capacity of the soil in the area

is about 8.0 t/m2. The soil is alkaline in nature with pH value between 8 to 9. The soil

contains fine clay which is compact and non-porous. The soil of the area is having low

organic content. The N, P & K content also does not support high crop yields and

therefore, low agricultural productivity is anticipated in the impact zone. However, the

analyses of heavy metals indicate that the soil is free from any chemical contamination.

Climate of Aonla

District Bareilly has a humid subtropical climate with high variation between summer

and winter temperatures. Summers are long, from early April to October, with the

monsoon season in between. Winter starts in October and peaks in January and is

notorious for its heavy fog. Extreme temperatures range from 4 °C to 44 °C. The annual

mean temperature is 25 °C (77 °F), monthly mean temperatures range from 14 °C to 33

°C (58 °F to 92 °F). The mean annual normal rainfall is approximately 1000 mm and

mean annual maximum rainfall is 1482 mm. Most of rainfall is received during monsoon

in the months of July and August.

Social Infrastructure

• Demography

According to the 2011 census Bareilly district has a population of 4,465,344,

roughly equal to the nation of Croatia or the US state of Louisiana. This gives it a

ranking of 39th in India (out of a total of 640). The district has a population density

of 1,084 inhabitants per square kilometre (2,810/sq mi). Its population growth

rate over the decade 2001–2011 was 23.4%. Bareilly has a sex ratio of

883 females for every 1000 males, and a literacy rate of 60.52%.

According to the 2005 census report of the Government of India, the total

population of Bareilly City Region (Bareilly Municipal Corporation and Bareilly

Cantt.) is 875,165 having distribution as 53% males and 47% females nearly. The

area under the city region is 123.46 km². The density of the population is among

the highest in the country, almost 5000 per km2.

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Hindus form 62% of population. The main population consists of Kurmis (Jadauns

and Gangwars, Patels), Mauryas, and other castes such as the Baniyas, others

like Jatavs, Balmikis, Thakurs, Kayasthas & Punjabis.

Minority population is about 35% of the total population of the district. Bareilly is a

category "A" district i.e. having socio-economic and basic amenities parameters

below the national average.

Muslims contribute 26%, (mainly Ansari, Behna, Rohila, Raveen, Ranghar &

Shaikh) of the population. Sikhs form about 10% of population and rest are Jain,

Buddhist and Christians.

Bareilly has an average literacy rate of 81% higher than the national average of

59.5%, with 88% of the males and 65% of females literate making it under top

three districts in terms of literacy in Uttar Pradesh. The main languages spoken

are Hindi, English, Urdu,Punjabi, and Kumaoni.

• Transport

Air Transportation

Nearest Domestic & International Airport is Indra Gandhi International Airport in

New Delhi 260 km away from Aonla and provides connectivity with domestic flights

to the Metropolitan and other major cities of India.

Rail Network

Aonla railway station is at a distance of 14 km and Bareilly railway station is at a

distance of about 27 km from Aonla fertilizer complex. Aonla lies on the railway

line connecting Bareilly to New Delhi.

Road Network

Aonla Unit is located at a distance of about 7 kms from State Highway No. 33

(connecting Bareilly to Badayun) on Lucknow Delhi Highway.

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• Communication

The access roads needed by the workers, for transportation of

equipment/machinery to plant site and also for raw material supply already exist.

The vehicles may consist of cycle/ motorcycles for workers; cars, pickups, vans,

for staff and public at large; while heavy machinery like trucks, cranes, rollers,

dozers, etc. for machinery haulage and raw material supplies.

The increased traffic owing to proposed project not only boost to repair/spare

shops to come up in the near-by area but also to restaurants and hotels for

eating/drinking facilities to operating staff & local people and eventual inflow of

income. The newer development has given chance to replace old

equipment/appliances being used and newer sophisticated ones will come in the

use.

