GSFC Energy Efficiency

Presented by :
M.N.Tekchandani
Chief Manager
GNFC Ltd.
Date : 26.02.2015
About GNFC Ltd.
2/27/2015
GNFC Ltd
Gujarat Narmada Valley Fertilizers & Chemicals Limited.

Bharuch Gujarat
Joint sector enterprise promoted GOG & GSFC ltd, Public.

Diversification :
Fertilizers such as ANP & CAN,
Industrial chemicals such as Methanol, Formic Acid, Acetic Acid, Nitric
Acid, Aniline, TDI, Ammonium Nitrate
Information Technology.
Certified Emission Reduction (CER) Company: 40,663 certificates for N2O
Abatement Project in Weak Nitric Acid (WNA) Plant, as well as 47,540 VER
for its 21 MW Wind Mill project in Kutch region of Gujarat.
CSR: Narmada Rural Development Society
Rs. 2001.57 lacs incurred in the year 2011 to 2014.
Mobile medical van, Nutrition Project, Vocational training center,
Model school project, safe drinking water for villages.
Camps for Blood donation, eye donation, handicapped,
Running School and College,
Relief assistance during natural calamities
2/27/2015
GNFC Ltd
ENERGY CONSERVATION STRATEGY AT GNFC

1. Selection of Technology
8. Employee Suggestion Schemes
2. Reliability Improvement
9. Renewable Energy
3. Up gradation of Technology
10. Energy Cell
4. Monitoring of Consumption
11. Awareness program
5. In house capability
6. Energy Saving Schemes

7. Energy Audits
1. Selection of Technology
Plant
Urea
Technology
Saipem, Italy
Ammonia
Linde Germany, Haldor

Topsoe -Denmark, Texaco
Ammonium Nitrophosphat
Calcium Ammonium Nitrate
Formic Acid
Acetic Acid
Con. Nitric Acid
Weak Nitric Acid/ Ammonium
Nitrate
Methanol
BASF, Germany
UHDE, Germany
Kemira OY, Finland
B.P.Chemical,UK.
Plinke, Germany
UHDE, Germany
Toyo,Japan
2. Reliability Improvement
Identify equipment system limitation.
Sustained operation.
CO Shift section revamp.

Gasifier Quench ring modification.
Addition of one new chimney in Boilers.

Additional feed oil pump in Ammonia plant.
Refrigeration compressor modification to reduce speed
below MCS.
Addition of Third Gasifier
3. Up gradation of Technology
A. New Catalyst basket S-50 Installation : Ammonia Plant

B.
C.
D.
E.
Syn. Section for reducing steam consumption

Pre Decomposer and Pre Evaporator Concentrator in
Urea Plant : For converting waste heat into steam
Isothermal Reactor : Improving energy Recovery in
Methanol-II plant Reactor section by replacement of
Axial Quench Type Reactor with of Isothermal Reactor
Revamp of Ammonia plant : for Feed stock conversion
(Fuel Oil to Natural Gas).
Gas Turbine based Co-generation CPSU. : Heat rate
reduced to around 2700 kcal/kWH
3. A: Installation of S-50 converter

Installation of S-50 converter along with
additional waste heat Boiler and newly
designed BFW prehaeater: The synthesis
gas from existing Ammonia synthesis
convertor R-701 is feed to new waste heat
re-boiler E-703M for recovering heat of
reaction. It is subsequently charged to new
Ammonia Synthesis converter R702 (S50). Exit synthesis gas from R-702 is fed to
existing waste heat boiler E-703. BFW
prehaeater E704 redesigned and replaced
for higher heat recovery.
Total investment, Rs. 5666 Lakhs
First year energy cost savings, Rs. 1924.6 Lakhs
Energy consumption before : 4.458 MT of HPSH Steam /MT Ammonia
Energy consumption after : 4.068 MT of HPSH Steam /MT Ammonia
3. B: Urea Revamp
Investment : Rs 2186 Lacs
Total Savings : Rs 468.14 Lacs/
Year
Urea Process was modified
with MP Pre Decomposer and
Urea
Pre
Evaporator
Concentrator installation for
converting waste heat into
steam.
MP Pre Decomposer
3. B: Urea Revamp Block Diagram
HP
Section
Modification
MP
Section
LP
Section
Modification
Vacuum
Section
Prilling
section
Pre decomposer
- MP pre decomposer
- Condensate collector
- Steam jet pump
Pre evaporator concentrator

- Pre concentrator
- Urea solution pump
- Vacuum system
3. C: Methanol-II Revamp
Investment : Rs 9600 Lacs

Total Savings : Rs 220.29 Lacs/ Year
Improving
energy
Recovery
in
Methanol-II plant Reactor section by
replacement of Axial Quench Type
Reactor with of Isothermal Reactor ,
resulting in 28 kg/cmg - Saturated
Steam generation @ 23 - 24 MT/h at
full load of plant. Installation of energy
efficient 3 column distillation system
(Methanol Distillation Unit - MDU) to
save steam and electricity and
replacement of air preheater resulted
in overall saving of Steam, Power and
Natural Gas.
4. Monitoring of Consumption
Review of Specific energy consumption at top

management level.
Addressing Energy issues :
Fuel management.
Operation of boilers and other furnaces.
Performance of steam and condensate system.
Performance of compressed air network.
Cooling Towers Performance evaluation and
monitoring.
Performance of rotating machines.
Electrical load management system and lighting
load.
Continuity in plant operation.
5. In house capability
Infrastructure
Technical Services group
Process Design and Simulation
Design & Construction Group
Piping ,Mechanical, Electrical,

Instrumentation and Civil Design,
Construction
PMG Group
S/D schedule, production budget, Hazop,

Safety, Lube oil, plants performance review.
Sr No.
1
2
3
4
5
6
7
Software Application
Software
Purpose
Aspen
Simulation
Chemcad
Simulation
HTRI
Heat Exchanger Design
HTFS
Heat Exchanger Design
Hysis
Simulation
Sinet
Simulation
Auto CAD
Drawing & Engg.

