ADITYA BIRLA GROUP

THE GROUP – IN PERSPECTIVE

 Amongst largest and most reputed industrial houses in India

 Committed to the future of the country for over 50 years
 Powering growth through involvement in the core sectors
 Domestic market leaders in key businesses
 Anchored by 72,000 employees; Trusted by 700,000
shareholders
 THE GROUP TODAY

Aditya Birla International Joint

Retail Operations Ventures

• Aluminium • Thailand: VSF, Chemical,

• Copper Acrylic & Carbon Black
• Indonesia: VSF & Yarns
M.Cap: Rs. 1000 Cr • Malaysia: Palm Oil
• Cement
• VSF • Fertiliser • Philippines: Yarns
• VFY • Egypt: Carbon Black & Acrylic
• Carbon Black Fibre
• Textiles • Canada: Pulp
• Garments
• Australia: Mines
• IT/ ITeS
• • China: Carbon Black
BSL Insurance
• Idea
PIONEERS OF GLOBALISATION IN INDIA

• Manufacturing across 10 countries in 4 continents

– Globalization efforts initiated in 1970s
– Operations in India, Thailand, Malaysia, Philippines,
Indonesia, China, Egypt, Australia, Canada, and the United
States

VSF
Carbon Black
Metals
Chemicals
Acrylic Fibre
Spinning
IT/ITeS
Trading offices
 ABOUT INDO GULF FERTILIZERS

• Indo Gulf Fertilizers is one of the blue chip companies of ADITYA BIRLA GROUP,
which was commissioned in October 1988.
• The urea complex located at Jagdishpur industrial area of District Sultanpur, situated at
about 80 km from Lucknow on the National Highway No.56.
 The company is engaged in the business of manufacturing nitrogenous fertilizers under the
brand name of BIRLA SHAKTIMAN.
 Fertilizer complex has
 Ammonia plant based on Haldor Topsoe Technology.
 Urea plant based on Snamprogetti Technology.
 Service Boilers, Gas turbine, DM plant, Effluent treatment plant etc.
 The feed stock is natural gas which is supplied by M/s. GAIL through HBJ
pipeline.
 Company is committed to continual improvement in its environmental & production
performance.
 VISION - 2014

To Be a 2000 crores company with all our

products and agri-services as first choise of
end customers.
 HISTORY

 Commercial production started on 1st Nov 88.

 Project completed in record time of 36 months - 3 months ahead of schedule.
 Total project cost - Rs 701 cr. (520 Million US $)
 Diversified into Copper Business. Commercial Production started in March 1999 with
initial capacity of 0.1 Million TPA with an investment of Rs 1850 Crs. After
subsequent revamps capacity increased to 0.25 Million TPA. Presently undergoing
expansion for 0.5 Million TPA
 De-merger of fertilizer business from Indo Gulf on 12th Feb 03. Fertilizer became
independent business entity as “Indo Gulf Fertilisers Ltd” (IGFL).
 Merger of fertilizer business to Indian Reyon on 31 March, 2006 and form a new
business entity as “Aditya Birla Nuvo Ltd”.
 PRODUCTS

BRAND : “BIRLA SHAKTIMAN”

UREA - Gold NEEM COATED UREA – Krishidev

FARMERS’ FIRST CHOICE

SEEDS PESTICIDES

Fertilizers, Agri Inputs & Agri-Solutions Provider

 GEOGRAPHICAL LOCATION

INDIA

IGFL

HBJ GAS PIPELINE

GAS BASED FERTILISER
PLANTS

Indo-Gulf Located on Cross Country HBJ gas pipe line at Jagdishpur, Uttar
Pradesh, North India
 PROFILE

 Manufactures and markets UREA.

 Production Capacity Urea - 2620 MTPD, About 1 Million MT / Year

 For FY 2009-10, Turnover 1022 cr.

 Employs about 850 people and offers indirect employment to over 4000 people.

 Direct contact with over 0.3 million customers per year through service programs.

 Adopted over 350 villages, for community development

MANUFACTURING FACILITIES
 MANUFACTURING OPERATIONS
AN OVERVIEW

Maintenance Q&EC
Carbon Dioxide

Ammonia Ammonia Urea Urea Bagging

Plant Plant Plant

Natural

Steam
Power
Steam
Power

Power
Gas
Water

Power Plant
& Utilities 50 Kg Urea bags

Naphtha
General Engg.
Fire & Safety

Process Engg.
13
BRIEF PROCESS
DESCRIPTION

14
 AMMONIA PLANT
 INSTALLED CAPACITY 1350 MTPD
 REASSESED CAPACITY 1520 MTPD (April 2000)
 PROCESS LICENSOR
 AMMONIA HTAS, DENMARK
 PGR PLANT BHPV, INDIA
 CDR PLANT KTI, USA
 PROCESS TECHNOLOGY NG – STEAM REFORMING
 RAW MATERIAL FEED – NATURAL GAS
FUEL – NATURAL GAS, NAPHTHA
FEED/FUEL Ratio:70/30
Ammonia process is a highly complex in nature due to :
 Handling of highly toxic and explosive gases
 Temperatures and pressures in the process vary from extra high (1050°C/ 200 Kg/Cm 2) to
absolute low (-180°C/Vacuum).
 Use of catalysts (Zinc, Nickel, Chromium, Copper and Iron)
 Three high speed, high pressure turbo compressors being operated (Process Air Compressor:
13 MW, Synthesis Gas Compressor: 24 MW, and Ammonia Compressor: 3.0 MW).
 Tail gas from PGR Plant is processed in AGR Plant to recover Argon.
15
 AMMONIA PROCESS

AIR H.P.
STEAM
COMPRESSOR STEAM

DESULFU- PRIMARY SECONDARY WASTE HEAT SHIFT

RISATION REFORMING REFORMING BOILER CONVERSION

CO 2 TO UREA PLANT

REFRIG.
COMPRESSOR

TO UREA PLANT

SHIFTED CO 2 SYN. GAS AMMONIA AMMONIA

METHANATION
GAS REMOVAL COMPRESSOR SYNTHESIS

TO AMMONIA PLANT

16
 UREA PLANT

 INSTALLED CAPACITY - 2 x 1100 MTPD

 RE-ASSESED CAPACITY - 2 x 1310 MTPD
 PROCESS LICENSOR - SNAMPROGETTI, ITALY
 PROCESS TECHNOLOGY - AMMONIA STRIPPING
 RAW MATERIAL - CO2 AND AMMONIA
 Major process steps
– Urea synthesis & high pressure section
– Medium pressure section
– Low pressure section
– Vacuum Pre-concentrator & vacuum section
– Prilling section
– Process condensate treatment
– Specific Ammonia Consumption : 575 Kg/Te of Urea
– Specific CO2 Consumption : 750 Kg/Te of Urea 17
 UREA PLANT

HIGH MEDIUM LOW

PRESSURE PRESSURE PRESSURE
CONDENSER CONDENSER CONDENSER

HIGH MEDIUM LOW

U 33.8 % U 46.0 % U 63.3 %
REACTOR PRESSURE PRESSURE PRESSURE
PRESS.-159 Kg/Cm2 STRIPPER DECOMPOSER DECOMPOSER
TEMP.-190 °C PRESS.-145.5 Kg/Cm2 PRESS.-15.5 Kg/Cm2 PRESS.-3.5 Kg/Cm2
TEMP.-208 °C TEMP.-160 °C TEMP.-140 °C

CO2 (GAS) U 71.0 %

NH3 (LIQUID)
HOT
AIR
U 99.7 %
OVERHEAD CONDENSOR CONDENSOR
CONDENSOR

PROCESS VACUUM VACUUM PRE-

CONDENSATE EVAPORATOR CONCENTRATOR
TREATMENT VAC-.0.035 ATA VAC.-.0.35 ATA
SECTION TEMP.-137 °C TEMP.-101 °C
PRESS.-1.5 Kg/Cm2
U 84.0 % UREA
PRILLS

TREATED WATER
TO D.M. PLANT
TO
BAGGING
18
 UREA PLANT - PRODUCT QUALITY
SL. PARAMETERS SPECIFICATIONS ACTUALS KEY CONTROLS
NO.
UREA PRODUCT QUALITY

1 Nitrogen Content 46% (Min.) 46.3 %

2 Moisture 1% (Max.) 0.4 – 0.58% Maintaining proper Vacuum

in concentrators
3 Biuret 1.5% (Max.) 0.97 – 0.99% No excessive temperature in
decomposers/evaporators
4 Particle size 10% (Max.) 2.0 – 3.0% • Optimization of bucket
+ 2.8 mm speed
• Time bound changeover of
Particle Size - 10% (Max.) 0.5 – 0.9% prill bucket
1.0 mm • Scheduled cleaning of
scrapper
5 Crushing Load 600 gms./ prill 620 -630 gms/ • Maintaining lower prill
(Min.) prill temperature
• Use of additive above 65°C
prill temperature
19
 POWER PLANT & UTILITIES

STEAM GENERATION POWER GENERATION

1 SERVICE BOILERS 1 GAS TURBINE
 UNITS 01 + 01  UNITS 01 + 01
 CAPACITY 2x100 TPH (105 ATA,
 CAPACITY 2x18 MW
505°C)
 FUEL NG / NAPHTHA
 FUEL NG / NAPHTHA
 SUPPLIER
 SUPPLIER MACCHI, ITALY
TURBOTECHNICA

