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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Efficiency improvement and cost optimizationin Fertiliser Plant- Case Study
Shriram Fertilisers & Chemicals : Kota
Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Cement Works Shriram Cement Works Shriram Cement Works Shriram Cement Works
Fenesta Building Systems Fenesta Building Systems Fenesta Building Systems Fenesta Building Systems Shriram Polytech Shriram Polytech Shriram Polytech Shriram Polytech
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Location
475 km fromDelhi on themainwesternbroad gaugeline linefrom Delhi toMumbai
235 km fromJaipur onthe NH 12From Jaipurto Jabalpur
Location
Manufacturing FacilitiesPLANTS / PRODUCTS UNIT CURRENT
PRODUCTION LEVELS
Power MW 133
Fertiliser - Ammonia- Urea
TPDTPD
7001200
Chlor Alkali - Caustic Soda- Chlorine Liquefaction- HCl- SBP
TPD
325180175
35
Plastics - Calcium Carbide
- PVC Resin
TPD
340
200Cement TPD 1200
Shriram Polytech - PVC Compounds TPD 60
Fenesta - Window and Door profiles TPA 3000
Common Services Rly. siding, Mech. Workshop, CentralStores, HR, Adm., IT, Accounts etc.
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
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Fertiliser Plant
Fertiliser Plant
Commissioned in 1969 with a capacity of 450 TPD Ammonia / 700 TPD Urea
Expanded in 1974 to 600 TPD Ammonia / 1000 TPD Urea
Present Operation level is 700 TPD Ammonia / 1200 TPD Urea
Ammonia Plant based on Haldor Topsoe Steam Naphtha reforming process
Urea plant based on Stamicarbon's total recycle process with crystallisation route
for urea finishing
Ammonia plant modified to use Natural gas and naphtha in any proportion in 2006
Plant started using gas from Sep.07
Plant running fully on natural gas since May,2009
Focused on reducing energy consumption
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Philosophy of improving energy efficiency
Identification of process bottlenecksIncreasing capacity utilisation
Incorporation of available retrofits
Systematic equipment replacement plan
Reduction in shutdown frequency and duration
Relook into original design of equipmentModifications in compression equipment
Redesign of boilers and exchangersSimplification of piping and replacement to decrease PChange of packings
Philosophy of cost reductionSteam conservation
Reuse and recycle of water
Cooling water treatment
Water conservation
Use of right temperature
Trap management
Online leak sealing
Better procurement strategies for cooling water chemicalsBenfield system chemicals
Reoxidation cooler for V2O5Better house keeping and maintenance practices.
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
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Philosophy of cost reduction
Compressor partsImport substitution
Vendor development
In house NDT
Vibration monitoring
Reclamation and reuse of old parts
Replacements on condition monitoring results
Reclamation of Lubricating Oil
Recycle tank for Urea solutionUse of Aspen for process analysis and design
Ammonia Plant
Reforming section
Modifications / upgradations
Reformer catalyst tubes MOC changed from original HK 40 toManuarite in 2000. With this ID of tubes increased from 115 mmto 131.6 mm
A water spray tower was installed in 1980 at the downstream ofthe waste heat boilers to maintain HTS inlet temperature byadding BFW
The primary reformer induced draft fan was also replaced with ahigher capacity one so that proper excess air of 2.5% O2 couldbe maintained
In order to reduce the heat duty of fired preheater upstream ofprimary reformer, a steam fired heater was installed
A convection section was added in direct fired preheaters toutilise waste heat from flue gases
Additional heat recovery from the Reformer convection zoneby addition of extra rows of tubes in air and steam coils
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
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Carbon dioxide removal and beyond
25 mm Metallic (SS) Pall rings were installed in the top twobeds and 38 mm rings were installed in the bottom two beds inplace of ceramic rings
In order to reduce gas velocities at the CO2 Absorber outlet anadditional Separator was installed in 1979 itself . This helped inavoiding liquid carryover to the methanator
To reduce the temperature of the bottom to top potassiumcarbonate solution a larger size HPC cooler had to be installedin 1983
The synthesis gas compressors which are motor drivenreciprocating machines posed a bottleneck in achieving fullplant loads. The cylinder bores of 1st stage were increasedfrom 289 to 305 mm as there was some margin in the motor.This enabled a capacity increase of 9 %
Modifications / upgradations
Period between turnarounds
Earlier the plant turnarounds were taken on annual basis.However, the IBR later allowed operation of waste heat boilersupto two years.
