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Energy Efficiency Opportunities at IPL

IPL, a global leader in fertilizer and explosive manufacturing with approximately 4,500 employees and 20 manufacturing sites, has focused on energy efficiency improvements across its major sites in Australia—Gibson Island and Phosphate Hill. Evaluations from 2007 to 2009 led to significant energy-saving opportunities, like the implementation of CETEK coating in heaters, resulting in a 6% reduction in fuel gas consumption. Comprehensive analyses and site visits facilitated informed investment decisions, highlighting the importance of assessing downstream impacts to maximize operational efficiency.

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Energy Efficiency Opportunities at IPL

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  1. Energy Efficiency Opportunities at IPL

  2. Company Overview • IPL is a Global Fertiliser and Explosive Manufacturer • Approximately 4500 employees • 20 manufacturing sites worldwide • Australian energy use 24.0PJ in 09-10 (inc feedstock) • 96% of energy use from 2 Sites: Gibson Island (Brisbane), Phosphate Hill (NW QLD) • The Ammonia plant is the major energy user on both sites

  3. EEO in the First Cycle • Gibson Island assessment 2007 - 2008 • Phosphate Hill assessment 2008 - 2009 • After initial assessments, subsequent work focused on progressing identified opportunities • Some opportunities require a full plant shutdown in order to implement. This activity only occurs 4 yearly

  4. Opportunity Identification Identification • Major opportunity identified in 2007 at Gibson Island workshop was coating of primary reformer with CETEK coating (a fired heater) • The coating is sprayed on to the furnace wall, and improves heat transfer to the tubes • Benefits are site specific • The project had been discussed in the IPL case study as a potential project being evaluated

  5. Opportunity Identification • Looking through inspection port into radiant section • Energy is radiated from the flame and wall to the tubes

  6. Opportunity Identification Gathering Information • Initial cost benefit analysis showed good payback • Concerns about the benefit of the technology for the specific design of furnace • Site visit by 3 staff to visit a similar plant with the coating in order to validate the claims • This visit revealed coating was working in a similar plant and gave confidence to request Capital for the proposal

  7. Additional Opportunity Gathering Information • Review of impact on modification to other aspects of the furnace • Specifically effect on downstream units, and potential to increase energy use in other areas was of concern • A mass and energy balance of the specific area of concern was commissioned • This study revealed that a downstream coil was significantly underperforming (another EEO opportunity)

  8. Additional Opportunity Gathering Information • Information from the study on the coil, was used to guide decision making • A number of alternative configurations was investigated to determine optimum scenario • The superheat coil was entirely replaced • Other potential impacts of plant performance (waste steam) reviewed

  9. Post Implementation

  10. Post Implementation - Outcome Measured Results • Reduced firing pressure in main furnace • No firing in superheat section • Total reduction of 600GJ a day in fuel gas flowrate for two projects combined • 6% reduction in fuel gas to furnace for constant feed

  11. Learnings • Business case for opportunity was strengthened by the considerable work put into evaluation stage • Study on downstream impacts revealed further opportunities • Involving site team and knowledge critical • Benefits matched well with that predicted from modelling

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