2 HRSG
 UNITS 01 2 DIESEL GENERATOR

 CAPACITY 1 x 55 TPH (38 ATA, 380°C)  UNITS 01

 FUEL NG  CAPACITY 2 MW
 SUPPLIER IDROTERMICI, ITALY  FUEL HSD
 SUPPLIER ENERDIESEL
20
 POWER PLANT & UTILITIES

RAW WATER TREATMENT EFFLUENT TREATMENT

 UNITS 02  UNITS 01
 CAPACITY 2 x 1150 M3/HR
 CAPACITY 103
 SUPPLIER GEO MILLER M3/HR
 FEED RIVER WATER
 SUPPLIER DORR
PRETREATMENT PLANT OLIVER
 UNITS 01
 FEED LIQUID/SOLID
 CAPACITY 1700 M3/HR
WASTE
 SUPPLIER GEO MILLER
 FEED TREATED RAW WATER
THRU’ 21 KM PIPELINE
DM PLANT COOLING TOWERS
 UNITS 03 + 01  UNITS 01 AMMONIA +
 CAPACITY 3 x 170 M3/HR 01 UREA
 SUPPLIER ION EXCHANGE,  CAPACITY
INDIA 24000+16000
 FEED APC,UPC,TC & SOFT M3/HR
WATER
 SUPPLIER
PAHARPUR,
INDIA 21
 POWER PLANT & UTILITIES

RAW WATER AMMONIA STORAGE TANK

 NO. OF TANKS 03  NUMBER 02
 CAPACITY 3 x 30000
 OLD TANK : COMMISSIONED IN
M3
1988 & HAVING CAPACITY OF
10000 MT
 NEW TANK : COMMISSIONED IN
DM WATER
 NO. OF TANK 01 2000 & HAVING CAPACITY OF

 CAPACITY 5000 MT
7000 M3

NAPHTHA STORAGE TANK

FUEL OIL STORAGE TANK  NUMBER 02
 NUMBER 02
 CAPACITY 10000 M3
 CAPACITY 10000 M3
7000 M3
7000 M3
22
 POWER PLANT & UTILITIES

GOMTI RAW WATER DM STEAM

RIVER WATER SOFTENER PLANT GENERATION STEAM
PLANT PLANT

SOLID AMMONIA COOLING

SOLID SLUDGE SEPARATION COOLING WATER
PLANT TOWER

COMPLETELY
ELIMINATED
BY ZEOLITE
SOFTENING
EFFLUENT UREA
KATHAURA NALLA TREATMENT COOLING COOLING
PLANT TOWER WATER

EFFLUENT FROM
AT PRESENT AMMONIA, UREA
EFFLUENT IS BEING & PPU
UTILIZED FOR
HORTICULTURE
PURPOSE
23
 BAGGING PLANT

 Bagging facility consists of 7 bagging streams, out of which 5 remain in

line and 2 remains as stand by.
 Each stream consists of one hopper, two Bagging machines and one
stitching machine.
 Capacity of each bagging stream is 44 TPH.
 Provision exists for loading in Trucks & Rail wagons through specially
manufactured mechanized loading arms.
 Urea storage facility (Silo) of 45000 MT is provided for diverting the entire
product in case of non availability of rakes & space for filled Urea bags.
 02 Nos. wet de-dusting system for dust collection and keep environment
clean. 24
 BAGGING PLANT

Urea Bulk urea Transfer Distribution

Prilling conveyors conveyor
Tower

Buffer
Screening
hoppers
section
(7 nos.)
SILO
CAPACITY
45000 MT Reclaimed
Weighing machines
urea
(14 nos.)
transfer
conveyor
Filling & stitching
(7 No. of streams)
Silo Diversion (Hrs)
Target Actual
Despatch Bagged urea Despatch
05-06 94 46 transfer
by Road by Rail
06-07 75 Conveyors &
20% 80% 25
loaders
 ARGON PLANT

• Argon is produced by cryogenic separation of tail gas from

PGR plant containing around 10% Argon.
• The plant is supplied by M/S BHPV with technical back up
from M/S Air-liquide France. The plant is designed to
produce 2.4 million sm3 Argon per annum liquid argon.
• Recently Argon plant was upgraded with installation of a
redundant compressor from ammonia plant resulting in
12% increase in Argon production.
• We are leading manufacturer of ultra pure Argon, Besides
producing Argon, nitrogen is also produced which is utilized
in the complex enabling the stoppage of inert gas plant. 26
 DESCRIPTION OF
SUPPORT FUNCTIONS
AND KEY ROLES

27
 PROCESS ENGINEERING
MANAGEMENT INFORMATION SYSTEM

DOF/FICC

GAIL
GAS DETAILS

LOGISTICS PE MAINTENANCE PRODUCTION Q&EC

DESPATCH B/D REPORT

PLANT DATA
ANALYSIS

DAILY WEEKLY MONTHLY QUARTERLY ANNUAL

ENERGY SHEET MPR
PRODN. FAX RG-1
PRODUCTION
MINISTRY C&F FAI MINISTRY TOP
REPORT TO
RG-1 MINISTRY FAI
MINISTRY
FINANCIAL FINANCIAL
MHO FAX MHO 28
 PROCESS ENGINEERING

SOURCES OF PROJECT CONCEPTUALIZATION

 BENCHMARKING

 PUBLISHED LITERATURE & INTERNET

 THINK TANK

TECHNICAL SUPPORT
 TROUBLE SHOOTING
 ASSISSTANCE IN CORE TEAM
 CATALYST EVALUATION
 MACHINE PERFORMANCE EVALUATION
PLANT PERFORMANCE MONITORING
 TO MONITOR THE OVERALL PLANT PERFORMANCE FOR
ACHIEVING THE IDENTIFIED TARGETS IN RELATION TO
PRODUCTION, RAW MATERIALS, UTILITIES & ENERGY
CONSUMPTION. 29
 GENERAL ENGINEERING

Key Functions
 Cost estimation of new schemes, provided by Process
Engineering Department.
 Preparation of specifications, detail engineering of piping,
equipment & isometrics.
 Project management
 Documentation of drawings and specifications of complete
plant since inception and updating time to time by
incorporating modifications through electronic media.
 Rendering services to maintenance and operation
departments.
Focus Area
 Optimization of project cost
 Adherence to Project Schedule 30
 MECHANICAL MAINTENANCE

Maintenance Practices
 Preventive or Time Based Maintenance
• Manufacturer Recommendation, Plant Experience & Insurance
Requirements
 Condition Based Maintenance
• Daily check List, On line and off line Condition monitoring &
equipment performance analysis.
 Identification & elimination of weak areas in plant with proactive
approach, using tools like TPM, COPQ, RCM & Six Sigma
 Learning from incidents at similar plants.
 Turn Around Maintenance Management
 Condition Monitoring Practices
• On-line vibration & temperature monitoring
• Off line vibration & temperature monitoring for all machines
• Off line monitoring as per weekly, fortnightly, monthly schedules
decided based on criticality, severity of operation etc
31
 MECHANICAL MAINTENANCE
Maintenance Practices
 Why-Why Analysis
• An analytical tool to identify root cause of abnormality by
questioning “Why” for probable causes to reach logical conclusion.
• Analysis of abnormalities/breakdowns having cross functional
implications, by cross functional team.
• Analysis of near miss incidents like abnormalities observed during
routine maintenance by grass root level person, in their pocket book
(KARAN VISHLASHEN PUSTIKA).
• Horizontal replication and training based on why-why analysis
recommendations, good to find, one point lessons etc.
 Cost Control
• Procurement from OEM sub-vendors, standardization & development
of alternate vendors for spares & consumables.
• Utilization of in-house expertise and developing local contractors.
• Recycling of lubricating oil wherever possible 32
 MECHANICAL MAINTENANCE

Reliability Centered Maintenance

 RCM practices are applied to equipments
• having recurring problems or high maintenance cost
• Which are critical for operation of plants
• Where failure may lead to hazardous consequences
 To improve equipment availability / reliability.
 By application of scientific analytical tools like FMEA and
visualizing potential failure modes, RPN is calculated
 Preparation & implementation of action plan for critical
failure modes
 Inculcates proactive approach in maintenance to avoid
failure
 At present, we have covered 11 equipments under RCM.
33
 MECHANICAL MAINTENANCE

Workshop Facilities
 IGFL workshop fully equipped to support plant maintenance, consists
of Machine, Fabrication, Auto and A/C shops with facilities for
• Precision machining, boring, drilling, milling
• Welding, Plasma Cutting, Stress Relieving
• Rolling
• Automobile Shop with material handling equipments
 Can fabricate small & medium size heat exchangers, pressure vessels,
spares
 Can handle erection up to 75 Tons at small heights and 3 Tons up to
50 Meters
 With fabrication of heat exchangers, pressure vessels, we could reduce
project implementation time and equipments fabricated in Workshop
are giving trouble free service.
34
 CONDITION MONITORING & N.D.T.

Key Functions
 Condition Monitoring & Non Destructive Testing of plant
equipment to improve reliability by prediction of failure which
results in maximisation of on-stream days in order to achieve
overall objective of the company.

 Quality Assurance to ensure quality during implementation of

plant improvement schemes / New Equipment erection &
commissioning, Inspection of equipment & spares during in-
house manufacturing.

 Compliance of Statutory Regulations as per Factory act & IBR.