• Occupational Pattern

The major occupation of people in the area is agriculture. During the operational

period, the IFFCO Aonla plant employed labours. There seems to be no additional

employment opportunities generation through IFFCO after commissioning of this

modernized project. However, there would be some employment generation during

the construction phase at IFFCO Aonla Unit.

• Medical and Public Health

The present infrastructure facilities with respect to health, power, sanitation,

communication etc. are sufficient and the proposed project does not demand any

additional changes in the existing facilities. Primary medical facilities are available

to the plant personnel at the plant as IFFCO already has a very good hospital with

well qualified staff and up to date medical facilities. There is no impact on the

medical and public health status in near-by villages in the study areas as most of

them have Primary health Centre, their own village dispensary/registered private

practitioner to meet their requirements. Moreover, IFFCO’s medical facilities are

being utilized by nearby villages as and when required.

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• Socio-Economic Environment and Human Use Values

Demographically, there will be some labour force migration into the project

complex or in the neighborhood due to anticipatory increase in the job

opportunities. During the construction phase of Energy Saving Project, a

substantial force of experts, technicians, other skilled and non-skilled labours will

be required. Most of the villages in near-by area are connected with metalled

roads with fairly adequate bus services. The local villagers should have an

opportunity for such direct/indirect employment to increase their income, while

some precisely skilled labour force, technicians & experts will have to be brought

from outside. The proposed project of IFFCO Aonla in such area, which is

otherwise an almost silent land, will trigger the multiplier effect to promote

infrastructural developments like transport, power/water supply, housing facilities

besides educational / medical / health care, banking and public utilities. Thus, the

proposed modernization project of IFFCO Aonla, is certainly expected to add more

to the existing facilities which would not only benefit the industrial workers but local

population also.

• Appreciation of Immovable

The project has led to appreciation in values of immovables, be it a house, open

plot or a cultivated land. The sale/purchase value of immovables has thus got

appreciated owing to the impact of the project. The seller on getting bulk money in

one stroke may coin the opportunity of investing that amount in another quick

money generating business and thereby he gets a chance to get higher social

status among villages and may even avail better share of amenities.

The people in neighboring areas have certainly taken advantage of higher rents of

residential premises.

• Education and Skill Up-gradation

The growing youths from neighboring villages are intending to go in for

professional training like para-engineering, para-medical profession so as to

enable themselves for an early entry into neighborhood project/factories like

IFFCO or alternatively the project itself may make the facility of skill up-gradation

to its own staff as well as apprenticeship to others in the vicinity of the project.

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CHAPTER-III

Land Use Planning

A total of 1273 Acres of land was acquired for establishment of Aonla fertilizer complex.

The break-up of acquired land is as under:

Plant : 450 Acres

Township : 482 Acres

Green Belt : 336 Acres*

Oxidation Pond : 5 Acres

Total : 1273 Acres

* Total area of Plantation in IFFCO Aonla Unit including Green Belt: 452 Acres

In addition to above, 110 Acres of land is used for Railway Siding. As the project

proposal is limited to Revamping/Modernization of existing Ammonia & Urea Plants

only; hence additional land use planning is not envisaged.

Green Belt Development:

The land provided for the factory and township was originally “USAR” and Sodic land

and was lying unutilized from long time. IFFCO had taken a challenge to reclaim this

usar land and it has been converted into a green land. 50 to 200 m wide green belt has

been developed around the complex. Today, the entire area is full of trees and

vegetation.

About 2.0 Lakh trees of wide variety of about 30 species including some of medicinal

species imparts scenic beauty besides providing suitable habitat for birds and other

flora and fauna. The greenery and the scenic beauty of Sanjivani Vatika, Buddha Vihar,

Nandan Udyan, Saras Kunj, etc. are remarkable and imparts healthy environment. The

species of plants planted are Peepal, Neem Shesham, Pakad, Jamun, Guava, Arjun,

Amla, Bel, Kanji, Ashok, Casurina, Gulmohar, Amaltas, Harre, Bahera, Karenj,

Bottlebrush etc.