With judicious planning of the overhauling of the reciprocatingcompressors the turnaround are now taken up once in two years.
This has improved availability of plant
Modifications / upgradations
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Installation of a radial ammonia convertorThe original TVA Type Axial Flow Ammonia Converter Basket wasdue for replacement in 1992
A radial flow converter was installed as replacement of old axialflow basket
This has made the running of smaller 120 TPD AmmoniaSynthesis loop unnecessary
Since the loop did not have any waste heat boiler, the energy wasbeing wasted to the cooling tower. This could be avoided with theinstallation of the radial converter
Modifications / upgradations
Feed stock conversionfrom
Naphtha to Natural Gas
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Why change to Natural gas
Energy cost constitutes about 80% of total cost of production of urea
After removal of APM from naphtha, its prices touched a very highvalue of Rs. 55,000/MT
Gas is a clean fuel as compared to naphtha
Gas is cheaper as compared to naphtha
Reduced cost of production leads to improved competitiveness
Favourable government policy for feedstock changeover
Reduced subsidy outgo
Conversion to Natural Gas
Modifications done in the plantto enable it
touse natural gas
Conversion to Natural Gas
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
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Replacement of all 252 burners from self aspirating naphtha firedburners to forced draft Natural gas / Naphtha fired burners
Installation of a Combustion Air preheater
This was necessary as the reformer furnace was originally designedfor 450 TPD only and it was difficult to fire sufficient heat withoutthe preheating of combustion air
Installation of a new feed Natural Gas preheater
Installation of new FD Fan and ID Fan at ground floor
Installation of fuel NG preheaters
Replacement of Steam Naphtha Coil and inlet distribution headersfor steam naphtha mixture going to the catalyst tubes
Removal of BFW Coil from convections section of primary reformerfurtnace
Conversion to Natural Gas
Control system upgradation
35 year old pneumatic controls required frequent maintenance andwere facing obsolescence
More accurate control helps in better optimization of plant parameters
Temperature scanner was also error prone and inaccurate
Plant interlocks were relay based
Old pneumatic controls replaced by state of the art Digital control System
This has enabled
Centralised Operation MonitoringProcess behaviour analysisMonitoring of Alarm managementProcess history storage
Conversion to Natural Gas
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
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DCS Chosen isEmersons Delta V system
Plant safety interlocks have been implemented in integrated Delta - V SISwhich is TUV approved system for SIL3 applications.
Salient features are
1100 Nos I/OsEase of operationTrends , process history, alarms available.Built on commercially available personal computers as work station andengineering satations.Windows platformProven ethernet communication technologyScalable to add more controllers and operating stations as required
Conversion to Natural Gas
SIL safety system
Foundation field bus
Latest technology foundation field bus has been used for temperatureSignals and few pressure and flow monitoring requirements.
Asset management system
Delta V AMS suite has been installed for centralised configuration ,diagnostics, maintenance and history record for HART and FF fielddevices.
Operator interface
5 Operating stations with 19 LCD monitors in a control roomScreens interchangeable in all respectsOperator can scroll through the entire plant seamlessly.
Conversion to Natural Gas
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
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Redundancy
100% plant availability ensured
Controller 1 HDS, Gas Purification and synthesis sections
Controller 2 Primary and Secondary reformer and LNG system
All critical Inputs/outputs are connected to redundant modules
Hazardous area interface
Input cards are Delta V inherently safe . However, as a precaution
i/o isolators for all hazardous ares have been instal led.