35
 CONDITION MONITORING & N.D.T.
Departmental Activities - At a Glance
Leak Detection Hardness
in Gas Lines & Ferrite Magnetic Particle
Measurement Testing
Vibration Ultrasonic
Testing Dye Penetrant
monitoring of
Rotary equipment Testing

Skin Temperature Radiographic

measurement Testing

Spark Testing of
Thickness Coated Lines &
Measurement Vessels

Temperature
monitoring of
Steam Trap
Rotary equipment
Survey
Insulation
Ultrasonic testing at
Survey
Elevated temperature
Oil Contamination Boroscopic
Analysis Inspection
36
 INSTRUMENTATION

ROLE OF DEPARTMENT:
• TO MAINTAIN ONLINE INSTRUMENTATION PROVIDED FOR

MEASUREMENT, ANALYSIS & CONTROLLING OF PROCESS

PARAMETERS.

• TO MAINTAIN UPS SYSTEM TO ENSURE UN-INTERRUPTED POWER

SUPPLY TO INSTRUMENTS.

• TO MAINTAIN SAFETY INTERLOCK SYSTEM PROVIDED FOR THE

SAFETY OF MAN, MACHINE AND MATERIAL.

• CALIBRATION OF INSTRUMENTS TO ENSURE THEIR PERFORMANCE

WITHIN SPECIFIED LIMIT OF ACCURACY

37
 INSTRUMENTATION

INSTRUMENTATION SYSTEMS USED

• MICROPROCESSOR BASED SINGLE CONTROL LOOPS
• DISTRIBUTED CONTROL SYSTEM & SCADA SYSTEMS
• ADVANCED CONTROL SYSTEM
• EMERGENCY SHUTDOWN SYSTEMS
• PLCs
• ALARM ANNUNCIATION SYSTEMS
• EVENT SEQUENCE RECORDERS

CALIBRATION FACILITIES
• HIGH ACCURACY MASTER INSTRUMENTS AVAILABLE
FOR VERIFYING CALIBRATION OF INSTRUMENTS
• CALIBRATION OF INSTRUMENTS TRACABLE
TO NATIONAL STANDARD. 38
 ELECTRICAL DEPARTMENT
To AGR
Power from
132/11kv UPSEB grid 132/11kv
16 MVA 16 MVA

11 KV

11 KV

3.3 KV

TG-701 LOAD EDG-704 TG-702

19 MW 415 V 2 MW 19 MW

LOAD
• Own generation : 11KV 19 MW gas turbine generators (2 Nos.) – One running & One
kept as standby.
• Purchased power : From UPSEB grid at 132KV (4000kva contract demand) as standby
power (with automatic change-over facility within 4 sec., in case of own
generation failure)
• Emergency supply : From own 2MW 11KV Emergency Diesel Generator (to meet the
power demand for safe shut-down of plant in case of total power failure) 39
 ELECTRICAL DEPARTMENT

• Facilities in Electrical Workshop

 Rewinding of LT motors up to 110 KW
 Overhauling of LT / HT motors up to 1200 KW
 Protective Relay Testing
 High voltage testing
• Other systems maintained by electrical department
 Cathodic protection for protection of underground
cooling water pipes, tank bottoms against corrosion
 Communication system (Public address, intercom,
wireless, pager systems)
 Fire alarm system
40
 CIVIL MAINTENANCE - PLANT & TOWNSHIP

Civil Maintenance (Plant)

 Maintenance of Railway Siding - 9.40 Km
 Foundation & Structures related to modification jobs
 Maintenance of plant & buildings
 Corrosion protection of prill tower, DM plant, Conveyor
Gallery & Bagging plant.
 Refractory Lining Repair of Boiler Chimney
Civil Maintenance (Township)
 Maintenance of houses, public buildings & farm house etc.
 Furniture repair & maintenance
41
 Q&EC-DEPARTMENT

QUALITY & ENVIRONMENT

CONTROL DEPARTMENT

CUSTOMER
QUALITY ENVIRONMENT
SUPPORT
ASSURANCE CONTROL
SERVICES

42
 Q&EC - QUALITY ASSURANCE ACTIVITIES

 Quality assurance through monitoring & feedback for In-coming, In-

process & Final product.
 Calibration of analytical instruments & standardization of chemicals.
 Review of quality affecting parameters in process & final product.
 Skill development of people.
 R&D activities for quality/process improvement.
 Soil testing for macro & micro nutrients.
 Recommendation for optimum dose of fertilizers.
 Updation of specifications for chemicals & bags.
 Development of supplier partnership.
 Visit to suppliers and interaction for improvement.
 Complete internal customer satisfaction.
 Review of all Quality related activities in
- Daily plant meetings
- Weekly core committee meetings.
43
 Q&EC - ENVIRONMENT CONTROL ACTIVITIES

 Regular Environmental monitoring & feed back for controlling-

 Ambient Air Quality
 Work Environment
 Stack emissions Pollutants
 Liquid effluents Quality & Quantity
 Monitoring of Air & Water stream outsides the boundary.
 Liaison with Ministry of Environment & Forests,Central Pollution
Control Board,U.P.Pollution Control Board &FAI
 Active participation in formulation of charter on corporate
responsibility (CREP).
 Compliance of all statutes & regulations.
 Calibration of internal monitoring through independent & approved
laboratories.
 Periodical environment impact analysis of the complex.
 Monitoring of trees mortality rate & replacement.
 Review of all environment related activities in daily plant meeting, core
committee & MPR 44
LANDMARKS

45
 AWARDS & RECOGNITIONS

AWARDS YEAR

Suraksha Puruskar- 2004” of National Safety Council of India 2006

Corporate Social Responsibility Award by FICCI 2005
Chairman’s WCM Gold Award 2004
Deming Application prize 2004
Most Energy Efficient Unit by CII 2004
Green tech Safety Award 2004
Asia Pacific Quality Award 2003
Golden peacock special commendation award for Environment 2003
protection
7-Star Category Award for Special Contribution in Industrial 2002
Development in UP. 46
 LANDMARKS

AWARDS YEAR

First Fertilizer unit to achieve ISO-9002 certification 1994

Best Environment Protection Award by Fertilizer 1995 &

Association of India (FAI) 2000
Second Best Production Performance Award by National 1995-96 &
Productivity Council (NPC) 1998-99
First Fertilizer Unit to achieve ISO-14001 certification 1998

Best Production Performance Award by Fertilizer 1999

Association of India
TPM Excellence Award – First Category by JIPM, Japan 2000

IMC-Ramakrishna Bajaj National Quality Award – 2000

Certificate of Merit
IMC-Ramakrishna Bajaj National Quality Award – Trophy 2001
47
KEY DRIVERS AND
ACHIEVEMENTS

48
 KEY DRIVERS

 Maximizing Production & Energy

consumption/conservation/Effective steam balance.
 Gas Supply Management
 Cost effective initiatives - Chemical consumption,
Maintenance expenditure and Inventory
 Natural resource conservation & environment
protection.
 Safety.
 Product Quality 49
MAXIMIZING PRODUCTION
AND
ENERGY CONSERVATION

50
 UREA PRODUCTION – PAST PERFORMANCE
1200
1020 1042 GOVERNMENT RESTRICTION
ON PRODUCTION
1000 879 865 862
850

800
Lacs MT

600

400 355 348 326 332 328 329

200

0
98-99 99-00 00-01 01-02 02-03 03-04
AFTER RESTRICTIONS IN OCT’ 2000, ACTIVITIES WERE MORE FOCUSSED
ON ENERGY CONSERVATION. ENERGY CONSUMPTION CONTRIBUTES TO
75% OF TOTAL COST OF PRODUCTION. 51
 UREA PRODUCTION PERFORMANCE
AFTER GOI ALLOWED HIGHER PRODUCTION
1200
985 996 996
1000
800
600
356 *
349
**
400 335

200
0
'04-05 '05-06 06-07 P&B
NG/ Naphtha Ratio
Production ( '000 MT ) OSD
04-05 : 78 / 22
05-06 : 96 / 04
Longest Uninterrupted Operation of Ammonia plant for 615 days

* 05-06 - 8 days S/D from 25th Nov to 2nd Dec 2005 for Revamp Phase I
** 06-07 – 8 days Shut down taken in May ’06 for Urea Strippers replacement. 25
days S/D planned for Revamp Ph II in March/April 2007. 52
 UREA ENERGY - PAST PERFORMANCE
6.20 UREA ENERGY INCREASED DUE
TO LOW LOAD OPERATION
5.95
6.00 5.89
REDUCTION

OF 0.26 REDUCTION
5.80 5.69 OF 0.14
M KCal/MT

REDUCTION
5.55
5.60 OF 0.11

5.36
5.40

5.20

5.00
99-00 00-01 01-02 02-03 03-04

DESPITE LOWER LOAD OPERATION, THERE IS CONTINUOUS REDUCTION IN SPECIFIC ENERGY

CONSUMPTION. BROUGHT DOWN ENERGY CONSUMPTION FROM 5.95 MKCAL/MT IN 2000-01 TO
5.37 MKCAL/MT IN 2005-06 EQUIVALENT TO FINANCIAL GAIN OF RS 18 CRS/ANNUM . 53
 ENERGY CONSUMPTION REDUCTION
AFTER GOI ALLOWED HIGHER PRODUCTION
5.5
Energy in 05-06 is Lower by 0.044 MKCal/MT
Due to High
w.r.t 04-05 eq to financial gain of Rs 1.4 Crs
Use of Naphtha