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CHAPTER-IV

Environment and Safety

IFFCO Aonla Unit is totally committed for maintaining an eco-friendly environment. For

controlling air pollution, plants have been provided with Dust Extraction Systems. A lush

green belt with about 2.0 lakh trees has been developed all around the IFFCO Aonla

Complex which is a natural means of air purification.

IFFCO Aonla Unit has always put its best efforts for conserving water. Around 70%

waste water generated in the plant is recycled back after treatment. Around 85%

effluent generated in plant is reused in irrigation of Green Belt of Complex after

treatment in ETP. Sewage water generated in the township is reused for Horticulture

after treatment in STP. The present specific water consumption is below the standard

norms fixed for fertiliser industry in the country. IFFCO Aonla Unit has ISO 14001

certification which speaks volumes about its environmental commitment. IFFCO Aonla

Unit has won number of awards for its environment improvement efforts.

IFFCO Aonla Unit is an OHSAS-18001 Certified Unit. Annual safety targets like hazard

identification and risk analysis, training to the employees and contractor labours, health

check up of the employees to find any Occupational Disease of any employees etc.

have been covered under OHS Management System. All jobs are evaluated with

respect to safety and a job safety analysis is being done for all important and critical

jobs. All critical jobs have been described in job procedures including the special

personnel protective equipments, which are always kept ready for the job. Relevant

standards, codes of practices, work permit systems are being followed. Checking of

Safety Relevant Components like Explosion Vents, Relief Valves, Rupture Discs,

Relays and Trip systems etc. are done in every annual shutdown. Employees have

been trained in all these aspects. Onsite and offsite emergency plan is well in place and

mock drills are conducted regularly. All modification jobs of the plants shall be carried

out after systematic HAZOP study and for proper documentation as per management of

change under process safety management system.

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Assessment of Infrastructure Demand

The existing infrastructural facilities available at IFFCO Aonla are having all the basic

requirements and are updated from time to time. Hence, there shall be no demand of

infrastructure during establishment of proposed project.

Amenities/ Facilities

IFFCO Aonla is having all the required amenities and facilities. Safety, healthy,

environmental, social, cultural requirements are periodically assessed and updated as

per requirements.

Proposed Infrastructure

The existing infrastructure of IFFCO Aonla with respect to residential colony, green belt,

Social infrastructure, road and rail facilities, supply of water, sewerage facilities, power

requirement etc. are readily available and are working efficiently. In view of the size and

magnitude of proposed project, no additional infrastructure is envisaged.

Rehabilitation & Resettlement Plan

IFFCO Aonla fertilizer complex is spread over an area of 1273 Acres of land. The total

area of land is under the administrative possession of IFFCO Management. The

proposed project shall be implemented within plant premises of existing Aonla Fertilizer

Complex. Hence, any planning with respect to rehabilitation & resettlement is not

applicable.

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CHAPTER-V

DESCRIPTION OF PROPOSED MODIFICATION TO BE CARRIED OUT AT IFFCO

AONLA UNIT

1. Description of modifications to be carried out in Ammonia Plant of Aonla-I

Unit

(I) Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0,

replacement of existing GV solution based CO2 removal section by

aMDEA solution based CO2 removal section and Replacement of one

Semi-Lean Pump condensing turbine with new motor for less energy

requirement.

The existing GV solution based CO2 Removal section shall be replaced by

aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to

existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from

process gas. CO2 rich aMDEA solution shall be regenerated. CO2 separated shall

be sent to Urea plant for the production of urea. Regenerated aMDEA solution

shall be again sent to CO2 Absorber to absorb CO2 from process gas.

Expected Energy saving: 0.27 Gcal/MT amm

(II) Replacement of HP boiler at downstream of High Temperature Shift

Converter with new steam superheater:

At the outlet of High Temperature Shift Converter, existing Waste Heat Boiler shall

be replaced by new Steam Super-Heater to superheat HP steam to about 350°C,

with consequent reduction of the firing in Auxiliary Steam Superheater. This

modification shall help to reduce steam production by around 20 MT/hr in the

ammonia plant (saving natural gas), which is less efficient than production of

steam in Heat Recovery Steam Generator (HRSG) of Gas Turbines of Power

Plant.


