Annexure-Brief Summary of Project IFFCO...

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Brief description of Modification/ Revamping of Ammonia-Urea Plant Including installation of GT-HRSG at IFFCO Phulpur

Introduction Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit –II in Year 1997. Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plant is based on Haldor Topsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti’s Italy.

It is proposed to implement various Modification/ Revamping of Ammonia-Urea Plant including installation of GT-HRSG at IFFCO Phulpur to implement the latest available proven Technological solution to improve Reliability of Process / Equipments and to reduce the Energy Consumption by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II. The application for granting TOR for the above project at IFFCO Phulpur was submitted (online) to Ministry on 23rd July, 2015. The Expert Appraisal Committee (Industry 2) during its 46th meeting held on 20th and 21st August, 2015 opined that the proposal is incomplete and to be submitted along with details of existing plant configuration and proposed modifications to be carried out. Further it was suggested to submit the revised proposal along with Form-1 which should include information such as existing water requirement, waste water management, solid waste management etc. Also it was observed by the Committee that there is no increase in production. However, only few units are being changed which involves amendment of existing environmental conditions. The copy of above letter No. J-11011/198/2015-IA II (I) dated 13th October, 2015 is enclosed. In line with the above the revised proposal is being submitted.

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CHAPTER-I Executive Summary

Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit –II in Year 1997. Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plant is based on Haldor Topsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti’s Italy. Total Urea Production Capacity of Phulpur Unit is 5145 TPD (18.78 lakh MT per annum considering 365 stream days). Initially, Phulpur Complex was designed and operated with Liquid Hydrocarbon & Naphtha to be used as Feed and Fuel. In line with the Government of India (GOI) directives, the Feed Stock and Fuel was switched over from Naphtha to Natural Gas in the year 2006.

The Site occupies an area of 432 hectares out of which about 130 hectares is occupied by the plant where industrial activity is performed.

1. The actual production for last 3 year is given below:

Products

Actual production (MT) 2012-13 2013-14 2014-15

UNIT-I : Ammonia Urea UNIT-II: Ammonia Urea

403801 673102 532376 992011

384930 651704 546520 950884

334354 577824 511604 883854

Total: Ammonia Urea

936177 1665113

931450 1602588

845958 1461678

2. The present Raw material consumption:

Particulars Unit Phulpur-I Phulpur-II Total

Urea Production MTPD 2115 3030 5145 Feed NG SM3/day 819450 1124816 1944266 Fuel NG SM3/day 350062 655203 1005265 Coal MT/day 784.6 - 784.6 Fuel to SG SM3/day 36000 248650 284650 Ammonia Energy Gcal/MT 8.692 7.197 7.811 Urea Energy Gcal/MT 6.305 5.390 5.751

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3. The utilities (Water, Power & Steam) consumption.

The Water consumption of Phulpur Complex is around 35,500 M3 per day. The water is being sourced through Borewells provided within IFFCO premises. Normally 4,200 M3 per day waste water which includes around 2,400 M3 per day Cooling water blow down is being generated which is treated in the Effluent Treatment Plant. Part of the treated Waste water is being recycled in the plant after treatment in Reverse Osmosis (RO) Plant. The reject of RO Plant is being used for dust suppression in Coal Yard/Ash Pond. The balance treated waste water is being used for Green Belt development, Horticulture and for dust suppression in Coal Yard and Ash Pond. There is no discharge of effluent from the complex. The quality of treated effluent meets the limit specified by Pollution Control Board. The Online monitoring system for flow and quality of treated Effluent has been installed.

The Steam Generation facil i ty consists of 3x125 MT/hr Coal Fired Boilers (2 working and 1 standby), 1x200 MT/hr LSHS/Gas Fired Boiler, with total Steam Generation capacity of 450 MT Steam per hr. Around 32.7 MT per Hour Coal and 12,387 SM3 per Hr NG is being used. For meeting the total power requirement, Phulpur unit is having two Turbo Generators of capacity 12.5 MW and 18 MW respectively.

The Offsites facil i t ies include water De-Mineralisation plant, Water Softening Plant, Ammonia Storage Tank, Inert Gas generation unit and Air Compressors for Instruments and Plants.

4. Energy Consumption of Plants: The average Energy Consumption of Phulpur Unit –I & II in last 3 years is as follows:

Table-1 Unit 2012-13 2013-14 2014-15 Average

Phulpur-I Gcal / MT Urea 6.697 6.736 6.651 6.695 Phulpur-II Gcal / MT Urea 5.716 5.668 5.634 5.673

5. Revamping / Modification of the Plant:

Urea business in India is covered under Essential Commodity Act (ECA) and same is governed by Department of Fertilizer (DoF), Government of India. As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced w.e.f. 1st June, 2015 tp 31st March, 2018 to 7.145 Gcal/MT Urea for Phulpur-I and 5.744 Gcal/MT Urea for Phulpur-II and for 2018-19, 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II.

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Table-2

Unit Unit Energy Norms as per new Urea

Policy 2015

Present Average Energy (in last 3 years)

Difference

Phulpur-I Gcal/MT Urea 6.5 6.695 - 0.195 Phulpur-II Gcal/MT Urea 5.5 5.673 - 0.173

From Table 1 & 2, it may be concluded that with present energy consumptions, the operation of Phulpur Complex will become unviable. Therefore, in order to remain competitive, IFFCO has undertaken Modification/ Revamping of its Ammonia–Urea Complex to reduce the Specific Energy consumption of Plant.

6. Proposed Modification/Revamping Schemes: It is proposed to implement various Modification/ Revamping of Ammonia-Urea Plant including installation of GT-HRSG at IFFCO Phulpur to implement the latest available proven Technological solution to improve Reliability of Process / Equipments and to reduce the Energy Consumption by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II. The configuration of Ammonia Urea Complex of Phulpur Unit along with proposed Revamping/ Modification is placed at Annexure-I.

The schemes being implemented are as under:

Phulpur-I

S. No. Schemes under consideration Plant

1. Modification in CO2 Recovery Process – aMDEA Process in place of existing GV Process Ammonia

2. New Efficient LO / SO Backpressure Turbines Ammonia

3. Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement Ammonia

4. Installation of VAM for Process Air Compressor Suction Chilling Ammonia

5. Ammonia Recovery from Synthesis Loop LP Purge Gases Ammonia

6. Saturated MP Steam Export from Synthesis Loop to Urea Plants Ammonia

7. Installation of MP Stripper for Process Condensate Stripping Ammonia

8. New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C) Ammonia

9. Synthesis Gas Converter (105D) Revamp Ammonia10. Installation of HP Ammonia Pre-heater Urea

11. Installation of VAM for Urea CO2 Compressor Suction Chilling Urea

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12. New Urea Reactor Trays Urea 13. New GT-HRSG package SGP

14. Replacement of Process Air Compressor Turbine (101-JT) & Refrigeration Turbine 105JT SGP

15. Installation of New Ammonia Storage Tank (double wall double integrity), Capacity 10,000 MT Offsite

Phulpur-II

S.No. Schemes under consideration Plant

1. Revamping of Synthesis Gas Compressor Ammonia

2. Modification in CO2 Recovery Process – aMDEA Process in place of existing GV Process Ammonia

3. Ammonia Wash (Syn gas drying) in synthesis compressor interstage and loop reversal Ammonia

4. Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement Ammonia

5. Revamping of CO2 Compressors Urea

6. Installation of HP Ammonia Preheater (2 Nos.) Urea

7. New Urea Reactor Trays (2 Set) Urea

7. Consumption of Raw Material and Utilities after Revamp.

The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM3 per day after Revamp at same production level. Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation.

The Water consumption of Phulpur Complex will not increase after Revamp and there will be reduction of wastewater generation. There will be reduction in emission of SO2 due to partial replacement of Coal with NG having Sulphur content as low as less than 10 ppm. Further, there will be reduction in daily consumption of NG which will reduce the over-all pollution load in the surrounding environment.

8. Emission Load- Before and after Revamp: The present emission loads of CO2 around 138.6 MT/hour considering the present Fuel consumption. After revamp the emission load of CO2 would be 95.3 MT / hour considering the projected Fuel consumption maintaining the same production level. Further, the emission level of PM, SOx & NOx is expected to reduce due to reduction in consumption of NG and Coal at same production level as explained above. Further, there will be reduction of wastewater generation around 900 m3 per day at same production level.

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9. Capacity of the Plant after Revamp: The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remain the same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days).