Aniline/TDI Plant: 6" line from
utility plant to ANI/TDI complex is
installed to stop air venting by
stoppage of one compressor.
:
Power saving
Total investment :
1460 MWh/Year.
Rs. 41 Lakhs
CNA Plant: Provision of Variable

Speed Drive for 50K060 blower.
:
Power saving
Total investment :
222000 kWh/Year
Rs.6.0 Lakhs

Ammonia plant: Improvement in Fan
Operating Efficiency by Revising Fan
specifications
to
match
actual
operation.
Power saving
:
39 kW
Investment
:
Rs 3.82
Ammonia plant: In Ammonia plant,
power saving achieved by removing
one of the impeller from MP BFW
multistage pump P-1302.
Power Saving :
514800 kWh
Total investment :
Rs. 1.0 Lakhs

Urea
Plant:
Additional
small
capacity Pump P-2 C was installed to
save energy at higher plant load.
Power Saving
: 10.32 Lakh kWh
Total investment
: Rs. 350 Lakhs
Ethyl Acetate Plant : With the help

of change in blade angle of Cooling
Tower Fans, one of the cooling water
pump was stopped .
Power Saving
556910 kWh
Total investment
Rs. Nil

Hazardous Plant: Total 71 defective traps/valve /fittings/
coupling and line leakages were indentified. 10 traps
replaced with new one, reduction in steam consumption of
LP steam @ 1 MT/Day in Hazardous plant
7. Energy Audits
Internal Audits & Surveys
Walk Through Audit
External Audits- Legal and Voluntary
Internal Audits and Surveys

Fans/Blowers
Steam Traps
Compressed Air
Cooling Towers
Cooling Water Pumps
Process Pumps for Possible Impellers trimming and Resizing
Insulation Surveys: steam piping & Boiler Insulation

Thermography of Boilers
Walk through Survey
Cooling Towers
Steam Trap
Energy audit of GNFC complex
Energy audits of GNFC complex by External Auditors

Year of Audit
2002
2005
2009
2013
Its various recommendations implemented.
8. Employee Suggestion Schemes
9. Renewable Energy
Installed capacity of Wind Power Generation 21 MW
9. Renewable Energy
Solar System is installed and working satisfactory at the
following locations.
Corporate Building:150 KW
Presently Guest House Solar system feeding 125 KWH / Day,
School solar System 625 KWH / Day and Corporate Solar
system 600 KWH / Day in the Electrical system.
10. Energy Cell

Forming of Energy Cell in 2001
Framing of Energy Policy
Energy efficient Purchase guide line

Mandatory Compliance (BEE,PAT)
Identification of Energy saving
potential
Energy Audit Support
Guideline for purchase of energy efficient items
Electric Motors
Electric Transformers, Heaters, Vibrators etc.
Criteria for Purchase of Rotating Machinery like

Compressors, Pumps, Blowers, Fans etc
Electrical Appliances like Lighting, Fans, Split and

Window Air Conditioners, Refrigerator, Coolers,
Geysers etc.
11.Awareness program
Awareness program from employee as
well near by school children

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Presented by :

About GNFC Ltd.

Gujarat Narmada Valley Fertilizers & Chemicals Limited.

Joint sector enterprise promoted GOG & GSFC ltd, Public.

ENERGY CONSERVATION STRATEGY AT GNFC

8. Employee Suggestion Schemes

10. Energy Cell

11. Awareness program

6. Energy Saving Schemes

Linde Germany, Haldor

CO Shift section revamp.

Addition of one new chimney in Boilers.

A. New Catalyst basket S-50 Installation : Ammonia Plant

Syn. Section for reducing steam consumption

3. A: Installation of S-50 converter

3. B: Urea Revamp Block Diagram

Pre evaporator concentrator

Investment : Rs 9600 Lacs

Review of Specific energy consumption at top

Process Design and Simulation

Design & Construction Group

Piping ,Mechanical, Electrical,

S/D schedule, production budget, Hazop,

6. Energy Saving Schemes

CNA Plant: Provision of Variable

6. Energy Saving Schemes

Rs. 1.0 Lakhs

6. Energy Saving Schemes

: 10.32 Lakh kWh

: Rs. 350 Lakhs

Ethyl Acetate Plant : With the help

6. Energy Saving Schemes

Internal Audits & Surveys

Walk Through Audit

External Audits- Legal and Voluntary

Internal Audits and Surveys

Insulation Surveys: steam piping & Boiler Insulation

Walk through Survey

Energy audit of GNFC complex

Energy audits of GNFC complex by External Auditors

8. Employee Suggestion Schemes

10. Energy Cell

Energy efficient Purchase guide line

Guideline for purchase of energy efficient items

Electric Transformers, Heaters, Vibrators etc.

Criteria for Purchase of Rotating Machinery like

Electrical Appliances like Lighting, Fans, Split and

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