Presentation for CII National Award on “EXCELLENCE IN ... Award... · Ammonia Plant Urea Plant ... Innovation - A way of our life (Design Stage) ... Neem Coated Urea Li-Br Chiller

Presentation for CII National Award on “EXCELLENCE IN ENERGY MANAGEMENT - 2010”

01-02 Sep, Chennai

Naresh RustagiArindam Ghosh

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The Glorious Tatas• Group Turnover (2009-10) : $70.8 Billion

• Contributes to 5.5% of India’s GDP

• Operations in more than 40 countries across 6 continents

• Total Number of Employees : >357,000

• Conglomerate of 90 companies in 7 Business Sectors:

• Materials• Energy• Chemicals• Services• Consumer Products• IT & Communications• Engineering

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Tata Chemicals

• Urea complex at Babrala commissioned in Dec, 1994• Urea complex at Babrala commissioned in Dec, 1994• Tata Chemicals Established in 1939 at Mithapur, Gujarat

M umbai

D elh i

Mithapur

Babra la

Haldia

Urea

DAPNPK

Urea Manufacturing Process

Hydrocarbons

Bagged Urea

Rail: 70%

Ammonia

Power & Steam

BaggingUrea

De-mineralisation

NH3

CO2

Dispatch

Urea

Ammonia storage

Cooling towers

Inert gas

Instrument air

Road: 30%

HBJ Pipeline

Urea PlantAmmonia Plant

AirSteam

Debottlenecked the plant capacity from 2620 TPD to 3500 TPD in 2008

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Care

Integrity Safety

Excellence

InnovationInnovation –A Way of Life

Three pronged strategy for achieving energy efficiency

• Energy Efficient Integration of the processes / operations• Energy Efficient Operations • Energy Efficient Design

Our APPROACH …….

Our Core Values

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Innovation - A way of our life (Design Stage)

Selected Unique and Pioneering Energy Efficient Design concepts for the First time in Nitrogenous Fertilizer Industry

1. Two converters for Ammonia synthesis (S-200+S-50)

2. MT/LT Shift conversion combination

3. Unfired super heater for KS steam resulting in lower Ammonia plant SEC

4. Dual stage & dual activator for efficient CO2 removal process

5. Major drives (>250 KW) on motors (including ID/FD fans) to utilize the higher

efficiency of motors as compared to steam turbine driven drives

6. Improved waste heat recovery in urea plant by installing Pre-vacuum

Concentrator , NH3 & Carbamate Preheaters

7. Lower urea content in waste water by installing Urea scrubber

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2001.. Redefining Urea CO2 compressor Anti-surge controller control parameters

2002.. BFW Pump turbine replacement with motor

2003.. CO2 compr seal losses reduced by injecting air in the vent line

2004.. Additional Urea Trays to increase conversion efficiency

2004.. Urea Plant off gas from C-03 to Pr Reformer as fuel

2004.. NG fuel Preheating through E204 along with NG Feed

2005..Advance Process Controller (APC) implementation in ammonia

2006..Additional E-602 DM Water preheater

2007..APC implementation in Urea plant.

2008..Boiler Blowdown waste ht. recovery. by pre-heating process cond.

2008..Stage blinding of BFWP (P-601A) to reduce power consumption

Innovation - A way of our life (Post Commissioning)

Key Operational Improvements

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Innovation - A way of our life (World class Performance)

5.30

BOC (IGCL)

Current Tech Best

5.38

Energy Efficient Operation……

World’s best plant for our technological supplier

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CHALLENGE

5.127 Gcal/MtOUR BEST

Energy Efficient Operation……Challenge after Debottlenecking

First fortnight energy consumption of 5.35 Gcal/Mt as against expected value of 5.25 Gcal/Mt ACTUAL

To bring down SEC back to best achieved figures with Higher Production of 12.5 Lakhs MT Urea