10. Proposal: As per the Notification dated 22nd August, 2013 of MoEF, any modernization of existing project entailing the capacity addition with change in Process and/ or Technology shall be undertaken only after prior Environment Clearance. The proposed Revamp does not entail any capacity addition and no process change and/or Technology Change are being carried out. Hence, seeking prior Environment Clearance was not applicable in this case.

Further, the Expert Appraisal Committee (Industry 2) during its 46th meeting held on 20th and 21st August, 2015 considered the above proposal. The MoEF&CC vide letter dated J-11011/198/2015-1A II (I) observed that there the proposal does not contain details of existing plant configuration and proposed modification to be carried out. Further, the information regarding water consumption, energy requirement, waste water management, solid waste management is incomplete. Further, it was opined that although there is no increase in production but only few units are being changed which involves amendment of existing environmental conditions. Accordingly, it was suggested to submit revised complete proposed with Form-I.

In view of the above, the revised proposal has been prepared which includes: (i) details of existing plant configuration and proposed modification to be carried out; (ii) water consumption; (ii) energy requirement; (iii) waste water management; and (iv) solid waste management, etc. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14th July, 2006 may be amended. Proposed changes in Environmental condition are attached as Annexure-II.

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CHAPTER-II The existing Environment & Pollution Control Management:

1. Various Emission Control Measures:

IFFCO Phulpur is committed to reduce Green House Gas (GHG) emissions through implementation of innovative and pioneering projects. The various init iatives that have resulted in signif icant reduction of GHG emission are: ( i) Switchover of Fuel and Feed from Naphtha to Natural Gas (NG); ( i i) Installation of Carbon Dioxide Recovery to recover 450 MT CO2 per day from Flue Gases to meet the short fal l of CO2 for Urea production; and (i i i) various energy eff iciency measures to reduce the consumption of NG. Further, for control of Air emission, Electro Static Precipitators (ESP), Cyclonic Dust Collectors, Scrubbers for Gaseous Emissions, Flare Stacks, and Chimneys of adequate height for Steam Generation units have been installed and operated eff iciently. The Stack emissions are always well with-in the prescribed l imits stipulated by UP State Pollution Control Board (UPSPCB) & National Emission Standards. The copy of report submitted to UPSPCB for Emission from the Stack and ambient air quality for the month of December, 2015 is attached as Annexure-III.

Stack Emission Quality (Range) for the last three year (2012-15) are as under:

Sample Point

UREA DUST (mg/Nm3) PCB limit: (i) 150 mg/NM3 for Prill Tower-I (ii) 50 mg/Nm3 for Prill; Tower-II)

SPM (mg/Nm3) (PCB limit: < 350 mg/NM3)

Year 12-13 13-14 14-15 12-13 13-14 14-15 Power Plant-I NA NA NA 342-290 337-285 342- 293Power Plant-II NA NA NA 18-09 17-06 21– 6 Prilling Tower-I 32.7-21.9 34.2-25.0 33.2 – 25.6 NA NA NA Prilling Tower-II 35.3-23.9 34.1-23.8 34.2 – 23.3 NA NA NA

Sample Point

SO2 (mg/Nm3) (PCB limit: <200 ppm

or 571 mg/NM3)

NOx (mg/Nm3)

(PCB limit: <100 ppm) Year 12-13 13-14 14-15 12-13 13-14 14-15

Power Plant-I 496-336 467-310 526- 305 90-72 92-74 95-72 Power Plant-II < 1.0 < 1.0 < 1.0 86-68 90-72 86-69 Pri. Reformer -I <1.0 <1.0 <1.0 52-42 56-42 52-32 Pri. Reformer -II Stack

<1.0 <1.0 <1.0 56-42 54-42 54-26

HRU stack <1.0 <1.0 <1.0 54-42 52-42 44-28

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The ambient air quality in surrounding area of the factory is well with-in the l imits. Ambient Air Quality (Range) for the last three year (2012-15) is given below:

AAQ Monitoring Stations

PM 10 (microgram/m3)

SO2 (microgram/m3)

12-13 13-14 14-15 12-13 13-14 14-15 CORDET 47-27 42-28 56-30 18-08 19-09 34-09 Central School 47-31 45-28 54-28 20-08 18-09 32-10 Railway Gate 47-31 46-28 56-30 22-08 18-09 32-09 B.W.No. 8 48-30 47-28 56-28 21-08 18-09 32-09 Gate No.4 47-32 44-28 56-28 26-08 18-09 34-09

AAQ Monitoring Stations

Ammonia (microgram/m3)

NOx (microgram/m3)

12-13 13-14 14-15 12-13 13-14 14-15 CORDET 54-28 55-32 55-22 26-08 28-08 28-09 Central School 53-29 54-28 52-22 28-09 26-09 36-09 Railway Gate 55-31 55-30 55-20 26-08 27-09 27-0 9 B.W.No. 8 55-28 55-27 54-22 27-06 27-09 30- 09 Gate No.4 56-27 55-30 46-20 28-08 28-09 28- 09

A brief description of Air Pollution Management Practices implemented at IFFCO Phulpur Unit is attached as Annexure-IV.

2. Effluent Management:

The liquid effluents generated from the various plants are subjected to adequate Treatment viz; (i) Deep Hydrolyser; (ii) Distillation Column; (iii) Stripper; (iv) Effluent Treatment Plant based on Steam Stripping; (v) Disc Oil Separator; and (vi) Reverse Osmosis Plant. The treated water from Reverse Osmosis plant is reused in process as cooling water make up. The domestic Sewage Water is treated in Sewage Treatment Plant and reused as Cooling Water make up and for Irrigation of Farm Land. The Sewage sludge after drying is utilised as manure in our Farm Land.

The present facility for liquid effluent treatment is sufficient for present & future need and IFFCO ensure that the treated water quality will confirm to the specification laid down by State Pollution Control Board. The entire effluent generated in the plant is being recycled / reused in plant process and irrigation after adequate treatment in the ETP. There is Zero Discharge of Treated Effluent from the plant premises.

The treated effluent quality is well within the specified limit of UPPCB. The copy of the report on quality of effluent at Guard Pond for the month of December, 2015 is placed at Annexure-V.

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The Analysis of Effluent (Guard Pond) for last three year (2012-15) are as under:

Characteristics (All values are mg/l except pH)

PCB norms

2012-13 2013-14 2014-15

pH 6.5-8.0 7.5-6.8 7.4 – 6.90 7.6– 7.0 TSS <100 52-30 46-30 58 – 30 BOD5 at 20 deg C <30 28.75-18.62 26.82-18.72 28.27 – 18.70 Oil & Grease <10 3-N.T. 3-2 3- Absent Total Chromium as Cr, 2.0 N.T. N.T. N.T. Hexavalent Chromium as Cr+6

0.1 N.T. N.T. N.T.

Zinc as Zn <5 0.82-0.28 0.68-0.28 0.62 – 0.36 COD <250 84-36 95-38 86 – 39 Chlorides as Cl <1000 800-312 560-346 570 - 312 Free Ammonia As N <4 1.38-0.07 0.49-0.12 0.57 – 0.20 Total Kjeldahl Nitrogen as N

<100 46.75-17.10 42.32-19.62 42.72-23.70

Nitrate Nitrogen as N <10 2.72-1.88 2.35-1.90 2.25-1.98 Dissolved Phosphate <5 3.65-1.72 2.36-1.46 3.16 – 1.52 Vanadium as V <0.2 N.T. N.T. N.T.

A brief description of Waste Water Management Practices implemented at IFFCO Phulpur Unit is attached as Annexure-VI.

3. On line Monitoring System:

On line monitoring systems for Flow and Quality of Liquid Effluent and emission from Boiler Stack have been installed at IFFCO Phulpur Unit. The Online monitoring system has also been installed at Prill Tower on trial basis as per direction of CPCB. The data connectivity with CPCB server has been established. Detail of this system is attached as Annexure-VII.

4. Solid Waste (Hazardous & Non-hazardous):

All the applicable provision of Hazardous Waste (Management, Handling & Trans Boundary) Rule 2008 are being complied as per Authorisation No. 108/ HW- 52/14 dated 10/07/14 issued by UPSPCB. The report on Hazardous Waste for the year 2014-15 is placed at Annexure-VIII.

Solid wastes are disposed in efficient manner. Fly Ash is being given to Cement Industry for use in manufacturing of Cement. Also Fly Ash is being used for Fly Ash Brick making, reclaimation of Usar land and Land filling of low lying area.

The Spent Catalyst & Waste Oil is being sold to authorized Recycler as per Hazardous Waste Rule is a regular process. Detail of Solid Waste Management practices is attached as Annexure-IX.