5.5
5.42
MKCAL/MT

5.4
5.37

5.4 5.33

5.3
'04-05 '05-06 'P&B 06-07

Reduction in energy by 0.1 MKCal/MT results in financial saving of about Rs. 3

Crs /Annum 54
 ENERGY CONSERVATION JOURNEY
CUMULATIVE IMPACT
22 0.5

Savings 0.458
20 19.67
0.45
18.87

18
Investment
16.83 0.4

16
14.87
0.35

14
0.333
0.3
11.89
12

9.8 0.25
10

0.23

8 0.2
2001-02 2002-03 2003-04
Saving w.r.t previous year
Gain Rs Crs/ Yr Investment Rs Crs Eenrgy Saving MKCal/MT 55
 ENERGY BENCHMARKING
GLOBAL
8
7.3
7.2
7
1999-00 UREA PLANT BATTERY LIMIT
IGFL 6.4
MKCal/Te of Urea

6
5.3
5.1
5 4.6
3.9
3.8
4 3.6
3.4
8
3.1 7.3
7.2
3
7 2001-02 6.4

M KCal/Te of Urea
2 IGFL
1 2 3 4 5 6 7 8 9 10 11 6
5.3
Plants 5.1
5 4.6
3.9
3.8
4 3.6
3.4
3.1
3

Since 2001-02 we have 2

implemented many initiatives. 1 2 3 4 5 6
Plants
7 8 9 10 11

We are in touch with M/s PDC

Netherlands to re-conduct the
Benchmarking Study 56
 ENERGY BENCHMARKING
INDIAN PLANTS (2005-06)
Same Vintage Plant Latest Generation Plant
IGFL energy is lower by about
5.80 0.3 MKCal/Te w.r.t the average
5.78 of same vintage
5.80

5.70
5.63
5.60
5.60 5.55
M KCal/Te

5.47 5.48
5.50

5.40 5.37 5.37

5.30
5.20
5.20

5.10
OCFL NFL V1 IFFCO-1 CFCL-1 IGFL CFCL-2 IFFCO-2 NFL V2 TATA IGFL 57
 BASIS OF ENERGY FOR 2006-07

 Energy consumption is influenced by cooling water and ambient temperature,

fouling of exchangers during long continuous operation of plant etc.

 Energy consumption for the year was 5.37 MKcal/MT of Urea. We had taken shut
down in Nov/Dec 2005 where in we carried out cleaning of heat exchangers and
implemented energy saving schemes.

 Base Energy (after Nov/Dec’05 shutdown) 5.293

 Impact of energy saving schemes - 0.016

 Impact of cooling water temperature (annualized) +0.022

 Revised Energy 5.299

 Impact of Stripper +0.015

 Expected Energy 5.314

 Targeted Energy (Normal) 5.310

NATURAL GAS
SUPPLY
MANAGEMENT

59
 RAW MATERIAL & THEIR SOURCE

NG NAPHTHA

SOURCE GAIL IOC

AMMONIA PLANT MSM3/ DAY (TPD)

 FEED TO REFORMER 1.00 N.A.

 FUEL TO REFORMER 0.40 NIL

 FUEL TO SUPERHEATER 0.01 50

UTILITIES

 FUEL TO GAS TURBINE 0.24 NIL

 FUEL TO SERVICE BOILERS 0.17 NIL

TOTAL 1.82 50
60
 NG SUPPLY NETWORK
DADRI 24”
DELHI
TCL, BABARALA

ORIGINAL ROUTE
REVISED ROUTE
24”

IFFCO, AONLA
36”
24”
CFCL, KOTA OCFL, SHAHAJAHANPUR
18” 24”
18” THULANDI
30” IGFL, JAGDISHPUR
36” DIBIYAPUR (220 KM)
BIJAIPUR
HAZIRA
IFFCO, PHULPUR

After commissioning of Phulpur line, supply pressure is expected go down. As per contract,
GAIL shall maintain 45 kg/cm2g pressure at IGF battery limit. In case, GAIL is not able to
maintain the pressure, then it may become difficult to meet the requirement after revamp. GAIL
has already assured. 61
 TYPES OF GASES AND CONTRACT

 Indo Gulf has contracted with GAIL for three different kind of gases. The details are
as follows:
Gas Type Contracted Quantity Valid up to Price (USD / MMBTU)
APM 0.78 Msm3/day May 2008 3.19
R-LNG 0.76 Msm3/day Jan 2008 4.64
JV-PMT 0.28 Msm3/day April 2008 3.19
Total 1.82 Msm3/day
• Highlights of R-LNG Contract
– Contract for 9200 BBTU. Take or pay and supply or pay obligations.
– In each contract year (Jan-Dec) annual take or pay quantity is 95% of the
annual contracted quantity.
– The take or pay obligation will be on the difference between the actual quantity
drawn and 8740 BBTU.
– We can exercise 5% upward / downward flexibility, if required.
– At a plant load of 3000 MTPD, there would not be any possibility of take or pay
obligation on R-LNG. 62
 TYPES OF GASES AND CONTRACT

Highlights of JV-PMT Contract

• Contracted quantity revised to 0.28 Msm3/day from 0.34 Msm3/day
w.e.f. April 2006. Contract valid for two years.
• Pricing as per the APM price.
• Take or pay obligation. Monthly computation of TOPQ at 80% of
total quantity.
• As per the gas contract, we can modify the quarterly forecast at
least 15-days before start of the quarter.
Highlights of APM Contract
• Entered into in May 1988. Renewed in May 2005 and valid up to
May 2008. 63
 CURRENT AND FUTURE NG SCENARIO

Current NG Scenario
 We are getting adequate quantity of gas for current operation of 3000 MTPD of
urea. The current gas allocations are as follows:
 APM - 0.78 Msm3/day
 R-LNG - 0.76 Msm3/day
 JV-PMT - 0.28 Msm3/day
 Total - 1.82 Msm3/day
 GAIL has communicated that any overdrawl of gas shall be treated as
unauthorized over drawl and shall be priced at spot price of gas, which is about
12 USD MMBTU.
 We are daily monitoring the gas consumption so as to avoid any overdrawl.
Consuming naphtha to keep consumption below allocation.
 We also got permission from DOF for drawing gas at spot price of about 12
USD/MMBTU for one month. 64
 CURRENT AND FUTURE NG SCENARIO
Future NG Scenario / Requirement:
 Gas supply situation likely to remain very tight till 2008-09.
 The renewal of all the contracts is due in 2008. The pricing of the gas shall be
based on the market price prevailing at that time and availability of gas.
 The requirement of gas shall be as follows:
 Contracted quantity :1.82 Msm3/day
 Add. Quantity Required for current production @ 3000MPD :0.12Msm3/day
 Add. Quantity Required for Ph I Revamp (1850/3215 MTPD) :0.14 Msm3/day
 Add. Quantity Required for Ph II Revamp (1910/3320 MTPD) :0.06 Msm3/day
 Total :0.32Msm3/day
 Current requirement can be met by drawing gas at spot price (Current spot Price
USD12/MMBTU) for which approval shall be obtained from DOF time to time
and/or use of Naphtha.
 We have already entered into Heads Of Agreement with GAIL for our additional
requirement. We need to enter in to agreement with GAIL for add gas.
 We will also initiate dialogue for entering into agreement with GAIL for existing
gas quantities from 2008. 65
COST EFFECTIVE
INITIATIVES

66
 CHEMICALS CONSUMPTION COST &
MAINTENANCE EXPENDITURE
70 1600
Due to higher Rs. /MT of Urea
MEA unit cost 1400
65
61
1200
59
60
1000

RsLakhs
55 52 52 800

600
50
400
45
200
40 0
03-04 04-05 05-06 'P&B 06-07 00-01 01-02 02-03 03-04 '04-05 '05-06

Initiatives Taken
 Use of imported carbon instead of indigenous Carbon. This is having longer life and thus less
replacement required.
 Optimization of COC in cooling water and trough puts in DM plant 67
 BAGGING PLANT
KEY QUALITY REQUIREMENTS
IN-PROCESS DEFECT REDUCTION
 UNSTITCHED BAGS
 MANUFACTURING DEFECT IN BAGS
 BAG RUPTURE
 SWEPT UREA
 PRODUCT GIVE AWAY

UNSTITCHED BAGS
0.080
0.07
0.070
PERCENTAGE

0.060
0.05
0.050

0.040

0.030
0.02
Good
0.020 0.01 0.008
0.005 0.0050
0.010

0.000
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
YEAR 68
 BAGGING PLANT
PERCENTAGE MANUFACTURING DEFECT BAGS
0.04
0.04
0.030
0.03

0.03
0.020
0.02
0.02
0.010 Good
0.01
0.006
0.01 0.002
0.001 0.001
0.00
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

YEAR

BAG RUPTURE
0.08
0.07
0.07
PERCENTAGE

0.06

0.05
0.04
0.04
Good
0.03
0.02
0.02
0.01 0.007
0.01 0.005
0.002
0.00
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
YEAR 69
 BAGGING PLANT
BAGS CONSUMPTION/MT OF UREA BAGGED

20.0160
20.0140 20.013
N o. of B ags

20.0120
Good
20.0100
20.008
20.0080
20.0060
20.004
20.0040 20.0020
20.002 20.002
20.0020 20.001

20.0000
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

YEAR

PRODUCT GIVE AWAY PER 50 KG BAG OF UREA

G R A M S /5 0 K G B A G

35
31.45

30
23.22
25

20 Good
15
8.16
10 6.33 6.06 6.00 6.00

0
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

YEAR
70
SAFETY PRACTICES

71
 SAFETY PRACTICES

Following activities are carried out to prevent accidents –

 Unsafe conditions are identified & rectified by various committees like Plant Level
Safety Committees etc
 Near-miss cases are analysed and communicated to employees to prevent recurrence.
 F&S training is imparted to all employees & contractors, twice/ year.
 Case studies of accidents happened at other plants are discussed every month.
 Mock exercise to control simulated emergency conditions is conducted half yearly.
 To inculcate safety awareness among employees and their family members, different
safety competitions are organized every year.
 Safety management system is in line with the requirements of OHSAS-18001
standards. All statutory compliances are met.
 To ensure LPG safety, twice every year survey at each house in township is conducted
to identify & rectify problems, if any.
 Safety training is imparted to Teachers & School children also.
 Third party safety audit is organized once every year.
72
 NATURAL RESOURCE
CONSERVATION &
ENVIRONMENT PROTECTION

73
 KEY ENVIRONMENT ACHIEVEMENT

 All statutory compliances are met. Environment and effluent conditions

are much below than the govt. norms.
 Water consumption is one of the lowest in fertilizer industry.