Old pneumatic controls replaced by state of the art Digital control System in 200
Conversion to Natural Gas
Old pneumatic controls replaced by state of the art Digital control System in 2006
Systematic effort to optimise the operation and with use of Natural Gas ,the energy consumption has been reduced significantly
7.3257.447
7.7147.779
7.857.887.85
7.81
7.97
8 . 0 9
8. 28.15
8.19
8 . 4 3
8 . 2 5
8 . 3 5
8.53
8 . 3 8
8.52
9 . 0 2
7.3
7.5
7.7
7.9
8.1
8.3
8.5
8.7
8.9
9.1
9.3
9 1
- 9 2
9 2
- 9 3
9 3
- 9 4
9 4
- 9 5
9 5
- 9 6
9 6
- 9 7
9 7
- 9 8
9 8
- 9 9
9 9
- 0 0
0 0
- 0 1
0 1
- 0 2
0 2
- 0 3
0 3
- 0 4
0 4
- 0 5
0 5
- 0 6
0 6
- 0 7
0 7
- 0 8
0 8
- 0 9
0 9
- 1 0
1 0
- 1 1
MKCal/MT Urea
Energy performance of the plant
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
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Session III III/
Old pneumatic controls replaced by state of the art Digital control System in 2006
Focus on reducing R & M Cost
12.24
13.85
12.312
12.33
14.84
5.25.8
4.7
7.5
5.7
10.7
7.5
10.0
8.3
11.0 10.5
12.911.5
9.7
12.9
13.1
8.0
0
2
4
6
8
10
12
14
16
18
20
8 8
- 8 9
8 9
- 9 0
9 0
- 9 1
9 1
- 9 2
9 2
- 9 3
9 3
- 9 4
9 4
- 9 5
9 5
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9 6
- 9 7
9 7
- 9 8
9 8
- 9 9
9 9
- 0 0
0 0
- 0 1
0 1
- 0 2
0 2
- 0 3
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- 0 5
0 5
- 0 6
0 6
- 0 7
0 7
- 0 8
0 8
- 0 9
0 9
- 1 0
1 0
- 1 1
( P )
Avg. inflation rate during last 7 years 5.18% per yearGrowth rate R & M Cost during last 7 years 0.5% per year
R & M Cost contained to below inflation rate Reduction in real terms
Rs.Crs/Yr.
Maintaining Plant Health with min. Capex
1.9
1.8
2.813.72
6.158.7
8.1
9.6
2.2
8.4
4.3
18.2
6.0
34.7
6.68.0
6.74.4
1.8
30.4
1.10.92.0
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
8 8
- 8 9
8 9
- 9 0
9 0
- 9 1
9 1
- 9 2
9 2
- 9 3
9 3
- 9 4
9 4
- 9 5
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- 0 0
0 0
- 0 1
0 1
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- 1 0
1 0
- 1 1
( P )
R
s . C
r s
.
Average Capex Rs. 7.8 Cr./Year
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
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Old pneumatic controls replaced by state of the art Digital control System in 2006
The way forward - Energy savings schemes
S.No.
Scheme Expected energysavings
MKCal/MT Urea
A. AMMONIA PLANT
1 Heat Exchange Reformer (KRES) 0.32
2 Additional cell in cooling tower 0.04
3 Chiller at synthesis gas compressor suction 0.02
B UREA :
1 High Efficiency Combined (HEC) process for Ureaor 1st stage heat recovery
0.16
2 Evaporation route for Urea Plant 0.073
3 Additional cell in cooling tower 0.04
4 Natural Draft prilling tower 0.02
5 DCS and N/C Metering for urea plant 0.01
Total (A+B) 0.683
Thank you
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Efficiency improvement and cost optimization inFertiliser Plant- Case Study
K M Tandon
Session III III/
Urea concession price
*
11771
8751 92809884
12183
18018
23178
19995
8000
10000
12000
14000
16000
18000
20000
22000
24000
SFC, Kota Pre-92 -gas
Post-92 -gas
Mixedfeed
Post-92 -Naph.
Imported FO/LSHS Pre-92 -Naph.
Rs./MT Urea
Comparison with other Indian plants and imported Urea