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5. Rain Water Harvesting Systems:

To conserve the Rain Water, we have installed 8 Nos. Rain Water Harvesting Systems at different places as per detail placed at Annexure-X.

6. Management System as per International Standards:

IFFCO Phulpur Unit has established and implemented Environment Management System, Quality Management System, Energy Management System and Occupational Health, Safety Management System as per the Norms of International Organisation for Standardization (ISO).

It has been accredited ISO 14001: 2004 for Environment Management System, ISO 9001: 2008 for Quality Management System, OHSAS 18001:2007 for Occupational Health, Safety Management System, & ISO 50001:2011 Certification for Energy Management System.

IFFCO Phulpur has received ISO 14001: 2004 Certification for: (i) Factory Premises; (ii) Residential Township, Ghiya Nagar; (iii) IFFCO Hospital, Ghiy Nagar; and (iv) Moti Lal Nehru Farmers Training Institute, Phulpur located nearby the factory. Copy of above certificates is attached as Annexure-XI.

7. Environment Clearance:

Existing Environment Clearance was issued by Ministry of Environment and Forest on 14th July, 2006 vide letter No. J-11011/150/2006-IA II (I) for Capacity Enhancement- De-bottlenecking and LNG Conversion Project of IFFCO Phulpur Unit. Copy of this Environment clearance is attached here as Annexure-XII. This LNG conversion project has been completed in July 2006 & Capacity Enhancement Project in December 2008.

Inspection of Unit to check the compliance of Environment Clearance condition by Officers of MoEF & CC are being carried out regularly. Certified compliance report of the conditions issued by MoEF&CC, Lucknow vide letter No. IV/ENV/UP/IND-83/204/2006/769 dated 11/09/2015 is placed at Annexure-XIII. The latest compliance report of April, 15 to September, 15 is attached as Annexure-XIV.

8. Consent for Air Emission, Liquid Effluent & their status:

Consent for Air Emission under Air Act 1981 (No. 186/C-9/Sahmati8(Vayu) /2/7/2014 dated 3/2/14) and consent for Effluent discharge under Water Act 1974 (No. 191/C-9/sahmati Jal /52/2014 dated 3/2/14), was issued by U.P. Pollution Control Board (placed at Annexure-XV) which is valid upto 31st December, 2015. Applications for renewal of both consents has been submitted to U.P. Pollution Control Board (placed as Annexure-XVI).

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CHAPTER-III

Description of Energy saving schemes to be implemented in Ammonia plant Phulpur-I Unit

Scheme-1: Reduction in Steam to Carbon ratio in Reforming Section from

3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal Section.

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas.

Scheme-2: Replacement of Process Air Compressor Turbine and Refrigeration Compressor Turbine in Ammonia-I Plant.

The Turbines will be replaced with new efficient turbines. The Replacement will be on the same base frame and inlet & outlet connections will be hooked-up with existing lines

Scheme-3: New Efficient LO / SO Back Pressure Turbines.

After changeover from GV to aMDEA System the LP Steam reboiler will be no more required. If the inefficient lube oil and seal oil turbines are not replaced, the LP Steam will be required to vent. With the replacement of New Efficient Steam Turbines there will be less generation of LP Steam and avoiding venting of steam.

Scheme-4: Installation of Fuel Gas Expander with power generator.

NG fuel which is let down in existing system from around 40 kg/cm2g to 4.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW.

Scheme-5: Installation of Vapour Absorption Machine for the cooling of inlet air to Process Air Compressor.

A Vapour Absorption Machine (VAM) shall be installed in Ammonia-I to generate chilled water for new process air chiller to be installed at the suction of Process Air Compressor. This shall cool the inlet air of Process Air Compressor from 40°C to 15°C, resulting in saving of NG being used as fuel for Gas Turbine drive of Process Air Compressor. The heating medium in VAM machine shall hot water from Primary Reformer Convection Coil.

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Scheme-6: Ammonia Recovery from Synthesis Loop LP Purge Gases.

It is proposed to recover ammonia from the flash gas from synthesis loop off gas in new Flash Gas Washing Column. This modification shall result in additional Ammonia Recovery of 2 MT/Day.

Sweet Water Cooler system shall be replaced with new heat exchanger using cooling water directly as cooling medium for better cooling of syn gas. This shall also reduce loop pressure by around 5 kg/cm2 and steam saving in Syn Gas Compressor turbine by around 2 MT/hr.

Scheme-7: Saturated MP Steam Export to Urea Plant.

The Saturated MP Steam will be exported to Urea Plant for use of Process Steam at 25 ata pressure after letdown from 39 ata. This will reduce requirement of Inlet Steam in CO2 Compressor Extraction- cum- Condensing Turbine of Urea Plant as there will be less requirement of extraction steam.

The Net Saving will be realized in terms of less condenser load of Synthesis Turbine and CO2 Turbine together.

Scheme-8: Installation of MP Stripper for Process Condensate Stripping.

The existing system will be replaced with MP Steam Process Condensate Stripper. With the proposed modification, the MP Steam is used which after stripping off the gases goes back to the steam circuit.

Scheme-9: New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C).

Existing 115-C is not sufficient enough to cool down the syn gas to the optimum temperature of 39 – 40 degC. With additional Exchanger I parallel the cooling water availability will be increased which will reduce the syn gas temperature.

In the new system one additional BFW Heater will be installed to recover heat from the hot process gas before it enters the CO2 Removal Section.

Scheme-10: Synthesis Gas Converter (105D) Revamp.

It is proposed to revamp the internals of Synthesis Gas Compressor with new patented technology internals. This intervention will result in improvement in the NH3 Conversion from 2.5 to 17 mol% and maximizing the heat recovery in the form of steam generation.

Description of Energy saving schemes to be implemented in Urea plant of

Phulpur-I Unit

Scheme-1: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion.

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion,

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by improving the heat and mass transfer phenomena occurring inside the reactor.

Scheme-2: Installation of Ammonia Preheaters.

In Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce.

Scheme-3: Installation of Vapour Absorption Machine for the cooling of inlet CO2 gas to CO2 Compressor.

A Vapour Absorption Machine (VAM) shall be installed to generate chilled water required for CO2 Gas chiller to be installed at the suction of CO2 Compressor of Urea plant. This shall cool inlet CO2 gas of CO2 Compressor from 45°C to 20°C, resulting in saving of steam consumption in CO2 Compressor turbine of Urea plant. The heating medium in VAM machine shall be LP steam.

Description of Energy saving schemes to be implemented in Ammonia Plant of Phulpur-II Unit

Scheme-1: Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section for less energy requirement.

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated in three stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The source of regeneration energy shall be only process gas. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas.

Scheme-2: New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge.

In order to increase the energy efficiency of the synthesis loop, a syngas dehydration system based on liquid ammonia washing shall be introduced at Synthesis Gas Compressor second stage discharge. The oxygenated compounds (H2O, CO and CO2) available in Syn Gas shall be separated in

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ammonia wash system. With this modification, Syn Gas Compressor 3rd stage discharge which is free from oxygenated compounds, can be mixed directly with recirculator discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st Ammonia Synthesis converter. With this modification, there shall be reduction in power requirement in tubine drive of Synthesis Gas Compressor by around 900 KW.

Scheme-3: Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency.

Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced by new barrels for increasing the efficiency of Syn Gas Compressor. This shall result in saving in steam requirement in turbine drive of Synthesis Gas Compressor by around 10 MT/hr.

Scheme-4: Installation of Fuel Gas Expander with power generator.

NG fuel which is let down in existing system from around 40 kg/cm2g to 5.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW.

Description of Energy saving schemes to be implemented in Urea plant of Phulpur-II Unit

Scheme-1: Replacement of existing CO2 Compressors by new higher efficiency compressors.

In both 31 & 41 Units of Urea plant, existing CO2 Compressor shall be replaced with new CO2 Compressor of higher efficiency. This shall result in saving in steam consumption in steam turbine drive of CO2 Compressor by around 9 MT/hr.

Scheme-2: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion.

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor.

Scheme-3: Installation of Ammonia Preheaters.

In both streams of Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped

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to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce.

Description of Energy saving schemes to be implemented in Steam & Power Generation Plant.

Scheme-1: New GTG-HRSG Package for Power and Steam Generation.

The Proposed System, GTG-HRSG will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam.

In Phulpur Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is 12500 Sm3/Hr RLNG and 250 MTPD Coal. Whereas, the same quantity of Electric Power & HP Steam will be generated by only 9455 Sm3/Hr RLNG in GT-HRSG

Detail of these schemes (comparison with existing) with estimated saving is attached as Annexure-XVII.