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Energy Conservation Efforts- Post DebottleneckingPROJECT

v Variable Frequency Drives (VFD)s for Ammonia pumps in Urea plants

v Running on single Gas turbine by modifying trip logics and ensuring ISO condition operations

v Old Cooling towers major repairs leading to 1.5 deg. Cimprovement in supply temperature

v Activated Carbon replacement in GV filtersv Remodeling of Advanced Process Controllers in Ammonia

and Urea plants v Improvement in KS steam generation in loop boiler by

increasing first ammonia converter R501 second catalyst bed inlet temperature (05TE27) by 10°C

SAVING (Gcal/Mt)

0.005

0.13

0.02

0.002

0.014

0.002

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Energy Conservation Efforts- Post DebottleneckingPROJECT

v Reduction in Waste water Reflux Drum Vent Valve opening (11PV165)

v Modify Connection of MV-50 Cond Outlet line from Carbamate Condenser to Steam Cond. Tank

v Improvements for HRSG-01 Load increase from 103 to 105.5 TPH

v KS temperature increased from 508 to 513-514°C by minimizing passing of quench valve 02TV52 and increasing superheater (E207) outlet temp by 1°C

v Synthesis gas compressor suction pressure increased by 0.8 Kg/cm2

SAVING (Gcal/Mt)

0.004

0.001

0.002

0.008

0.007

Reduction of 0.195 Gcal/Mt SEC

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ENCON…..A deep rooted cultureNo of Projects

Total W/o Invest

Investment

Rs lacs

Energy SavingGcal / annum

07 - 08

08 - 09

09 - 10

1245

2720

Inv /Gcal-saving/yearINR

05 0 38.6 4.52

04 0 1120.2 41182

6208 6 30 48034

Rs Million /annum

3100

56.60

43.56

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Benchmarking

TCL is Benchmark in Nitrogenous Fertilizer sector for:

v Lowest Specific Energy Consumption

v Lowest Specific Water Consumption

v Lowest Specific Waste water generation

v SHE Performance

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Benchmarking - India’s Best Urea SEC (Gcal/MT)

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Benchmarking - World’s Best

• Last Survey ranking (Nov 2007) by Plant Survey International Inc, USA (an independent agency covering 33 plants worldwide)Parameters Unit – 1 Unit - 2

• Ammonia loss 1 1• Reliability factor 4 6• Electrical power usage 5 5• Net steam usage 8 13

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World’s Best – Urea Specific Energy

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Future Energy Reduction / Carbon Abatementprojects

Schemes Estimated Impact on Energy -

tons of CO2 per annum

APC for Service Boiler 0.674 Gcal/hr 1254.26

Syn turbine efficiency improvement

8.75 Gcal/hr 16245.03

21 Urea Stripper replacement. 0.656 Gcal/hr 1217.91

11 Urea Stripper replacement. 0.656 Gcal/hr 1217.91

CO2 compressor suction chilling

0.0112 Gcal/MT

3037.82

Equipment Energy Efficiency/Energy Efficient Buildings/Offices – New Efficient Machinery under LAMP

Recovery of Low Level waste heat/energy

Process intensification/integration /Heat Exchanger Network /SCM

New Project ideas Abatement Projects-

Babrala

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1) APC Remodelling of Urea & Ammonia Plant After debottleneck of plant

BenefitsEnergy Saving : 17230 Gcal /yrTotal Saving : 194.7 lakhs /yrInvestment : 25.0 lakhs

Ø Advance Process Control was first implemented on Ammonia process in 2005-

2006 and on Urea Process in 2006-07 in our plant.

Ø After de-bottlenecking, plant parameters have changed with increased

capacity.

Ø Study was done by our in-house technical team.

ØThe engineering & implementation of project was done by in-house Technical

team & Honey Well Inc. (Our technology Provider).

Ø This project has resulted into saving of Specific energy consumption of 0.014

Gcal / MT and improved Process stability Sigma level of key parameters.

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2) Synthesis gas compressor suction pressure increase by 0.8 Kg/cm2

BenefitsEnergy Saving : 8000 Gcal /yrTotal Saving : 91.0 lakhs /yrInvestment : Nil

Ø The idea of Synthesis gas compressor suction pressure increase was captured during the Brain Storming session .