 Planting about 5000 trees every year. So far planted 1.33 Lacs trees
since inception. 36% of total available area is covered under green belt.
 Plant final effluent is being utilized for horticulture in plant and township.
About 66% of effluent is being utilized.
 Environment clearance (EIA) for proposed de-bottlenecking (1910
MTPD) is under active consideration at UP Pollution Control Board,
Lucknow. Public Hearing conducted, which was very successful.
74
 WATER CONSUMPTION & EFFLUENT
DISCHARGE
70
SPECIFIC WATER CONSUMPTION EFFLUENT UTILIZATION 66.5
9 8 60

% Use of efflu en t
M3/ Te of Urea

50

6 .0 3
5 .7
40 34.6
5 .2 3 5 .2 2 28.6
30

20
11 14
10
3
Go vt .No rm 2 0 0 2 -0 3 2 0 0 3 -0 4 2 0 0 4 -0 5 2 0 0 5-0 6
Ye a r 0
2001-02 2002-03 2003-04 2004-05 2005-06
400 120
360
SPM AT FACTORY BOUNDARY AMMONIA AT FACTORY BOUNDARY
3 50 100
100
300
80
2 50

200 60

15 0
40 27
71 25
10 0 61 61 60 20 20
20
50

0 0
Govt. 2002-03 2003-04 2004-05 2005-06 Go vt. 2002-03 2003-04 2004-05 2004-05
Norms No rm s 75
 Q&EC - CORPORATE RESPONSIBILITY FOR
ENV. PROTECTION
S.No Recommendation of CREP Activities & Status
1. Efforts to conserve water with In compliance. Water
a target to have < 8 M /Te of consumption is 5.3M /Te of Urea
3 3

Urea produced. produced.

2. Adequate treatment for Oily water treatment plant

removal of oil will be provided. working satisfactorily. Oil is not
traceable in final effluent.

3. Ground water monitoring. Monitoring is being done regularly

for TAN, NO3, pH, PO4, F, TDS.

4. Storm water drain to be kept Storm water drains are being kept
dry except rainy season. dry other than in rainy season.

76
 Q&EC - CORPORATE RESPONSIBILITY FOR
ENV. PROTECTION

S.No Recommendation of CREP Activities & Status

5. Monitoring of Ambient air Regular monitoring of ambient air quality

quality. with respect to SO2, NOX & PM is being
done.

6. Action plan for proper handling, Spent catalyst is sold to user party who
storage and disposal of spent has got the approval from PCB as per
catalyst. Hazardous Waste Rule.
7. Chalk shall be properly Totally eliminated Calcium Carbonate
managed and disposed off in sludge by installing Zeolite softening plant.
secured landfill.

77
OTHER PRACTICES

78
 PRACTICES TO ACHIEVE EXCELLENCE

THINK
TANK
BENCH CORE
MARKING COMMITTEE

PROCESS INTERNAL
CAPABILITY COUSTOMER
SATISFACTION

FERTILISERS
RCM & WCM
WHY WHY
ANALYSIS

CROSS
COPQ FUNCTIONAL
SAFETY
PRACTICES
79
 PRACTICES
Practices Owner
• Think Tank – N.K.Thakur
• Benchmarking – A.K. Gupta
• Core Team
– Ammonia – N.K.Thakur
– Urea – K.K.Singh
– Bagging – Md.Anwar
– Power Plant – S.N.Sharma
• Internal Customer Satisfaction – A.K. Bhargava
• Process Capability – S. Venkatraman
• R.C.M. and Why-Why Analysis – S.K.Singh
• Condition Monitoring – S.K. Sipani
• New Safety Practices – R. Kapoor
• Delegation – N.C. Bansal
• Cost of Poor Quality – D.Sahai
• Farmer interaction by Op.Staff – B.P.Padhee
• Cross Functional Teams – A.K. Bhargava
80
 CORE TEAM

• To provide a platform to remove barricades amongst the

departments and improve response time in resolving

problems or issues.

• Cross Functional Team comprises of members all

departments and meets once in a week. The performance

is reviewed and monitored by Apex Team

• Focuses on problems related to quality, safety, reliability,

energy, cost, losses & environment.
81
 BENCHMARKING

PURPOSE

To benchmark world class organizations to identify potential areas of

improvement and Target setting for achieving all round excellence

TYPES
GLOBAL

BENCHMARKING

EXTERNAL INTERNAL
82
 BENCHMARKING

Global Benchmarking
• We appointed M/s. PDC, Netherlands to carry out
benchmarking study for urea plant energy efficiency.
• Based on the data Obtained from Japan Institute of
Planned Maintenance (JIPM)

External Benchmarking - A systematic process for

identifying better practices and processes followed by
Indian competitors for setting improvement goals.
• Benchmarking study by FAI
• Benchmarking study by data collection and comparison
from various fertilizer plants.

Internal Benchmarking - A systematic process of

comparing our own actual performance on various quality
indicators with respect to our best performance for setting
improvement goals. 83
 QUALITY IMPROVEMENT
Purpose : To make processes more efficient, effective and goal
oriented.
Process :
SP1 : Introduction of Six Sigma concept in the Organization

SP2 : Recognition / Definition of Six Sigma Projects

SP3 : Training Programs for All Teams on Analytical Tools

SP4 : Project execution based on DMAIC Methodology

SP5 : Validation of Improvement and Control Methods

SP6 : Prepare “Project Control Plan”

84
 QUALITY IMPROVEMENT

At present 5 projects are under progress.

3 projects in improve /control phase, target for sign off : 15th July ’07.

2 projects in analyze phase.

Champions training by CWCM coordinator in third week of June ’06.

New projects to be taken up under his guidance in July ’06.

85
 THINK TANK

To provide a platform to employees for unleashing their creative

potential and create healthy competitive environment
Participation - Any Employee
Frequency - Monthly
Status :
☺ No. of Presentations - 49
☺ No. of Suggestions Received - 480
☺ No. of Suggestions Implemented - 232
☺ No. of Suggestions Not Viable - 248

Financial Gain - Rs 2 Crs/annum

86
 CROSS FUNCTIONAL ANALYSIS

 IT’S A PROCESS OF LEARNING FROM OUR OWN FAILURES &

MISTAKES AS WELL AS, HAPPENED IN OTHER INDUSTRIES.

LEARNINGS ARE ALSO DERIVED FROM INCIDENCES PRESENTED
AND PUBLISHED BY AIChE SYMPOSIUM EVERY YEAR.
 ANY BREAK DOWN / UPSETS / SYSTEM FAILURES ARE BEING

ANALYSED THREADBARE BY A CROSS FUNCTIONAL GROUP.

 UNEARTHS THE ROOT CAUSE & SUGGESTS RECOMMENDATIONS.

 THESE RECEOMMENDATIONS AS WELL AS THE LEARNINGS ARE

PRESENTED AND DISCUSSED IN A CROSS FUNCTIONAL

GATHERING.
 FINALISED RECOMMENDATIONS ARE IMPLEMENTED.
 ONE MEETING IS HELD EVERY MONTH.
87
 DAILY MORNING MEETINGS
PURPOSE: To facilitate faster decision making for resolving day-to-day plant
problems and performance deviation w.r.t. targets by Functional
Head, HODs & concerned departmental personnel

SCHEDULE : Duration 8.30–9.00 AM 9.05–9.30 AM 9.35–10 AM 10–10.30 AM

Department PP&U/Bag. Urea Ammonia Process

PROCESS :
HOD compiles problems of previous day related to safety, quality, reliability, environment, cost,
energy and system failure

All problems are discussed one by one. All present put fourth their ideas / analysis to overcome
the problem.