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CHAPTER-IV The Impact of proposed Revamp:

1. Energy Consumption:

The average Energy Consumption of Phulpur Unit –I & II in last 3 years is as follows:

Table-1 Unit 2012-13 2013-14 2014-15 Average

Phulpur-I Gcal / MT Urea 6.697 6.736 6.651 6.695 Phulpur-II Gcal / MT Urea 5.716 5.668 5.634 5.673

As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced to 7.145 Gcal/MT Urea for Phulpur-I and 5.744 Gcal/MT Urea for Phulpur-II for the period of 1st June, 2015 to 31st March, 2018 and 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II for the period of 2018-19.

Table-2 Unit Unit Energy Norms as

per new Urea Policy 2015

Present Average Energy (in last 3 years)

Difference

Phulpur-I Gcal/MT Urea 6.5 6.695 - 0.195 Phulpur-II Gcal/MT Urea 5.5 5.673 - 0.173

Modification/ Revamping of its Ammonia–Urea Complex has been undertaken to reduce the Specific Energy consumption of Plant by 0.947 Gcal per MT Urea in Phulpur-I and 0.386 Gcal per MT Urea in Phulpur-II.

2. Consumption of Raw Materials:

The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM3 per day after Revamp. Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation from 274 MT to about 91 MT.

3. Consumption of Utilities (Water, Steam & Power);

(i) Power Consumption:

Presently the total power requirement of 23 MW is being met by two Nos. of Turbo Generator (TG) of 12.5 MW and 18.0 MW Capacity. Now it is proposed to install GTG-HRSG which will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam.

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In Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is 12500 Sm3/Hr RLNG and 250 MTPD Coal. The GTG-HRSG will generate 23.65 MW Electric Power & 60 MT/Hr HP Steam by using only 9455 Sm3/Hr RLNG in GT-HRSG. Hence, the Coal consumption will reduce by 250 MTPD. After installation of GT-HRSG both the TG will be stopped. Further, one No. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped. The Power Balance before and after Revamp are as under:

Before Revamp

After Revamp

Increase after Revamp

1. Generation MW MW MW

(i) TG-I 10.5 - (ii) TG-II 12.5 - (iii) New GT-HRGS - 23.65

Total generation 23.0 23.65 0.652. Consumption (i) Ammonia-I 0.55 0.37 (-)0.18

(ii) Urea-I 2.58 2.57 (-)0.01(iii) Ammonia-II 1.10 2.50 1.40(iv) Urea-II 3.50 3.18 (-)0.32

(v) Ammonia-I CT 1.40 1.40 0

(vi) Urea-I CT 1.80 1.82 0.02

(vii) Ammonia-II CT 1.00 2.55 1.55

(viii) Urea-II CT 2.50 2.60 0.10(ix) Offsites & non plants 4.26 4.26 0

(x) CDR 1.10 1.10 0

(xi) SGP I&II 3.15 1.30 (-)1.85

Total consumption 22.94~ 23.00

23.65 0.65

(ii) Steam (HP) balance:

There are three Nos. Coal Fired Steam Generation plants of 125 MT/hr capacity Coal Fired Boilers (2 working and 1 standby), and one No. LSHS/Gas Fired Boiler of 200 MT/hr capacity. Further, in Ammonia-II, 94.40 MT/Hr HP Steam is generated.

After installation of GT-HRSG, one Nos. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped.

The Steam Balance before and after Revamp are as under:

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Before Revamp

After Revamp

Decrease after Revamp

1. HP Steam Generation MT per hr MT per hr MT per hr

(i) SGP-I 189.70 72.00 117.70(ii) SGP-II 94.60 0 94.60(iii) Ammonia-II 94.40 93.80 0.60(iv) New GT-HRGS - 48.80 (-)48.80

Total generation 378.70 214.60 164.102. HP Steam Consumption (i) Ammonia-I 41.50 37.60 3.90(ii) Urea-I 87.20 54.70 32.50(iii) Urea-II 128.00 122.30 5.70

(iv) TG-I 56.80 0 56.80(v) TG-II 65.20 0 65.20

Total consumption 378.70 214.60 164.10

(iii) Water Balance:

The Water consumption of Phulpur Complex is around 35,500 M3 per day. Out of this 25,680 M3 per day is being used in Cooling Tower, 4,345 M3 per day is being used in DM Plant, 1,370 M3 per day is being used for Service Water requirement and 4,105 M3 per day is being used in Township. The Water consumption of Phulpur Complex after Revamp will reduce to 30,120 M3 per day, at same production level (reduction by 5,400 M3 per day) which includes 22,800 M3 per day is being used in Cooling Tower and 1,850 M3 per day is being used in DM Plant. The Water requirement for Services and Township may remains unchanged. Due to reduction in water consumption, there will be substantial reduction of about 900 m3/day of wastewater.

The Water Balance before and after Revamp are as under:

Before Revamp After Revamp Decrease after Revamp

M3/ hr M3/ day M3/hr M3/day M3/hr M3/ day 1. Raw Water

supply 1479 35496 1255 30120 224 5376

2. Consumption (i) Cooling Tower 1070 25680 950 22800 120 2880(ii) DM Plant/CPU 181 4344 77 1848 104 2496

(iii) Service Water 57 1368 57 1368

- -

(iv) Township use 171 4104 171 4104 - -

Total consumption

1479 35496 1255 30120 224 5376

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3. Waste water generation (i) C.T. Blow

down 100 2400 70 1680 30 720

(ii) DM/CPU waste

75 1800 68 1632 7 168

(iii) Waste water from

Ammonia/ Urea/SGP

- - - - - - (occasional) (occasional)

Total waste water

generation

175 4200 138 3312 37 888

The Power, Water and Steam balance before and after Revamp is placed at Annexure-XVIII.

(iv) Pollution Load: The Natural Gas (NG) is being used as Feed and Fuel whereas Coal is being used as Fuel. The consumption of NG and Coal at three scenario i.e. (i) Present Production of 5145 MTPD Urea; and (ii) Production of 5145 MTPD Urea after Revamp have been derived as under:

S No. Particular Plant / Section Unit Present 5145

MTPD 5145 MTPD

after Revamp

1) Feed Phulpur-I Sm3/Hr 34144 33450

Phulpur-II Sm3/Hr 46867 46860

Total Phulpur-I + II Sm3/Hr 81011 80310

2) Fuel Ammonia-I Primary Reformer

Sm3/Hr 12486 12200

Ammonia-I Aux. Boiler

Sm3/Hr 2100 1950

SGP Boiler 1,2,3 Sm3/Hr 1500 1500 Ammonia-II

Primary Reformer Sm3/Hr 16551 15910

Ammonia-II PAC GT-HRSG

Sm3/Hr 10749 9284

SGP Boiler 4 Sm3/Hr 10887 -

GTG-HRSG Sm3/Hr - 9597

Total Phulpur-I + II Sm3/Hr 54273 50441

3) Total Feed+ Fuel

Phulpur-I + II Sm3/Hr 135284 130751

MMSCMD 3.2468 3.1380

4) Coal SGP Boiler 1,2,3 MT/Hr 32.7 11.0

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MTPD 785 264

5) CO2 Emission

Phulpur-I + II MT/Hr 138.6 95.3

Emission factors: Source IPCC Gudlines Vol 2 Table 1.4

It may be observed that the NG consumption will reduce by 1,08,800 SM3 per day after Revamp, whereas there will be reduction of 521 MT per day Coal at this production level. Hence, CO2 emission will reduce by 43.30 MT/Hr after Revamp.

(iv) Production Capacity:

The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remain the same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days).

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CHAPTER-V

Estimated Capital Cost

The estimated capital cost of these is as under (Rs. in crore): Sr No Units Equipment Cost

(including Contingency)

BEDP DEDP Total

1. Phulpur-I 601.35 19 7 627.35

2. Phulpur-II 329.00 16 4 349.00

3. TOTAL 930.35 35 11 976.35

BEDP : Basic Engineering Design Package DEDP : Detailed Engineering Design Package Pay Back period: The overall saving in Urea specific energy at each Unit and pay back period will be as under:

Particulars UNIT P-I P-II Total Urea Plant Capacity MTPD 2115 3030 5145 Energy Saving Gcal/MT 0.947 0.386 0.467 Estimated Investment Rs in crore 627.35 349 976.35Monetary Savings Rs in crore 151 97 248 Payback Years 4.16 3.60 3.94

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CHAPTER-VI Request for Amendment in existing Environment Clearance condition: The scope of work includes replacement of 34 years old machineries in the complex. It is envisaged that energy reduction shall be about 0.467 Gcal/MT of Urea. There shall be savings in consumption of raw materials like NG, Coal & Water as explained earlier. Further, the emission of CO2, PM, NOx, & Sox will reduce. As per the Notification dated 22nd August, 2013 of MoEF, it is mentioned that the any modernization of existing project entailing the capacity addition with change in Process and / or Technology shall be undertaken only after prior Environment Clearance. The proposed Revamp does not entail any capacity addition and no process change and/or Technology Change are being carried out. Hence, seeking prior Environment Clearance was not applicable in this case.