Ø Higher the suction pressure, lesser is the steam consumption in the steam turbine.

Ø Study was done by in-house technical team to explore the possibility to increase the suction pressure of Synthesis Gas compressor and concluded that it can be further increased to 25.5 Kg/Cm2g from 24.7.

Ø The engineering & implementation of innovative idea was done in-house by the technical team.

Ø This innovative idea has resulted into saving of 1.22TPH of KS steam i.e. 0.0065Gcal/MT of Urea energy.

Ø The idea was captured during the Brain Storming session Ø The in-house idea validated by Process Licensor.Ø R501 second bed i/l temperature (05TE27) was running

395°C, the same was increased by 10°CØ This has increased differential temp across R-501 and

hence conversion across it has improved resulting into increased steam generation by 0.43 TPH. .

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3) Improvement in KS steam generation in loop boiler by increasing first ammonia converter R501 second catalyst bed inlet temperature (05TE27) by 10°C

BenefitsEnergy Saving : 2831 Gcal /yrTotal Saving : 32 lakhs /yrInvestment : Nil

S 200Converter

Steam

Steam

BFW

NH3 (L) NH3 (L)

NH3 (L)Purge Gas

Product AmmoniaMake-up

Gas

S 50Converter

Syn Gas Compressor

CW

Waste Water Generation (M3 / MT)

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ENVIRONMENTAL PERFORMANCE….Set the benchmarks

Water Consumption (M3 / MT of Urea)))

1.01

1.190.95

0.940.74

0.64

0.86

0.89

0.000.200.400.600.801.001.201.40

01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09

First Fertilizer Industry to get RC-14001 Certification.

De-BotProject & ATR

5.34 5.25 5.26 5.204.82 4.62 4.785.10

5.01

44.5

55.5

01-0202-0303-0404-0505-0606-0707-0808-0909-10First company to get BSC 5 star Rating for EMS in the World and3 years consecutively

1.011.19

0.95 0.9410.74 0.637

0.859 0.891 0.77

0

0.5

1

1.5

01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10

5.20Best of Comparison

Industry Average 6.8

Benchmark in Fertilizer industryfor water consumption

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CDM Projects

Three projects identified & Project Design Documents (PDD) preparation are under progress

Three Projects implemented

Total accumulated CERs approx : 14,138/ yr

Neem Coated UreaLi-Br ChillerCDR

Implemented Projects

Future Projects



All the Projects have been approved by UNFCCC and also 44,942 CERs are verified & issued by UNFCCC.

Two projects identified & Project Design Documents (PDD) preparation is under progress

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Two projects identified & Project Design Documents (PDD) preparation is under progress

CDM Projects Registered with UNFCCC

SrNo

Project Description CER per year

Verified CERs

1 Utilization of Urea plant MP section Off-gas as fuel in primary reformer 7226

29224(20-10-2008)

2 Pre-heating of fuel NG along with feed NG in reformer convection zone 1845

7778(20-10-2008)

3 Additional trays in Urea reactor to increase conversion efficiency 2827

7940(31-03-2007)

TOTAL 11898 44942

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SrNo

Project Description Expected CER per year

1 Provision of Chiller in Synthesis gas compressor and Process Air Compressor suction 9500

2 Variable frequency drive for Ammonia feed pump motors in urea plant 8000

TOTAL 17500

CDM Future Projects Implemented

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Driving Excellence through People Involvement,Teamwork and efficient methodologies

ProcessImprovement Techniques

Process Framework

Benchmarking

5 S

F M E A

ADAPT

R C A

C O Q

Integrated Management Systems (ISO 9001, 27001,14001 & OHSAS 18001)

Balanced Scorecard

Six-Sigma

SPC MANTHAN

KM

BSC model – SHE

RCM

Tata Business Excellence Model

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MONITORING……Measure, Analyze and Improve

• Comparison of critical parameters with daily checklistsCorrective & preventive actions for identified gaps

• Reliability centered maintenance using specialized formats like PS3LDAvoiding energy loss due to sudden breakdown of machines

• Energy measurement of motorsMeasurement of power absorbed by critical motors

• Weekly Energy consumption review by Senior managementNegative Variance is analyzed and action plans implemented

• Energy audits for Furnaces, Insulation and steam traps at defined frequencyTime bound corrective actions for gaps

• Daily balance of utilities consumption by Process EngineeringAwareness creation among the employees

• On-time measurement of Ammonia and Urea APCEnsuring optimum process operations.