Appropriate decision is taken and action plan is prepared

HOD monitors the performance and if problem continues, it is taken up by Core Team for
minute analysis. 88
 INTERNAL CUSTOMER SATISFACTION

 CONCEPT OF INTERNAL CUSTOMER SATISFACTION INTRODUCED IN

OCTOBER’01 TO IMPROVE INTER-DEPARTMENTAL COHESIVENESS &
TO DEVELOP A SYSTEM FOR MEASURING CUSTOMER SATISFACTION
INDEX.
 IT FOCUSES ON IDENTIFYING MAJOR HURDLES IN COMMUNICATION
BETWEEN ALL FUNCTIONAL DEPARTMENTS ACROSS THE
ORGANIZATION.
 EVERY DEPARTMENT HAS IDENTIFIED THEIR CUSTOMERS ALONG
WITH NEEDS OF/FROM CUSTOMERS FOR ENSURING THEIR
SUCCESS.
 WE HAVE DEVELOPED A SYSTEM FOR MEASURING CUSTOMER
SATISFACTION INDEX. SURVEY BY EACH DEPARTMENT IS CARRIED
OUT EVERY SIX MONTHS.
 DEPARTMENT’S PROGRESS IS REVIEWED EVERY TWO MONTHS.
89
 FARMERS FEED BACK BY CROSS
FUNCTIONAL TEAM
 The customer’s needs are identified through field visits once
in a month.
 The visiting team comprises of representatives from
Operations, Maintenance, Technical, Q&EC & marketing,
takes feed back from stockists, retailers & farmers.
 Feedback is taken regarding the quality of product and the
services being rendered by the company.
 Urea samples are collected for our product and also of other
brands. The quality parameters are compared and areas of
improvement are identified.
 Based on feed back, corrective & preventive actions are
taken to improve the satisfaction level of customers. 90
 MULTI-SKILLING

What is Multi-skilling
• To impart knowledge of areas other than “Core”.
• To enable individuals to perform jobs of other discipline with little
guidance.
Purpose
• Increase availability of manpower having interdisciplinary skills.
• Improve analytical capabilities with cross functional knowledge
• Improvement in response time.
• Improved safety.
Status
• Training commenced wef 02.06.2003 under a task force
• Covered total 68 employees till date
• Methodology for training is explanation with cut models, simulations,
dynamic models, drawings, theory etc.
91
 SKILL BASED TRAINING

• Review of Skills & Skill Levels of each employee

every year.
• Skill Levels are measured by respective supervisors.
• Skill Levels are as follows:
1 - Do not Know
2 - Knows
3 - Can do with occasional guidance
4 - Can do independently
5 - Can Teach
• Training needs are identified based on gap.
92
 SKILL GAP – AN EXAMPLE

1 MOTORS :
6 .0 0

2 POWER & DISTRIBUTION

11 HT/ LT BREAKER 4.80
5 .0 0

TRANSFORMER
4.69 4.93
4 .0 0

10 CABLES 4.67 3.69 3 GENERATOR

3.61
3 .0 0

4.53
3.58
3.78 2 .0 0

3.00
3.22 1 .0 0

2.43 3.67
4.58 1.84
9 BATTERY BANKS 2.58 4 AVR

3.22 3.40
3.83 3.80

5 RELAY COORDINATION AND

8 TELEPHONE & PA SYSTEM
SETTINGS
5.00 5.00
7 ELECTRICAL SYSTEM AT
6 132 KV SWITCHYARD
SATHINGHAT

93
AREAS OF CONCERN

94
 AREAS OF CONCERN

RG Boiler:-
 The existing RG Boiler has become week as more than 10% tubes are plugged.
 We have new RG Boiler available with us which we are planning to replace in
March/April 2007 Phase II revamp.
Steam Super Heat Coil:
 Coil is installed in convection section of primary reformer.
 Upper Coil has bowing and tube sheets are damaged. Order has been placed on
M/s L&T. Planned replacement in Phase II revamp shut down
Carbamate Condenser
 Installed in both Urea streams. Produces LP steam utilizing heat of condensation
 During May’06 shut down inspection reveled thinning of baffle plates & liner
thickness reduction. Working out action plant with technology suppliers.
 AREAS OF CONCERN
Synthesis Turbine Parting Plane Leak
 Turbine casing is two halves. Steam is leaking from parting plane. In long run
may cause damage to casing. Planned repair in Phase II revamp S/D.
Urea Reactor Liner
 Reactor shell is made of CS. Lined from inside to protect from corrosive liquid.
Liner thickness has reduced from original 7 mm to 3.5 mm (minimum). Planned
relining in Phase II revamp shut down
Exit of talented & qualified professionals
 Talented engineers are leaving organization. After revamp, plant operation will
be very stretched and therefore for sustained superior performance, retaining the
talent is a key driver. The reasons for exit are:
• Opportunities are available in India as well as abroad.
• No growth at site
• Higher pay packages
• Better positions.
VALUE ADDED
PRODUCTS

97
 NEW PRODUCT DEVELOPMENT
NEEM COATED UREA

450
400
400

350
'0 0 0 M T

300
300
250 251 Plan
Actual
250

200 175

150

100
'04-05 '05-06 '06-07 '07-08

• Yield Improvement 15% -18%

• Share in UP sales : 04-05 - 34% 05-06 - 62% 06-07 – 63%
• Neem coating chemical cost reduced from originally Rs 91/MT to Rs 34/MT. Now it
is Rs 29/MT of Urea. 98
 NEW PRODUCT DEVELOPMENT
ZINCATED UREA
Zincated Urea
 Four grades having Zinc content of 2.0, 1.5, 1.0 & 0.5% produced.
 Field trial conducted in Kharif by IARI Delhi ,ND University (NDUAT)
Faizabad & by us at our R&D farm
 IARI Kharif trial results received
% of Zn Added Yield Improvement
1 % ZnSo4 17 % BEST OPTION
1 % Zn O 10 %
2 % ZnSo4 25 %
2 % Zn O 18 %

 Results of trial at our farm & NDUAT are more or less same as that of IARI
Sulphur Coated and Boronated Urea
 We also produced small quantities of Sulphur coated and Boronated Urea
using the infrastructure for Zinc coating.
99
THRUST AREAS
 CDM
 DEBOTELLNECKING
 ENERGY CONSERVATION

100
CLEAN DEVELOPMENT
MECHANISM (CDM)

101
 CLEAN DEVELOPMENT MECHANISM

 Global initiative taken in Rio earth summit in 1992. Initiative further strengthened
in 1997 under Kyoto protocol. Countries agreed to reduce aggregate emission by
5.2% below 1990 levels by 2008-12.
 Under CDM, developed countries can buy carbon emission from the developing
countries so as to reduce their equivalent obligations.
 Prevailing carbon credit rate is about 20 Euro/ MT of CO2.
 Registered GV system up-gradation under CDM. CERs 60,239 MT (net) issued on
11th March 06 by UNFCCC

 Globally First project in Fertilizer Industry. Entered into Contract with M/s
Barclays @ EURO 20/MT

 Gain on accrued CERs (60,239 MT) Rs.6.25 Cr. In future Rs.2.6 Cr. per
annum on 25000 T of CO2 p.a.. 102
 CLEAN DEVELOPMENT MECHANISM
Future Potential Projects - Expected Gain Rs 25 Crs/Yr

Phase I: Energy Saving Schemes as Potential CDM projects

 We have identified 7 more energy saving projects as potential CDM projects.
 Expected CERs shall be about 57000 Te. Proving their uniqueness is most critical factor
for their registration with UNFCCC. We have appointed E&Y as our consultant with fees
of Rs 30 Lacs.
 Expected gain from these projects if all get registered shall be about Rs 6 Crs/annum @
20 Euro/MT of CO2. Gain realization only after registration.
 Expected Registration with UNFCCC by March 2007.
 Appoint agencies for verification & Validation of projects. Expected expenses shall be
about Rs 40 Lacs.
Phase II: Exploring Neem Coated Urea as Potential CDM projects
 Neem Coated Urea could also be a potential CDM project. Neem coating reduces
emission of N2O in the field. A GHG, impact is 300 times more than CO2 . Yield also
improves resulting in lesser consumption of Urea.
 Combined reduction could be1 Te of CO2/MT of Urea.
103
 CLEAN DEVELOPMENT MECHANISM
Future Potential Projects - Expected Gain Rs 25 Crs/Yr

 No proven CDM approach available

 Methodology yet to be framed and approved by UNFCCC, N2O reduction
results are to be established with actual field trials.
 If we are able to get project registered then there is expected gain of Rs 25
Crs/annum.
Path Ahead:
 We need to establish actual reduction of N2O in field during Rabi and Kharif at
different locations where Neem coated Urea is being used.
 We are appointing agriculture university for field trials to determine N2O
reduction. This will take one year to establish data.
 Based on the established data registration can be done with UNFCCC.
 In the mean time Methodology shall be prepared with the help of E&Y and same
shall be approved by UNFCCC. We have appointed E&Y as consultant at a fees
of Rs 15 Lacs. 104
 CLEAN DEVELOPMENT MECHANISM
PATH AHEAD

 Registration of theses projects, subsequent yearly verifications and annual

agreements with buyers is voluminous job and require a focused attention.

 Planning to establish a CDM cell headed by a Manager ( JB 9) which will

have following responsibilities:

 Regularly identification of projects and their evaluation as CDM project.
 Appoint agencies and carry out Validation, Verification of projects
 Registration of projects with UNFCC.
 Tracking of CERs rate, identification of Potential buyers and entering

into sale/purchase agreement.

 Continuous compilation and recording data of all CDM projects, annual

verification by accredited agencies like TUV, DNV etc.