Further, the Expert Appraisal Committee (Industry 2) during its 46th meeting held on 20th and 21st August, 2015 considered the above proposal. The MoEF&CC vide letter dated J-11011/198/2015-1A II (I) observed that there the proposal does not contain details of existing plant configuration and proposed modification to be carried out. Further, the information regarding water consumption, energy requirement, waste water management, solid waste management is incomplete. Further, it was opined that although there is no increase in production but only few units are being changed which involves amendment of existing environmental conditions. Accordingly, it was suggested to submit revised complete proposed with Form-I.

In view of the above, the revised proposal has been prepared which includes: (i) details of existing plant configuration and proposed modification to be carried out; (ii) water consumption; (ii) energy requirement; (iii) waste water management; and (iv) solid waste management, etc. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14th July, 2006 may be amended. Further, the Expert Appraisal Committee (Industry 2) during its 46th meeting held on 20th and 21st August, 2015 considered the above proposal and that observed that there is no increase in production. However, only few units are being changed which involves amendment of existing environmental conditions. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14th July, 2006 may be amended.

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ANNEXURE-I

Annexure-II Proposed Changes in Environmental Clearance Condition

Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause

no. Existing Environment Clearance granted vide letter No. J-

11011/150/2006-IA II (I) dt 14.07.2006 Proposed

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Subject Capacity enhancement/de-bottlenecking and LNG conversion of IFFCO at P.O. Ghianagar, Allahabad, U.P. by M/s IFFCO – Environmental clearance reg.

Modification/ Revamping of Ammonia-Urea plant including installation of GT-HRSG at IFFCO Phulpur Unit, P.O. Ghiyanagar, Allahabad, U.P.–Amendment of EnvironmentClearance Condition reg.

Para 1 This has reference to your letter no. nil dated 12th April, 2006 on the above mentioned subject alongwith questionnaire, EIA/EMP, risk assessment report and CD containing above mentioned document and subsequent communication dated 12th May, 2006, 22nd May, 2006 and 1st June, 2006 seeking environment clearance under the Environmental Impact Assessment Notification, 1994.

This has reference to your online application dated ____ on the above mentioned subject seeking amendment of the existing environment clearance conditions under the Environmental Impact Assessment Notification, 1994.

2.0 The Ministry of Environment & Forests has examined the application. It is noted that M/s IFFCO have proposed for the capacity enhancement (debottlenecking and LNG conversion from 4290 to 5145 MTPD Urea and 2497 to 2955 TPD Ammonia at Phulpur, Allahabad in Uttar Pradesh. Feed Naphtha will be replaced with R-LNG (Re-Gasified liquid Nitrogen Gas) except in case of LNG shortage/emergency when LNG will be used. Total Land available is 432.2 ha and no additional land will be required for the expansion project.

The Ministry of Environment & Forests and Climate Change has examined the application. It is noted that M/s IFFCO Phulpur Unit has proposed modification/revamping of its Ammonia- Urea plant. The production capacity will reamin same as (i) Urea: 5145 MTPD (18.78 Lakh MTPA); and (ii) Ammonia: 2955 MTPD (10.79 Lakh MTPA).

Total Land available is 432.2 ha and no additional land will be required.

3.0 SO2 emissions from Ammonia Plant will be reduced due to use of cleaner fuel. Installation of CO2 recovery plant will reduce CO2 emissions in the environment. Total water requirement from the ground water for the existing plant is 35,500 m3/day and no additional water will be required for the expansion project. All the treated effluent will be recycled and reused in the process or green belt development.No additional effluent will be generated and discharged outside the premises except during rainy seasons. Ash. Lime sludge and spent catalyst will be generated as solid waste and will be disposed off properly.

Emission and Ash generation is expected to reduce due to implementation of the proposed Schemes including GT-HRSG. Total water requirement from the ground water for the existing plant is 35,500 m3/day and no additional water will be required after Revamp / Modification. All the treated effluent will be recycled and reused in the process or green belt development. No effluent will be discharged outside the premises except during plant interruption/ rainy seasons. Ash, Lime sludge and spent catalyst will be generated as solid waste and will be disposed off properly.





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4.0 Public hearing meeting was held on 8th August 2005. ‘NOC’ has been accorded by the UPPCB vide letter no. F55.780/c-2/NOC/3306/05 dated 08/02/2006. Total cost of the project will be Rs. 263.09 Crores.

Total cost for implementation of the proposed schemes would be Rs. 976.35 crore.

5.0 The Ministry of Environment and Forests hereby accords environmental clearance to the above unit under the EIA Notification, 1994 as amended subsequently subject to the compliance of the terms and conditions mentioned below:

The Ministry of Environment and Forests and Climate Change hereby accords approval for amendment of Environment Clearance condition to IFFCO Phulpur Unit as per the EIA Notification, 2006 as amended subsequently subject to the compliance of the terms and conditions mentioned below:

Specific Conditions :

Sr.No. Conditions (existing) Conditions to be Change

1. The gaseous emissions (SO2, NOx, NH3, Urea dust) particulate matter from various process unit shall conform to the standards prescribed by the concerned authorities from time to time. CO2 recovery plant shall be installed to reduce CO2 emissions in the environment. At no time, the emission levels shall go beyond the stipulated standards, In the event of failure of pollution control systems(s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency.

The gaseous emissions (SO2, NOx, NH3, Urea dust), particulate matter from various process shall conform to the standards prescribed by the concerned authorities from time to time. At no time, the emission levels shall go beyond the stipulated standards, In the event of failure of pollution control systems(s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency.

2. In urea plant, particulate emissions shall not exceed 50 mg/m3. Monitoring of prilling tower shall be carried out as per CPCB guidelines. Hydrocarbon monitors shall be installed.

In Urea plant,, particulate emissions shall not exceed the prescribed standard stipulated by CPCB/SPCB / as given in consent. Monitoring of Prilling tower shall be carried out as per CPCB guidelines.

3. Ambient air quality monitoring stations shall be set up in the downwind direction as well as where maximum ground level concentration are anticipated in consultation with the UPPCB and data submitted to the Ministry’s Regional Office at Lucknow six monthly and UPPCB quarterly

Data of Ambient air quality monitoring stations (5 nos.) shall be submitted to the Ministry’s Regional Office at Lucknow six monthly and UPPCB quarterly alongwith statistical analysis.





Page 3 of 5

alongwith statistical analysis.

4. Total water requirement after expansion shall not exceed 35,500 m3/d. All the effluent generated shall be recycled & reused in the process toreduce the fresh water consumption or green belt development. No effluent shall be discharged outside the premises except during the rainy season after meeting the norms prescribed under the E (P) Act, 1986 and UPPCB whichever are more stringent.

Total water requirement in the plant after revamping shall not exceed 35,500 m3/d. All the effluent generated shall be recycled & reused in the process to reduce the fresh water consumption or green belt development. No effluent shall be discharged outside the premises except during the rainy season after meeting the norms prescribed under the E (P) Act, 1986 and UPPCB whichever are more stringent..

5. Regular monitoring of ground water by installing peizometric wells around the guard pond and Chromium sludge disposal site shall be periodically monitored and reports submitted to Ministry’s Regional Office at Lucknow, CPCB and UPPCB.

Regular monitoring of ground water around the guard pond and Chromium sludge disposal site shall be done and reports will be submitted to Ministry’s Regional Office at Lucknow, CPCB and UPPCB.

6. As per the Fly ash notification, 100% utilization of the fly ash generated shall be ensured. Ash shall be provided to different users for making bricks etc. or properly used for filling low lying areas of town ship, surrounding villages and developing green belt.

Spent catalysts generated shall be properly stored in closed metallic drums before selling to authorized recyclers / re-processors. Waste oil shall be used in steam generation plant as fuel alongwith coal or sold to authorized recyclers/ reprocessors.

