RECENT EFFORTS IN ENERGY CONSERVATION BY FERTILISER INDUSTRY

1. RECENT EFFORTS IN ENERGY CONSERVATION BY FERTILISER INDUSTRY Dr. S. Nand Director (Technical) Fertiliser Association of India New Delhi tech@faidelhi.org

2. Capacity and Production of Major Fertiliser Products (2007-08) India is the third largest producer of fertilisers in the world

3. Relative Energy Intensity Of Fertiliser Industry (Indicative Figures) continued..

4. Relative Energy Intensity Of Fertiliser Industry (Indicative Figures) • Ammonia-Urea segment of the industry is more energy intensive accounting for 84% of total energy consumption in the sector. • In the ammonia-urea segment, production of ammonia accounts for 80% of the total energy required for production of urea.

5. Characteristics of Operating Ammonia Plants

6. Characteristics of Operating Urea Plants

7. (1987-88 to 2007-08) 10

8. (1987-88 to 2007-08)

11. Feedstock wise Capacity and Energy Consumption in Operating Ammonia Plants (2007-08)

13. BENCHMARKING WITH WORLD PLANTS (Energy consumption of Ammonia) For the year 2002-03 Most ammonia plants (>90%) in the IFA survey are based on NG as feedstock. Almost 40% of Indian capacity was based on less efficient naphtha and fuel oil. Still average energy consumption of Indian plants is comparable to the world average. Indian gas based plants are more efficient than the world plants.

14. ENERGY CONSERVATION SCHEMES – RECENTLY IMPLEMENTED

15. REFORMING • Additional heat recovery in reformer convection zone e. g. • New BFW coil in convection section • Air pre-heater • Feed Gas Saturator

16. SHIFT • LTS Guard Bed with heat recovery • HTS & LTS Converter revamp with radial or axial-radial converter catalyst basket

17. CO2 REMOVAL • Single stage to two stage regeneration • Use of more efficient packings • Replacement of solution • Hydraulic turbine

18. SYNTHESIS • S-50 and S-300 Converters • Additional gas purification • Liquid ammonia wash of makeup synthesis gas • Molecular Sieve drying • Chilling of Makeup synthesis gas

19. MOVING MACHINES • Modification of internals of compressors • Modification or replacement of turbines • Chilling of suction air to air compressor

20. ENERGY SAVINGS

21. ENERGY SAVINGS SCHEMES IMPLEMENTED AT IFFCO AONLA II

22. ENERGY SAVING SCHEMES IMPLEMENTED AT IFFCO KALOL • Conversion of ID fan turbine from back pressure to condensing type • Revamp of CO2 removal system to 2-stage MDEA process • LTS Guard with BFW Pre heaters • Drying of makeup gas (ammonia wash) • S-50 radial flow converter with MP Boiler • Synthesis gas compressor LP/MP modifications Total Energy Savings 0.837 GCal/MT ammonia i.e. ~9%

23. Conclusions contd… • Average energy consumption has been reduced from 12.48 in 1987-88 to 8.97 GCal/MT in 2007-08 • Average energy consumption for urea has been reduced from 8.87 to 6.29 GCal/MT over the same period. • Improvement has been possible due to more efficient feedstock, better technology in new plants, modernisation of old plants, improved operating and maintenance practices

24. Conclusions • By and large, Pricing Policy encouraged investment in new capacity and energy saving schemes. It is expected that policy would continue to encourage investment in energy saving schemes • Energy conservation schemes continued to be implemented as an on-going efforts in spite some drawbacks in the pricing policy. • There is need for clear incentives for energy conservation in pricing policy.