105
DE-BOTTLENECKING

106
 DEBOTTLENECKING JOURNEY

• Govt. reassessed capacity of Ammonia and Urea to 1520 MTPD and

2620 MTPD respectively w.e.f. April 2000.
• Govt. announced policy regarding de-bottlenecking of Ammonia/Urea
plants in January 2004
• The step-wise journey of revamp is as follows:
Step-1: Revamp to 2100 MTPD Ammonia
• Carried out feasibility study for 2100 MTPD Ammonia and 3600 MTPD
Urea. Project cost for Ammonia was Rs.244 Crores having IRR of 11%.
Step-2: Revamp to 1950 MTPD Ammonia
• Worked out 1950 MTPD as the better option than 2100 MTPD.
• Approval from Chairman accorded on 9th Sept’04 .
 Investment - Rs.137.78 Crores (Rs116+ Rs22 Crs)
 IRR/Pay Back - 15% / 9.7 years
 DEBOTTLENECKING JOURNEY

Step-3: Optimization of 1950 MTPD Ammonia Revamp cost by utilizing in-house talent.
We brought down project cost to Rs.112.5Crores. Financial Indicators were:
 Revised Project Cost - 112.5
 Revised IRR/ Pay back Period - 20 % / 7.8 years
Step-4: Innovative Thinking to further make project more attractive
• Original sanctioned was for 1950 MTPD revamp at Rs 137.7 Crs (with IRR of 15%) which
was revised in March 05 P&B to Rs 112 Crs with IRR of 20%
Process Adopted :.
• In March 2005 P&B we presented to Chairman to implement revamp in two phases as
approval from DOF was awaited for revamp.
• In phase I revamp up to 1850 MTPD with an investment of only Rs 13 Crs with in
shortest time by Sept/October 2005.
• Till we get approval from DOF, to work most optimum capacity with minimum investment
and implement as phase II in March 2007 108
 DE-BOTTLENECK
INNOVATIVE THINKING
Step-4: Innovative Thinking to further make project more attractive
OUTCOME :.
 Implement Phase I revamp of 1850 MTPD ammonia in Sept/Oct 2005 at an
investment of Rs 13 Crs which was very attractive ( IRR of 96%). We obtained
approval in March 2005 P&B from Chairman.
 1910 MTPD was found to be most optimum capacity for Phase II Revamp at a
cost of about Rs 65 Crs.
 We obtained Chairman approval in March 2006 P&B.
 Total project cost reduced from Rs 112 Crs to Rs 78 Crs (IRR 22%).
 Phase I (1850 MTPD Ammonia) Successfully implemented in Nov/December
2005 within 8 days. Start up was vertical. Sanctioned Amount. Rs13 Crs
 DE-BOTTLENECK STATUS

Phase II – 1910 MTPD Ammonia

 Sanctioned Amount : Rs.64.5 Crore
 Implementation : Mar / Apr’07
 Major Jobs to be carried out:

 Putting both the existing converters in series along with new loop boiler

 Suction chilling of process air compressor

 Trimming of recycle stage rotor/impeller in synthesis compressor.

 Installation of Bulk Flow cooler

 Order has been placed for following items Basic & Detail Engg. Of suction chilling

of Process Air compressor. Order to be placed for Trimming of recycle stage

rotor/impeller of Synthesis gas compressor.
 Complete BEP received and detailed engineering by 5th June 2006.
 DE-BOTTLENECK STATUS
Step-5: Implementation of Phase II in Two Parts
 DOF gave permission of De-bottlenecking, however the conditions provided
there-in are not favorable to us.
 We made representation to DOF and final decision from them is awaited along
with Stage III fertiliser Policy. Till we get approval from DOF, we can not
implement revamp. So we decided to implement the Ph II revamp in two Parts:
 Part I : Implement the two major revamp schemes viz Suction chilling and
series operation of converters in Marc/April 2007 (35 days S/D) as Energy
saving schemes. Total expenditure shall be about Rs 25 Crs.
 Part II : Implement 1910 MTPD revamp as soon as we get clearance from
DOF. Expected expenditure shall be about Rs 40 Crs.
 This will have following advantages:
 There will be reduction in energy consumption by 0.046 MKcal/MT of Urea.
 Air compressor and Synthesis loop are two major bottlenecks for 1910 MTPD
which will be already taken care in Part I and thereafter we expect, plant can
be operated at 1910 MTPD. This will help in further optimizing the investment.
 Part II of revamp can be implemented in short shut down of about 10 days.
 DE-BOTTLENECKING
BENCHMARKING WITH COMPETITORS
• Other fertiliser plants in India are also applied for revamping of plants.
• Published data reveals that investment Rs Crs/ Lacs MT of incremental Urea is 91, 84, 48 and
44 at IFFCO (P), IFFCO (A), TCL and IGFL respectively, thus it is minimum at IGFL. TATA

IFFCO (P)
IFFCO (A)
IGFL
IGFL - Under
Implementatio
140
IMPLEMENT
140 ED
n

120 110.0
64.5
100
' R s C rs

80 115
60
13.0
40
20
0
'1750MTPD 1750MTPD 1850 MTPD 1910 MTPD 2020 MTPD
112
 ENERGY
CONSERVATION

113
BENCHMARKING WITH
TATA CHEMICALS
 YEARWISE ENERGY COMPARSION
IGFL Vs. TATA
• TATA incorporate many energy saving features like S 50 converter, MTS, HP
HRSG, condensing/extraction PAC turbine, since inception which resulted in their
higher project cost, however giving advantage on best energy consumption.
• The energy consumption reduction at TATA w.r.t. IGFL is given below:

Year Tata Energy (MKCal/Te) Indo Gulf Energy

(MKCal/Te)
2000-01 5.53 5.95
2001-02 5.373 5.68
2002-03 5.438 5.55
2003-04 5.307 5.36
2004-05 5.227 5.41
%age Reduction 5.5% 10%
2005-06 5.242 5.37
115
 COMPTETIVE COMPARISON - ENERGY
IGFL Vs. TATA

6.00
TCL HP steam balance gives a
5.871 gain of 0.08 Mkcal / MT
5.90

5.80 Design Energy

TCL:
5.70 Due to 5.73MKcal/MT
technological IGFL:
5.565
5.60 difference 6.24MKcal/MT
.
MKCal/Te

5.50
5.38
5.40

5.30 5.20
5.20

5.10

5.00
FICC Norm IGFL FICC Norm TCL TCL'05-06 IGFL'05-06 116
 TECHNOLOGICAL DIFFERENCE
IGFL Vs. TATA
Area IGFL TCL Energy Impact
MKCal/Te of urea
Condensing load in Compressor 58 Te/hr 38 Te/hr 0.11

Low pressure synthesis loop 140 Bar 195 Bar 0.065

Gas Turbine HRSG/ Stack 180°C 140°C 0.045

Temperature
Service Boiler Stack Temperature 120 °C 90°C 0.008

Shift Conversion – CO slip 0.27% 0.11% 0.035

CO2 Removal System 600 Kcal/ Nm3 of 500 Kcal/ Nm3 of 0.038
CO2 CO2
Total 0.301

Following are two thrust areas:

 Reducing condensing load in the turbines and effective steam balancing
 Low synthesis loop pressure. This is being taken care by putting both
117
converters in series in Mar/Apr’07.
 REDUCING HEAT DUMPING IN COOLING
WATER – THRUST AREA
HIGH CONDENSING LOAD/HIGH HEAT DUMP IN COOLING WATER
 At IGFL (38 ata) steam generated from gas turbine flue gases whereas Tata generates high
pressure (110 ata) steam. MP steam requirement is also met from the extraction of syn.
compressor turbine.
 Reduction in MP steam consumption results in more condensing (heat dump to CW)
IGFL TATA

HP STEAM HEADER (110 Bar)

HP
SYN. TURBINE SYN. TURBINE Steam

GT WHB GT WHB
44 TPH MP
CONDENSATE Steam CONDENSATE
(min.) 40 Te
51 Te

MP STEAM HEADER (38 Bar)

Problem-
More heat
dumping in
OTHER USERS AND BACK PRESS. TURBINES
CW

LP STEAM HEADER (3.5 Bar)

118
 REDUCING HEAT DUMPING IN COOLING
WATER – THRUST AREA

 We worked out a scheme and highlights of the same are as follows:

 Replace MP HRSG with HP HRSG. Up-gradation of synthesis
turbine for increasing the extraction. The total expenditure
required shall be about Rs.37 Crores.
 This may result in energy saving of 0.08 MKCal/Te of urea,
equivalent to financial gain of Rs.2.8 Crores. Pay back period is
high.
 However, if we implement this scheme we could have achieved
energy level of 5.23 MKcal/MT. Similar fertiliser plant (IFFCO,
Aonla-I) is investing Rs 80 Crs. to achieve 5.45 MKcal/MT
119
 LOW GRADE HEAT RECOVERY
THRUST AREA

Path Ahead
 We are exploring possibilities of recovering heat being dumped in

Cooling Water. We may have to appoint a consultant which we have

considered in P&B.
 Visit to latest generation fertiliser plants to identify new areas of

energy conservation. Expenses for Visits considered in P&B.