No change

7. The company shall undertake adequate protection measures for handling of ammonia vapours in case of plant upset condition. Safety well exhaust and drains shall be connected to a separate close header from which ammonia vapours shall be vented from vent stack after diluting with stream.

No change.

8. The company shall implement all the recommendations made in the Charter on Corporate Responsibility for Environmental Protection (CREP)

No change.





Page 4 of 5

for fertilizer industries.

9. The company shall develop rain water harvesting structures to harvest the run off water from the roof tops and by laying a separate storm water drainage system for recharge of ground water.

Rain water harvesting structures (8 Nos.) shall be properly maintained toharvest the runoff water from the roof tops and by a separate storm waterdrainage system for recharge of ground water.

10. Green belt already developed in 33% shall be properly maintained and an effort shall be made to further increase the percentage by regularly planting trees at all the vacant spaces to mitigate the effects of fugitive emissions all around the plant. Further development of green belt shall be as per the Central Pollution Control Board guidelines. Density of trees at the site shall be maintained as 2,000-2, 500 trees/ha.

No change.

General Conditions:

1. The project authorities must strictly adhere to the stipulations made by the U.P. Pollution Control Board (UPPCB) and the State Government.

No change

2. No further expansion / modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests.

No further expansion or modernization of plant entailing capacity addition with change in Process or Technology and or Product Mix shall be under taken without prior approval of the Ministry of Environment and Forests and Climate Change (MoEF & CC).

3. The project authorities must strictly comply with the rules and regulations with regard to handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management & Handling) Rules, 2003.

The Unit must strictly comply with the rules and regulations with regard to handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management, Handling & Transboundary Movement) Rules, 2008.

4. The project proponent shall also comply with all the safeguards recommended in the EIA/EMP Report.

To be deleted.

5. The project authorities will set up a separate environmental management cell for effective implementation of all the above stipulations under control

The Unit will maintain a separate environmental management cell for effective implementation of all the above stipulations under control of





Page 5 of 5

of Senior executive. Senior executive.

6. As proposed in EIA/EMP, Rs.60.50 Crores and Rs.9.00 Crores allocated towards capital cost and recurring expenditure/annum shall be judiciously utilized to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State Government and a time bound implementation schedule for all the conditions stipulated herein shall be submitted. The funds so provided shall not be diverted for any other purposes.

To be deleted.

7. The Regional Office of this Ministry at Lucknow/Central Pollution Control Board/ U.P.Pollution Control Board will monitor the stipulated conditions. A six monthly compliance status report and the monitored data alongwith statistical interpretation shall be submitted to monitoring agencies regularly.

No change.

8. The Project Proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the U.P. Pollution Control Board/ Committee and may also be seen at Website of the Ministry of Environment and Forests at http:/envfor.nic.in. This should be advertised within seven days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the Regional Office at Lucknow.

To be deleted.

9. The Project Authorities shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of commencing the land development work, if any.

To be deleted.

Page 1 of 2


Annexure-III

Stack, Prill Tower emission Quality:

Page 2 of 2


Page 3 of 2


Ambient Air Quality:

Page 1 of 2


Annexure-IV AIR POLLUTION MANAGEMENT PRACTICES AT IFFCO Phulpur UNIT:

Sr. No.

Plant Emission Generated

Pollution Control Device

Method of Control

1. Ammonia Plant

Purge gases from hydro-de-sulphurization section The purge gases from syntheses section of Ammonia Plant-I The relief valves outlets gases and other flue gases CO2 Emission

Purge Gas recovery system Flare Stacks Carbon Di-Oxide Recovery Plant

Purge gases are burnt in the primary reformer. The purge gases from syntheses section of Ammonia Plant-I is sent to the purge gas recovery plant for Hydrogen and Ammonia recovery before burning the remaining in Primary Reformer furnace. Gases are burnt in the 30 m & 79 m. high two flare stack located away from Ammonia Plant-I and Ammonia Plant-II respectively. A carbon Dioxide Recovery Plant has been installed to recover the CO2 gas from flue gases of Primary Reformer of Ammonia Plant. This stripped CO2 is utilized for Urea production

2. Urea Plant

Urea dust from the top of prill towers.

96 meter (in Urea-I) high & 104 meter (in Urea-II) high natural draft prilling tower in

The height of Prill Towers has been kept sufficient which keeps the dust concentration of urea from the Prill Towers well within the limits laid by the UPPCB and CPCB.

3. Boilers Generation of Ash, SO2 & NOx gases

Combustion air control systems have been provided in each boiler. The electrostatic precipitators provided for each coal fired boiler, Low NOx burners have been provided

The Fly Ash generated from Coal Fired Boilers is recovered from Flue Gases through Electrostatic Precipitators (ESP). Flue gases containing SO2 and NOx are discharged into the atmosphere through a 100 m high chimney (Coal Fired Boilers) & 120m high chimney (LSHS/ Gas fired Boilers).

4. Bagging Plant:

dust Cyclone Separator

The bagging plant has been provided with cyclone separators to keep the urea handling area dust free.

5. Noise Abatement in Plant area

Noise Neutralization pit, ETP & lagoons

Silencers have been provided at vent stacks to reduce the noise level. The attenuation of noise levels achieved by the green belt all around the plant boundary also contribute positively in minimizing the impact on existing

Page 2 of 2


noise levels. Acoustic enclosure has been provided in Diesels generator room. We have issued ear muffs / plugs to all the employees and use of ear muffs / plugs while working in noisy environment is already in practice.

CO2 Recovery Plant Prill Tower Chimney & Electrostatic Precipitator

Cyclone Separator Silencers in Ammonia Plant Acoustic enclosure

(Generator room)

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Annexure-V

Liquid Effluent (Guard Pond) Quality:

Page 2 of 3

Page 3 of 3

Page 1 of 6


Annexure-VI WASTE WATER MANAGEMENT PRACTICES AT IFFCO Phulpur UNIT:

Sr. No.

Plant Effluent Generated

Pollution Control Device

Method of Control

1. Ammonia Plant

Process Condensate Steam Condensate

Turbine condensate

Process Condensate Stripper in both Ammonia plant & Condensate Polisher Unit Condensate Polisher Unit Condensate Polisher Unit

Process Condensate from Ammonia plant is stripped in Process Condensate Stripper to remove the dissolved impurities like Methanol, Ammonia and CO2. The stripped process condensate is reused as Boiler Feed Water after polishing in DM Plant.

The Steam condensate from Ammonia plants having traces of dissolved impurities are passed through Condensate Polisher Unit and reused as Boiler Feed Water. The turbine condensate from both Ammonia plants is treated in Activated Carbon Filtration & is reused as Boiler Feed Water after polishing in Condensate Polisher Unit.

2. Urea Plant

Process Condensate

Steam & Turbine Condensate

Urea Deep Hydrolyser and Distillation Tower in both Urea Plants separately Polishing Units in DM Plant

Process condensates from Urea plants contain 4.0% to 5.0% Ammonia and 1.0% to 1.5% Urea. It is treated in Urea Deep Hydrolyser, where Urea is decomposed to Ammonia and Carbon Dioxide. The Ammonia and Carbon Dioxide are recovered through distillation tower and reused in Urea plant. The remaining condensate is reused either as Boiler Feed Water after further polishing it in Condensate Polisher Unit or as cooling tower make up. The steam and turbine condensates from both Urea plants having traces of dissolved impurities are passed through Condensate Polisher Unit and reused as Boiler Feed Water.

3. Ammonia & Spilled Oil & Gravity Oil The spilled oil / oily water is

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Urea Plants Oily Water separator & Disc Oil Pit with rotating disc for Oil collection in Ammonia and urea plants separately.

collected in Gravity Oil Separator / Disc Oil Pit where it separates in two layers. The top layer of oil is collected via a Rotating Disc in drums and is sold to Authorised Recyclers as per Guideline of CPCB. The remaining wastewater is sent to Effluent Treatment Plant for further Treatment.

4. Ammonia, Steam Generation and Power Plant

Continuous Blow Down

Reused as cooling tower make up

The Blow Down (BD) from Boilers from Ammonia and Steam & Power Generation plants (SGPG) is reused as Cooling Tower make up.

5. DM Water Plant

Acid – alkali waste water

Neutralization pit, ETP & lagoons

The acid / alkali wastewater generated in DM Plant after regeneration of exhausted cation/ anion resins is collected in the neutralization pit in DM Plant. Its pH is adjusted to 6.5 to 8.0 and is mixed with other treated waste water in Guard Ponds for further treatment in Effluent Treatment Plant based on Reverse Osmosis Technology. The treated water is being reused as cooling tower make up.