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(III) New Ammonia wash system in Synthesis Gas Compressor 2nd discharge

to remove oxygenated compounds from synthesis gas and sending 3rd

stage discharge directly to recirculator stage discharge:

In order to increase the energy efficiency of the synthesis loop, a syn gas

dehydration system based on liquid ammonia washing shall be introduced at

Synthesis Gas Compressor second stage discharge. The oxygenated compounds

(H2O, CO and CO2) available in Syn Gas shall be separated in ammonia wash

system. With this modification, Syn Gas Compressor 3rd stage discharge which is

free from oxygenated compounds, can be mixed directly with recirculator

discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st Ammonia

Synthesis converter. With this modification, there shall be reduction in power

requirement in turbine drive of Synthesis Gas Compressor by around 900 KW.


(IV) Replacement of existing sweet cooling water system using DM water as

cooling medium for cooling of synthesis gas with new heat exchanger

using cooling water as cooling medium:

Sweet Water Cooler system shall be replaced with new heat exchanger using

cooling water directly as cooling medium for better cooling of syn gas. This shall

also reduce loop pressure by around 5 kg/cm2 and steam saving in Syn Gas

Compressor turbine by around 2 MT/hr.


(V) Revamp of Synthesis Gas Compressor involving replacement of HP case

and LP case barrels by new barrels for increase in efficiency:

Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced

by new barrels for increasing the efficiency of Syn Gas Compressor. This shall

result in saving of steam in turbine drive of Synthesis Gas Compressor by around

10 MT/hr.


20 of 32


(VI) Replacement of existing condensing turbine with electric motor drive

for BFW pump

Existing condensing turbine drive of BFW Pump shall be replaced by motor drive.

The BFW Pump driven by new motor, shall be kept in operation. With this, the

energy loss to cooling water through condensing load of condensing turbine would

be stopped.

Expected energy saving: 0.070 Gcal/MT amm

(VII) Replacement of existing combustion Air type pre-heater with new plate

type exchanger in Ammonia-I.

Existing combustion air preheater made of carbon steel shall be replaced by a new

one using SS plates. This shall reduce leakages and also increase the heat

transfer efficiency. This way, primary reformer global efficiency is expected to

increase and stack temperature is also expected to decrease from existing 186

degC to 135 degC.


(VIII) Installation of Fuel gas expander with power generator

NG fuel which is let down in existing system from around 40 kg/cm2g to 4

kg/cm2g, shall be passed through Fuel Gas Expander connected with power

generator for generation of electricity of around 1 MW.


21 of 32


2. Description of modifications to be carried out in Urea Plant of Aonla-I Unit

(I) Replacement of existing CO2 Compressors by new higher efficiency

compressors

In both 11 & 21 Units of Urea plant, existing CO2 Compressor shall be replaced

with new CO2 Compressor of higher efficiency. This shall result in saving in steam

consumption in steam turbine drive of CO2 Compressor by around 10 MT/hr.

Expected Energy saving: 0.07 Gcal/MT Urea

(II) Installation of Casale High Efficiency Trays (HET) in existing Urea

Reactors achieving higher conversion

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays

(HET). The function of the HET trays is to increase the CO2 conversion, by

improving the heat and mass transfer phenomena occurring inside the reactor.


(III) Installation of Ammonia Preheaters:

In both streams of Urea plant, Ammonia Preheater shall be installed in the

upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the

ammonia entering the reactor. The heating fluid shall be the mixture of vapors

coming from the top of LP Decomposer, and the solution coming from Distillation

Tower Reflux pumps. The exchanger shall result in energy saving by utilizing

energy of LP Decomposer off gas which in existing system is dumped to cooling

water. With this modification, heat requirement in form of MS steam in HP Stripper

shall reduce.