• Sigma level calculation of critical process parametersCalculating performance of individual process units

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MONITORING……Measure, Analyze and ImproveDaily Energy Check List

Production Date:S N Description Unit Std. Value Actual Remarks1 Reforming Section

- Excess Oxygen (02AT11) % 0.8-1.2 - Burner Flame Condition Flat, No Smoke

2 CO2 Removal System / Methanation - Steam Required / Actual Mt / hr As per GV - Lean soln flow Required / Actual M3 / hr As per GV

6 Steam System - SiO2 in blowdown as per lab ppm 0.1 - 0.15 - KS vent condition (Visual) No Steam - 02PV302 op % 0 - KS/HS let down op % < 1

7 Process gas venting* if any % 0 Flare Condition (Visual)

- Backend No Flame8 Specific Energy

Sp. Energy (Feed) GCal/MT 5.81Sp. Energy (Fuel) GCal/MT 1.56Sp. Energy (Feed + Fuel) GCal/MT 7.37Sp Energy [incl utilities] - BSC target GCal/MT 7.734

Checked by : Reviewed by:

Ammonia Plant Energy Check List

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ISO 9001 and ISO 14001 Certification

• Year 2006 – Recertification audit by Intertek Quality Registrar

Year No of NC major

No of NC minor

No of corrective

actions

No of preventive

actions

Remarks

2007 0 0 0 - -

2008 0 2 2 Not required All closed

2009 0 4 8 Not required All closed

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RENEWABLE ENERGY ……Beyond the Business

Bio gas plant• 43 nos of Bio-Gas plant

commissioned• 08 Plants repaired

Solar Energy• Installed Solar Geyser in

94 houses of the township.• Installed One solar pump• Distributed 15 Solar Lights• Distributed 20 Solar Lanterns

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WASTE UTILIZATION & ENVIRONMENTAL PROJECTS……….Beyond the Business

Utilization of waste• 100 % Effluent generated from plant

used for watering of trees in Green Belt• Production of organic fertilizer (Vermi

Compost )• Bio-manure generation from garden

waste ,dry leaves & t/s waste

Environmental Projects• Carbon Foot Printing •Tree plantations 5000 Nos• Rain water harvesting• Segregation of township waste• Distribution of Guest House, Canteen

and Hostel mess waste for animal feed.

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AWARDS & ACCOLADESENERGY Awards in 2007-09

v FAI Best Technical Innovation Award 2007

v CII-National Award for Efficient Water 2007Management

v CII-National Energy Management 2007Excellence Award

v CII -Excellent water Efficient unit 2008- Within the fence

v CII - Excellent energy Efficient unit 2008

vCII -Excellent water Efficient unit 2009- Within the fence

vCII - Excellent energy Efficient unit 2009

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AWARDS & ACCOLADESSHE Awards in 2007-09

v Excellence in safety performance : 2009from FAI

v Pransha patra from NSCI : 2009

v 1st runner up award from IFA : 2008

v Surksha Purashkar from NSCI : 2007

v Sword of Honour from BSC, UK : 2005, 06, 07

v 5 Star rating from BSC, UK (Environ.) : 2005, 06, 07

v Five star rating in Environment : 2007sustainability

•Awarded Most Prestigious“Sarva Srestha Suraksha Puraskar”from NSCI for 2006-07. Awarded to Best amongst 400 applicants Beat Petrochemicals, Oil & Nuclear Sector Companies

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AWARDS & ACCOLADESSHE Awards in 2007-09

v Greentech Safety Gold Award : 2005, 06, 07

v ICC Aditya Birla award for Best : 2004-05, 2006-07 Responsible Care Company

Thanks

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