Future Energy
 After Part I Revamp Expected Energy consumption shall be about

5.27 MKcal/MT of Urea

 REDUCING COST OF PRODUCTION
FUTURE STRATEGY – COAL FIRED BOILER
 At present whatever Natural gas/Naphtha is used is pass through.
 If we use cheaper fuel like Coal this will help in reducing cost of production
which will give benefit in decontrol scenario. This will require investment of
about Rs 100 Crs for Coal fired Boiler.
 In present scenario GOI subsidy burden will also reduce if we use coal.
However they may have profit sharing, as in case of more than 100%
production.
 We had invited quotations from M/s. Cethar Vessels & M/s. Krupp for 150 Te/hr
high pressure boiler. Erected cost of boiler comes out to be about Rs.100
Crores, including coal/ash handling & civil work. Economics is being worked out.
Advantage
 About 0.2 Msm3/day natural gas can be made available for production. Can
mitigate the gas shortage in future .
 Cost of production per Te of urea will reduce and will be competitive in open
scenario.
Path Ahead
 To appoint a consultant for working out feasibility. Fees considered in P&B.
 GROWTH PLANS
 BROWNFIELD EXPANSION

 FERTILIZER COMPLEX AT EGYPT

122
 BROWNFIELD EXPANSION

 Expansion proposal 2000 MTPD ammonia submitted to DOF in Feb

03. Investment : Rs. 1693 Cr. Investment was revised to Rs 1925

Crs.
 DOF requires Detailed Project Report.

 Appointed PDIL for the preparation of DPR.

 All details required from technology suppliers have been provided to

PDIL for preparation of DPR.

 KRIBHCO & RCF are pursuing their expansion proposal , capacity

2000-2200 MTPD Ammonia.

 FERTILIZER COMPLEX AT EGYPT

 Presentation was made to Chairman in P&B meeting on 15th Mar’06 for

expanding our business overseas by putting fertilizer complex at Egypt.
 We were advised to get feasibility done and revert back to BRC with firm
numbers.
 The fertilizer complex shall have Ammonia, Urea, DAP / NPK,
Phosphoric Acid Plants. The key drivers at Egypt are:
• Adequate availability of gas at 1 USD as compared to 7-8 USD /
MMBTU in India.
• Many fertilizer plants in USA / Europe are closed down due to high
gas price.
• Many old plants are likely to closed down globally as they are end of
their life cycle.
 FERTILIZER COMPLEX AT EGYPT

 Contacted renowned consultants – British Sulphur, UK, Informa

Economic, USA and Fertecon, USA. They have conducted similar
studies worldwide.
 We have already received offers from these consultants for
comprehensive feasibility study. The expected expenses will be about
Rs.1.20 Crores for study. Study completion in three months.
 The study will indicate long term gas availability & market potential,
economic sizing of plant, technology selection, total investment required
which will help us in taking decision for going ahead.
 We may be accorded approval of Rs.1.20 Crs. for carrying out the
feasibility study.
 A visit to Egypt may be planned to gather information like Gas
availability, Egyptian Govt. Policies etc to mid June 2006.
 FERTILIZER COMPLEX AT EGYPT

Key points to be considered.

 Plants should of world scale size so that investment is competitive.

 Surplus ammonia will be sold in international Market.

 Out sourcing of some items viz Phosphoric acid and utilities like, steam,

power etc which will help in reducing investment.

 Expected investment will be about 550 -600 Million USD

 In future we can diversify to synergistic promising products like Methanol

( a future fuel), Hydrogen Peroxide, Formic Acid etc.

 Second Hand ammonia / urea etc Plants are available which can be

relocated which will reduce investment.

127
 CLEAN DEVELOPMENT MECHANISM
FUTURE POTENTIAL PROJECTS

Sl. Name of Activity Year Anticipated

No. CERs
1 Elimination of methane gas emission to atmosphere from C-3, by Apr-02
effectively utilizing these gases as a fuel in primary reformer 11,000

2 Effectively Utilization of heat, which was being dumped in cooling Sep-01

water, for saving low pressure steam in Vacuum Concentration section. 18,500

3 Reducing heat loss in to atmosphere along with the flue gases from the Apr-02
service boiler by utilizing it for preheating of combustion air for service 3200
boiler
4 Reducing heat loss in to atmosphere along with the flue gases from the Oct-02
primary reformer by utilizing it for further preheating of combustion air. 7500

5 Enhancing the power generation capacity of gas turbine by inlet air Apr-01
cooling employing concept of water fogging and utilizing electric power 15,000
for energy conservation by reducing heat dumping in cooling water.
6 Utilization of low grade heat getting dumped in CW and utilizing it as Mar-07
heat source in VAM for producing chilled water for suction chilling of 2700
process air compressor.
  TOTAL ESTIMATED CERS   57,900
128
 ENERGY SAVING INITIATIVES
DETAILS
Sl. Schemes Energy Saving Saving Investment
No. (MKCal/Te of (Rs/Lacs/Yr) (Rs. Lacs)
Urea)

A) ENERGY SAVING INITIATIVES DURING 2001-02

1 Installation of VPC in both the units of Urea Plant 0.075 409.5 935.0

2 Provision of Naphtha firing in both service boilers 0.030 200.0 5.6

3 Conversion of CW / BFW pumps from turbine 0.108 465.0 37.0

driven to motor driven
4 Installation of magnetic resonators in one of the 0.007 80.5 2.3
service boiler
5 Stoppage of Inert Gas Generation Plant 0.005 18.6 NIL

6 Stoppage of one service boiler 0.004 15.0 NIL

Sub-Total (A) 0.229 1188.6 979.9
B) ENERGY SAVING INITIATIVES DURING 2002-03
1 Combustion Air Pre heater in Service Boiler 0.016 74 68
2 Running of both the Ammonia Converters in 0.02 89 107
Parallel 129
 ENERGY SAVING INITIATIVES
DETAILS

Sl. Schemes Energy Saving Saving Investment

No. (MKCal/Te of (Rs/Lacs/Yr) (Rs. Lacs)
Urea)
3 Utilization of C-3 off gases as fuel in Service 0.015 62 17
Boilers
4 Modified GV Aeration Scheme 0.003 10 3
5 Diversion of MV-01 off-gases 0.005 20 2

6 Combustion Air Preheater in Ammonia Plant 0.033 149 256

7 Interconnection of discharge headers of ACT 0.021 89 55

& UCT and installation of lower capacity CW
pump
Sub-Total (B) 0.113 493 507
C) ENERGY SAVING INITIATIVES DURING 2003-04
1 Up-gradation of CO2 Removal System 0.115 284 400
Grand Total (A+B+C) 0.457 1965 1887
130
 ENERGY SAVING INITIATIVES
DETAILS
S. Schemes Saving Saving Investment
No. MKCal/MT Rs Lacs/Yr Rs. Lacs
A) IMPLEMENTED IN 2005-06
1 Feed pre-heater of Hydrolyser 0.005 16 29
2 Up Gradation of Combustion air pre- 0.005 16 187
heater
3 Utilization of Ammonia process 0.005 16 3
condensate heat
4 Utilization of condensate heat in 0.001 3 10
preheating tail gases
B) Planned in 2006-07
1 Variable speed drive for clear water 2 3.5
pump.
2 Ceramic Coating in Primary reformer 15 40
3 Lighting Transformer 1.5 4
4 Suction chilling of process Air 0.023 100 *Rs.26 Crs
Compressor
5 Series operation of Converters 0.023 100
* Implementation in March/April 2007.
131
 DEBOTTLENECKING
COST COMPARISON (APPROVED Vs. REVISED)
S. No. Equipment Description 1950 TPD 1950 TPD
Approved Revised
A) Ammonia Plant (Rs/ Crs.)
1 Pre-reforming & Boiler drum 21.53 5.00
2 CO2 removal system 15.00 5.45
3 Air compressor 28.90 28.90
4 Synthesis Compressor 40.66 25.00
5 Existing Converter modification 0 12.00
6 Exchangers 7.00 7.00
7 Reformer Burners, ID fan & Turbine 0 7.00
8 Miscellaneous 2.85 2.85
Sub- Total (A) 115.94 93.20
B) Urea Plant 6.28 6.28
C) PP&U 1.0 1.0
D) Basic / Detail Engineering 14.50 12.00
Total (A to D) 137.22 112.48 132
 DEBOTTLENECKING - Journey

March 06 P&B
1910 MTPD
March 05 P&B Rs.64.5 Crs
1950 MTPD
Rs 99 Crs
Investment Rs/Crs.

2
s e-
a
Ph
1850 MTPD
Ammonia
Rs.13 Crs D)
Revamp Journey
ETE
P L • Sept’04 - Sanctioned Rs.138 Crs. for 1950 MTPD
M revamp. IRR: 15%
O
(C • Mar’05 – Revised Project cost to Rs.112 Crs. for
e -1 1950 MTPD. IRR: 20%.
has
P • Nov/Dec’05 – Implemented 1850 MTPD Revamp
with Rs.13 Crs. IRR:96%
• Mar/Apr’07 – Revamp to 1910 MTPD with addl.
Rs.64.5 Crs. Overall IRR: 22%.
1650 MTPD Ammonia

Production capacity
 ENERGY CONSUMPTION – TARGET Vs. ACTUAL

6.0
5.9 (ACTUAL- NOV.00)
TARGET SET IN NOV.00

5.8 5.78 (ARP.01)

5.74
(ACTUAL) 5.66 (AUG.01) 5.63(APR.02)
JUL’01
(ACTUAL)
5.6
FEB.02 5.51 5.55 (APR.03)
(ACTUAL)
5.45
AUG’02
5.4 (ACTUAL) 5.36
TARGET REVISED IN AUG.01

5.205 (APR.04)
5.2

TARGET REVISED IN MAR.02 ACTUAL

ACHIEVED 5.346
5.0
134