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3. Description of modifications to be carried out in Ammonia Plant of Aonla-II

Unit

(I) Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0,

replacement of existing GV solution based CO2 removal section by

aMDEA solution based CO2 removal section and Replacement of one

Semi-Lean Pump condensing turbine with new motor for less energy

requirement.

The existing GV solution based CO2 Removal section shall be replaced by

aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to

existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from

process gas. CO2 rich aMDEA solution shall be regenerated in three stages, firstly

in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The

source of regeneration energy shall be only process gas. CO2 separated shall be

sent to Urea plant for the production of urea. Regenerated aMDEA solution shall

be again sent to CO2 Absorber to absorb CO2 from process gas.


(II) New Ammonia wash system in Synthesis Gas Compressor 2nd

discharge to remove oxygenated compounds from synthesis gas and

sending 3rd stage discharge directly to recirculator stage discharge

In order to increase the energy efficiency of the synthesis loop, a syngas

dehydration system based on liquid ammonia washing shall be introduced at

Synthesis Gas Compressor second stage discharge. The oxygenated compounds

(H2O, CO and CO2) available in Syn Gas shall be separated in ammonia wash

system. With this modification, Syn Gas Compressor 3rd stage discharge which is

free from oxygenated compounds, can be mixed directly with recirculator

discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st

Ammonia Synthesis converter. With this modification, there shall be reduction in

power requirement in tubine drive of Synthesis Gas Compressor by around 900

KW.


23 of 32


(III) Revamp of Synthesis Gas Compressor involving replacement of HP

case and LP case barrels by new barrels for increase in efficiency

Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced

by new barrels for increasing the efficiency of Syn Gas Compressor. This shall

result in saving in steam requirement in turbine drive of Synthesis Gas

Compressor by around 10 MT/hr.


(IV) Installation of Vapour Absorption Machine for the cooling of inlet air to

Process Air Compressor

A Vapour Absorption Machine (VAM) shall be installed in Ammonia-II to generate

chilled water for new process air chiller to be installed at the suction of Process Air

Compressor. This shall cool the inlet air of Process Air Compressor from 46°C to

15°C, resulting in saving of NG being used as fuel for Gas Turbine drive of

Process Air Compressor. The heating medium in VAM machine shall be process

condensate.


(V) Running of one BFW pump with motor in place of turbine whereas

another BFW pump shall be run by turbine

Existing operation philosophy of running 2 Condensing Turbine driven BFW

Pumps shall be changed to new operational philosophy of running 1 Condensing

driven BFW Pump and 1 motor driven BFW pump. With this, the energy loss to

cooling water through condensing load of condensing turbine would be stopped.


(VI) Replacement of existing combustion Air type preheater with new plate

type exchanger

Existing combustion air preheater made of carbon steel shall be replaced by a new

one using SS plates. This shall reduce leakages and also increase the heat

24 of 32


transfer efficiency. This way, primary reformer global efficiency is expected to

increase and stack temperature is also expected to decrease.


(VII) Installation of Fuel gas expander with power generator

NG fuel which is let down in existing system from around 40 kg/cm2g to 4

kg/cm2g, shall be passed through Fuel Gas Expander connected with power

generator for generation of electricity of around 1 MW.


4. Description of modifications to be carried out in Urea Plant of Aonla-II Unit:

(I) Replacement of existing CO2 Compressors by new higher efficiency

compressors

In both 31 & 41 Units of Urea plant, existing CO2 Compressor shall be replaced

with new CO2 Compressor of higher efficiency. This shall result in saving in steam

consumption in steam turbine drive of CO2 Compressor by around 10 MT/hr.


(II) Installation of Vapour Absorption Machine for the cooling of inlet CO2

gas to CO2 Compressor

A Vapour Absorption Machine (VAM) shall be installed in Urea-II plant to generate

chilled water required for CO2 Gas chiller to be installed at the suction of CO2

Compressor of Urea plant. This shall cool inlet CO2 gas of CO2 Compressor from

40°C to 20°C, resulting in saving of steam consumption in CO2 Compressor

turbines of 31 & 41 Units of Urea plant. The heating medium in VAM machine shall

be Ammonia-II process condensate and LP steam.