6. Cooling Tower

Cooling Tower Blow Down

The Cooling Water treatment is based on Eco-friendly, Non-Chromate based corrosion inhibitor. The Cooling Tower blow down is mixed with other treated waste water in Guard Pond for further treatment in Effluent Treatment Plant based on Reverse Osmosis Technology. The treated water is being reused as cooling tower make up.

7. Effluent Treatment Plant (ETP)

Occasional wastewater having Ammonia as contaminant

Effluent Holding Tank, Sand Filters, Air & steam Strippers and Lagoons

Occasional waste water generated during upset, start-up and shut-down of the plants which contains Ammonia, is collected in the effluent holding pits provided separately in all the plants, from where it is pumped to Effluent Holding Tank in Effluent Treatment Plant for the treatment. The ammonia is stripped off through steam strippers. The

Page 3 of 6


treated waste water is being reused as cooling water make up.

8. Guard Pond & Effluent Treatment Plant based on R.O. Technology

Cooling water blow down, D.M. Plant regeneration effluent etc.

Effluent Treatment Plant based on R.O. Technology

The treated waste water collected in Guard Pond is reused for plant process after further treatment in Reverse Osmosis Plant. The reject of RO plant is used for dust suppression in coal yard & ash Pond.

The schematic diagram of Effluent Treatment is given below

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Hydrolyser ETP based on Steam Stripping

Disc Oil Separator Condensate Polisher Unit

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Neutralization Pit of D.M. Plant Guard Pond

Effluent Treatment Plant based on Reverse Osmosis Technology

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Sewage Treatment System at IFFCO Phulpur:

TREATMENT AND REUSE OF DOMESTIC EFFLUENT FROM TOWNSHIP (SEWAGE TREATMENT PLANT): The Sewage Treatment plant of 3000 m3/day capacity was designed and installed by M/s Hindustan Dorr Oliver, Ltd., Bombay. This treatment plant involves a series of unit processes, i.e. Physical, Biological and Chemical Process. This treatment plant consists of bar screen, grit removal channel, parshall flume indicator, raw sewage collection sump, aeration tank, clarifier, filter feed sump, pressure sand filter, activated carbon filter and disinfectant (bleaching powder) dosing system. The treated water is recycled to plant for Cooling Water makeup and used for irrigation of Farm land as per requirement. The dry sludge generated from domestic sewage treatment plant is being used as manure.

Sewage Treatment Plant

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Annexure-VII On Line Monitoring System:

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Annexure-VIII Detail of Hazardous Waste submitted to UPPCB, Lucknow:

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Annexure-IX Management of Solid Wastes: Non Hazardous Wastes :

01. Disposal of Ash : a. Disposal of Dry Ash directly from ESP :

A mechanised system to transport fly ash from the Electrostatic Precipitators to a 240 MT capacity silo by pneumatic conveying has been commissioned in April - 2000 and in operation. With this system, it has been possible to load and dispatch about 80% to 90% of the dry ash generation from the silo to the Cement Factories. The dry ash from the ESP is being directly dispatched to the Cement Industries.

b. Utilisation of Pond Ash for Reclamation of Usar Farm Lands

The Pond Ash is utilised for Reclaimation of “Usar” farm land located within a radius of 10 - 20 KM.

c. Utilisation of Pond Ash by Cement Manufacturers Pond Ash are also being Used by Cement manufacturer for

manufacture of Cement. d. Utilisation of Fly Ash for the manufacture of clay Bricks by local

Brick kilns. IFFCO Phulpur endeavoured to create awareness among nearby Brick Kiln owners to educate them on the use of Fly Ash mixed with clay for the manufacture of clay bricks by the conventional process. IFFCO Phulpur is also promoting brick kiln owners to mix fly ash with clay.

e. Production of Fly ash bricks

Fly ash is also being used for production of fly ash brick. A fly ash brick plant has been installed. Last year about 627 MT of fly ash was used in fly ash brick plant for fly as brick manufacturing.

02. Lime Sludge From Water Softening Plant : In the water softening plant approx. 550 m3/day of lime sludge having

about 2.5% solids is pumped to a pond to settle down the solids. This lime sludge is dried and then dispatched free of cost to out side parties.

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Hazardous Wastes: 01. Spent Catalyst:

Catalysts used in different reactors of Ammonia Plant are mainly Nickel, Iron, Copper and Zinc base. After a certain time of interval, these catalysts are checked and if found exhausted, replaced by fresh catalysts. The spent catalysts are stored in closed metallic drums under shed inside the factory premises for sale to outside authorised parties. During 2014-15, 23.7 MT Spent Catalyst was sold to authorised Recyclers.

02. Waste Oil:

Waste Oil is collected and stored in metallic drums. The same is either sold to authorized parties or mixed with fuel oil (LSHS /RFO) for use in Steam Generation Plant as fuel. During 2014-15, 45 KL Waste Oil was sold to authorised party.

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Annexure-X Rain Water Harvesting System installed at IFFCO Phulpur IFFCO’s philosophy does not end with manufacture of fertilizer only – It has unstinted commitment toward environmental protection. IFFCO Phulpur is conscious of its responsibilities towards resource conservation. IFFCO is committed to ensure sustainable development & ecological balance. To sustain the ground water availability to all stakeholders, IFFCO Phulpur implemented ground water recharging scheme through installation of several Rain water harvesting system (RWHS) within premises. Artificial recharge to ground water through properly designed structure has now been accepted world-wide as a cost-effective method to augment ground water resources. It also provide an opportunity to utilize the surplus monsoon runoff which otherwise is lost to drains or rivers unutilized. Installation of Rain water harvesting system within premises of IFFCO Phulpur was initiated after a series of consultation with Central Ground Water Board, Allahabad.

Rain Water Harvesting Systems (double bore type) have been installed at different places within IFFCO Phulpur’s premises viz. RWHS near Gate No.1, behind Gas Godown in Tapti sector, near Borewell No. 12, Central School (Rain water collection system through roof top drains) and 3 Nos Rain water harvesting system in the premises of Guest House (single bore type).

Rain Water Harvesting System installed at IFFCO Phulpur Volume of Recharge Sump (each): 310 M3 No. of Bores : Two Size of Bores : Dia- 6 inch Depth of Bores: 105 m

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RWHS installed at Central School building within IFFCO Phulpur’s premises

RWHS installed near Borewell No. 12 within IFFCO Phulpur’s premises

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RWHS installed near Gate No.1 within IFFCO Phulpur’s premises

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Annexure-XI

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Annexure-XIII

Certified Compliance report:

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Annexure-XIV

Latest Compliance report (Existing Environment Clearance Conditions):

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Annexcure-XV

Copy of Consent Order (Air & Water):

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Annexure-XVI

Copy of Consent Renewal Application:

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Annexure-XVII

Description of Energy saving schemes to be implemented in Phulpur-I Ammonia plant: Scheme-1: Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section for less energy requirement: Existing system Modified system In CO2 removal section of Ammonia-I plant, GV solution is used to absorb CO2 from process gas in CO2 Absorber. CO2 rich GV solution is regenerated in two stage i.e. in 1st Regenerator and then in 2nd Regenerator. CO2 gas separated, is sent to Urea plant for the production of urea. The source of regeneration energy is process gas and LP steam. Regenerated GV solution is again sent to CO2 Absorber to absorb CO2 from process gas. CO2 content in the process gas at the exit of CO2 Absorber: 500 ppm Regeneration energy required: 950 kcal/NM3

In reforming section, superheated MP steam is mixed with feed natural gas to meet steam requirement for reforming reactions in Primary Reformer and Secondary Reformer. Steam to Carbon ratio at Primary Reformer inlet is maintained around 3.3. Higher steam to carbon ratio is maintained to meet energy requirement of CO2 removal section for the regeneration of GV solution. Steam to carbon ratio at Primary Reformer inlet: 3.3

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated in thress stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The source of regeneration energy shall be only process gas. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas. CO2 content in the process gas at the exit of CO2 Absorber: <= 500 ppm Regeneration energy required: 550 kcal/NM3 Expected Saving: HP steam saving: 10 MT/hr Electrical power increase: 0.6 MW Energy saving: 0.13 Gcal/MT Ammonia With decreased regeneration energy requirement in CO2 Removal section and better CO2 removal in CO2 Absorber, steam to carbon ratio at Primary Refomer inlet can be decreased from existing 3.3 to 3.0. This shall reduce front-end pressure drop and also save steam. Expected Saving: HP steam saving: 5 MT/hr Gas Saving: 200 Sm3/Hr Energy saving: 0.10 Gcal/MT Ammonia