25 of 32


(III) Installation of Casale High Efficiency Trays (HET) in existing Urea

Reactors for achieving higher conversion

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays

(HET). The function of the HET trays is to increase the CO2 conversion, by

improving the heat and mass transfer phenomena occurring inside the reactor.


(IV) Installation of Ammonia Preheaters

In both streams of Urea plant, Ammonia Preheater shall be installed in the

upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the

ammonia entering the reactor. The heating fluid shall be the mixture of vapors

coming from the top of LP Decomposer, and the solution coming from Distillation

Tower Reflux pumps. The exchanger shall result in energy saving by utilizing

energy of LP Decomposer off gas which in existing system is dumped to cooling

water. With this modification, heat requirement in form of MS steam in HP Stripper

shall reduce.


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CHAPTER-VI

The impact of proposed Revamp:

1. Energy Consumption:


Table-1




As per revised energy norms under new Urea Policy-2015, the Specific Energy

consumption norms has been reduced w.e.f. 1st June, 2015 to 31st March, 2018 to

5.656 Gcal/MT Urea for Aonla-I and 5.505 Gcal/MT Urea for Aonla-II and for

2018-19, 5.5 Gcal/MT Urea for Aonla-I & II.

Table-2

Unit Unit Energy Norms as per new Urea Policy 2015 for 2018-19


Difference


Modification/ Revamping of its Ammonia–Urea Complex has been undertaken to

reduce the Specific Energy consumption of Plant by 0.358 Gcal per MT Urea in

Aonla-I and 0.396 Gcal per MT Urea in Aonla-II.

2. Consumption of Raw Material

The overall consumption of Natural Gas is expected to reduce by 258,000SM3 par

day after revamp.

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3. Consumption of Utilities (Water, Steam & Power):

(i) Power Consumption:

Presently the total power requirement of IFFCO Aonla Unit 31.7 MW is met by

2 Nos. GTGs of capacity 25 MW (ISO) each. Although power consumption of

IFFCO Aonla Unit will increase by 4.8 MW due to change of turbine driven pumps

to motor driven pumps being more energy efficient; but overall consumption of

Natural Gas is expected to reduce by 258000SM3 par day after revamp. The

Power Balance before and after Revamp are as under:

Before Revamp

After Revamp

Increase after

Revamp

1. Generation MW MW MW

(i) GTG-HRSG- I 18.5 18.1 (-) 0.4

(ii) GTG-HRSG -II 13.2 18.4 5.2

Total Generation 31.7 36.5 4.8

2. Consumption

(i) Ammonia-I 2.30 4.40 2.10

(ii) Urea-I 2.82 2.82 0.00

(iii) Ammonia-II 1.98 5.49 3.51

(iv) Urea-II 3.25 3.25 0.00

(v) Ammonia-I CT 3.87 3.53 (-) 0.34

(vi) Urea-I CT 2.89 2.70 (-) 0.19

(vii) Ammonia-II CT 3.33 3.13 (-) 0.20

(viii) Urea-II CT 3.03 2.98 (-) 0.05

(ix) Offsites & non plant 5.90 5.90 0.00

(x) CDR 0.89 0.89 0.00

(xi) SG & CPP 1.40 1.40 0.00

Total Consumption 31.66

~ 31.7

36.49

~ 36.5

4.83

~ 4.8

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(ii) Steam (HP) balance:

The Steam Generation facilities consist of 150 MT/hr SG Boiler, 2 X 80 MT/hr

Waste Heat Boilers (CPP), 120MT/hr Heat Recovery Unit (Ammonia-II) with total

Steam Generation capacity of 430 MT/hr. The Steam Balance before and after

Revamp are as under:

Before Revamp

After Revamp

Decrease after Revamp

1. HP Steam Generation Quantity (MT/hr)

Quantity (MT/hr)

Quantity (MT/hr)

(i) GTG-1 80 80 0

(ii) GTG-2 80 80 0

(iii) HRU (NH3 2) 98 57 41

(iv) SG 55 0 55

313 217 96

2. HP Steam Consumption

(i) NH3 1 20 6.5 13.5

(ii) Urea-1 140 117.5 22.5

(iii) Urea-2 140 113 27

(iv) NH3 2 13 (-) 20 33

Total Consumption 313 217 96

(iii) Water Balance

The Water consumption of IFFCO Aonla Complex is 34,200 M3 per day. Out of

this 26,400 M3 per day is being used in Cooling Tower, 3,120 M3 per day is being

used in DM Plant, 1,392 M3 per day is being used for Service Water requirement

and 3,288 M3 per day is being used in Township. The Water consumption of

IFFCO Aonla Complex after Revamp will reduce to 33,720 M3 per day at same

production level (reduction by around 500 M3 per day) which includes 26,400 M3

per day is being used in Cooling Tower and 2,640 M3 per day is being used in DM

Plant. The Water requirement for Services and Township may remains

unchanged. Due to reduction in water consumption by about 500 m3/day, there

will be substantial reduction in wastewater generation. The Water Balance before

and after Revamp are as under:

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Before Revamp

After Revamp Decrease after Revamp

M3/ hr M3/ day M3/hr M3/day M3/hr M3/day

1. Raw Water supply 1425 34200 1405 33720 20 480

2. Consumption

(i) Cooling Tower 1100 26400 1100 26400 0 0

(ii) DM Plant/CPU 130 3120 110 2640 20 480

(iii) Service Water 58 1392 58 1392 - -

(iv) Township use 137 3288 137 3288 - -

Total consumption 1425 34200 1405 33720 20 480

3. Waste water generation

(i) C.T. Blow down 158 3792 157 3768 1 24

(ii) DM/CPU waste 80 1920 64 1536 16 384

(iii) Waste water from Ammonia/ Urea/SGP

- - - - - -

(occasional) (occasional)

Total waste water generation

238 5712 221 5304 17 408

(iv) Pollution Load:

The Natural Gas (NG) is being used as Feed and Fuel. The details of consumption

of NG as Feed and Fuel, before and after revamp has been derived as under:

Sr.

No.

Particular Plant/Section Unit Before

Revamp

After

Revamp

1 Feed Aonla-I Sm3/day 1056529 1038185

Aonla-II Sm3/day 1052734 1006952

Total Sm3/day 2109263 2045137

30 of 32


Sr.

No.

Particular Plant/Section Unit Before

Revamp

After

Revamp

2 Fuel Ammonia-I Primary

Reformer

Sm3/day 430340 376221

Ammonia-II Primary

Reformer

Sm3/day 673059 638683

SG Sm3/day 108791 0

CPP-I & CPP-II Sm3/day 463469 467013

Total Sm3/day 1675659 1481917

3 Total

(Feed +

Fuel)

Sm3/day 3784922 3527054

4 CO2

Emission

Aonla-I + Aonla-II MT/hr 144 127

It may be observed that the NG consumption will reduce by 258000SM3 per day

after Revamp. Hence, CO2 emission will reduce by 17 MT/Hr after Revamp.

(v) Production Capacity:

The production Capacity of Urea for the IFFCO Aonla Unit (Aonla-I & Aonla-II) will

remain the same as 6000 MTPD (21.90 lakh MT per annum considering 365

stream days). Similarly, the production Capacity of Ammonia for the Aonla Unit

(Aonla-I & Aonla-II) will remain the same as 3,450 MTPD (12.59 lakh MT per

annum considering 365 stream days).

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Annexure-1

LAY-OUT PLAN OF IFFCO AONLA UNIT

32 of 32


Annexure-2

Documents

Pre-Feasibility Report IFFCO Aonla - Welcome to …environmentclearance.nic.in/writereaddata/Online/TOR/11_Apr_2016...1 of 32 Pre -Feasibility Report for Modification/ Revamping of