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Scheme-2: Replacement of Process Air Compressor Turbine and Refrigeration Compressor Turbine: Existing system Modified system The Process Air Compressor and Refrigeration Compressor are driven by 10 MW Rated Capacity Medium Pressure Condensing Turbines. These Turbines were installed in the year 1979-80 and have become inefficient with due course of time

The Turbines will be replaced with new efficient turbines. The Replacement will be on the same base frame and inlet & outlet connections will be hooked-up with existing lines Expected Saving: Reduction in steam production in Ammonia plant: around 15 MT/hr Energy saving: 0.17 Gcal/MT Ammonia

Scheme-3: New Efficient LO / SO Backpressure Turbines: Existing system Modified system The lube oil pump of Process Air & Refrigeration Compressor/Turbine and Synthesis Compressor/Turbine are driven by MP to LP Backpressure Turbines. Similarly, the Seal Oil Pump of Synthesis Compressor is also driven by Back pressure Turbine. The LP Steam is used for LP Reboiler and LP Heater of the Plant

After changeover from GV to aMDEA System the LP Steam Re-boiler will be no more required. If the inefficient lube oil and seal oil turbines are not replaced, the LP Steam will be required to vent. With the replacement of New Efficient Steam Turbines there will be less generation of LP Steam and avoiding venting of steam Expected Saving: HP steam saving: 4.1 MT/hr Energy saving: 0.06 Gcal/MT Ammonia

Scheme-4: Installation of Fuel Gas Expander with power generator Existing system Modified system NG supplied from GAIL at pressure of around 40 kg/cm2g, is used as feed and fuel in Ammonia-I plant. NG fuel is let down from 40 kg/cm2g to 5.5 kg/cm2g and then is used in burners of Primary Reformer and Auxiliary Boiler.

NG fuel which is let down in existing system from around 40 kg/cm2g to 4.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW. Expected Saving: Electricity generation: 700 KW Energy saving: 0.02 Gcal/MT Ammonia

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Scheme-5: Installation of Vapour Absorption Machine for the cooling of inlet air to Process Air Compressor: Existing system Modified system Process air is required in Secondary Reformer at pressure of around 36 kg/cm2g for the reforming reaction and also to meet N2 requirement for the synthesis of ammonia. For this purpose air from atmosphere is compressed in four stages of Process Air Compressor. The drive of compressor is MP Steam Condensing Turbine.

A Vapour Absorption Machine (VAM) shall be installed in Ammonia-I to generate chilled water for new process air chiller to be installed at the suction of Process Air Compressor. This shall cool the inlet air of Process Air Compressor from 40°C to 15°C, resulting in saving of NG being used as fuel for Gas Turbine drive of Process Air Compressor. The heating medium in VAM machine shall hot water from Primary Reformer Convection Coil

Expected Saving: Temperature decrease: from 40 degC to 15 degC Power decrease: 0.5 MW HP steam saving: 1.1 MT/Hr Energy saving: 0.017 Gcal/MT Ammonia

Scheme-6: Ammonia Recovery from Synthesis Loop LP Purge Gases Existing system Modified system The off gases from Synthesis loop are being burnt in the Primary Reformer as Fuel. The Gas consist of 25 ~ 27 % NH3

It is proposed to recover ammonia from the flash gas from synthesis loop off gas in new Flash Gas Washing Column. This modification shall result in additional Ammonia Recovery of 2 MT/Day. Sweet Water Cooler system shall be replaced with new heat exchanger using cooling water directly as cooling medium for better cooling of syn gas. This shall also reduce loop pressure by around 5 kg/cm2 and steam saving in Syn Gas Compressor turbine by around 2 MT/hr. Expected Saving: Saving: Additional NH3 Recovery: 2 MT/Hr Gas Savings: 1330 Sm3/day Energy saving: 0.008 Gcal/MT Ammonia

Scheme-7: Saturated MP Steam Export to Urea Plant: Existing system Modified system In the Synthesis Loop, MP Boiler is The Saturated MP Steam will be exported to

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installed to recover waste heat from Ammonia Converter 105-D. This Saturated MP Steam is used as Process Steam in Primary Reformer.

Urea Plant for use of Process Steam at 25 ata pressure after letdown from 39 ata. This will reduce requirement of Inlet Steam in CO2 Compressor Extraction- cum- Condensing Turbine of Urea Plant as there will be less requirement of extraction steam. The Net Saving will be realized in terms of less condenser load of Synthesis Turbine and CO2 Turbine together. Expected Saving: HP steam saving: 4 MT/hr Energy saving: 0.06 Gcal/MT Ammonia

Scheme-8: Installation of MP Stripper for Process Condensate Stripping Existing system Modified system Existing Process Condensate Stripper operated as LP Steam. 4 MT/Hr of LP Steam directly fed to the Column which is finally vented to atmosphere and 4.5 MT/He of LP Steam is fed to reboiler and the Condensate to Deaerator. Equivalent HP steam: 5.5 MT/hr

The existing system will be replaced with MP Steam Process Condensate Stripper. With the proposed modification, the MP Steam is used which after stripping off the gases goes back to the steam circuit.

Expected Saving: HP steam saving: 5.5 MT/hr Energy saving: 0.08 Gcal/MT Ammonia

Scheme-9: New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C) Existing system Modified system Presently, Methanator Effluent Cooler is installed at downstream of Methanator to cool down the syn gas which is then compressed from 25 kg/cm2g to 145 kg/cm2g before entering the synthesis converter. The lower the temperature of syn gas lesser will be power consumption in Syn Compressor.

Existing 115-C is not sufficient enough to cool down the syn gas to the optimum temperature of 39 – 40 degC. With additional Exchanger I parallel the cooling water availability will be increased which will reduce the syn gas temperature. In the new system one additional BFW Heater will be installed to recover heat from the hot process gas before it enters the CO2 Removal Section. Expected Saving: Power Saving = 150 KW Energy saving: 0.002 Gcal/MT Ammonia

Scheme-10: Synthesis Gas Converter (105D) Revamp Existing system Modified system The NH3 Synthesis Converter (105-D), converts NH3 from 2.5 to 15.5 mol%. At the

It is proposed to revamp the internals of Synthesis Gas Compressor with new

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downstream of 105-D, second converter is installed where NH3 percentage increase upto 19.5 mol%.

patented technology internals. This intervention will result in improvement in the NH3 Conversion from 2.5 to 17 mol% and maximizing the heat recovery in the form of steam generation. This modification will result in additional MP Steam generation in the tune of 7 MT/Hr. Expected Saving: HP steam saving: 5.25 MT/hr Energy saving: 0.075 Gcal/MT Ammonia

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Description of Energy saving schemes to be implemented in Phulpur-I Urea plant Scheme-1: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion: Existing system Modified system In Urea reactor, NH3 and CO2 gas are fed in the bottom and reacted at pressure of around 150 ata and temperature of around 1800C to form Ammonium Carbamate, a part of which dehydrates to Urea. The first reaction i.e. from ammonia and CO2 to Ammonia Carbamate, takes place in the bottom of Urea Reactor and dehydration of Carbamate to Urea takes place in the rest volume of reactor. For better mixing of liquid and gas mixtures to enhance 2nd reaction i.e. dehydration of carbamate, there are 15 number of sieve trays in Reactor.

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor. Expected Saving: MS steam saving: 66 kg/MT Urea HP steam saving: 4.3 MT/hr Energy saving: 0.03 Gcal/MT Urea

Scheme-2: Installation of Ammonia Preheaters: Existing system Modified system Ammonia from Ammonia plant is received in Ammonia Receivers of Urea plant. In each stream, from Ammonia Receiver, ammonia is pumped by Ammonia Booster Pump and then by Ammonia Feed Pump to feed ammonia to Urea Reactor. After synthesis reaction in Urea Reactor, the solution consisting of urea, carbamate and water is sent to HP Stripper for the recovery and recycling of NH3 and CO2 from carbamate solution. In HP Stripper, MS steam is used to meet the requirement of heat for the decomposition of carbamate to ammonia and CO2.

In Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce. Expected Saving: Ammonia temperature increase: from 23°C to 75 °C HP steam saving: 3 MT/hr Energy saving: 0.02 Gcal/MT Urea

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Scheme-3: Installation of Vapour Absorption Machine for the cooling of inlet CO2 gas to CO2 Compressor: Existing system Modified system In Urea plant, CO2 gas at 450C received from Ammonia plant is compressed in four stages of CO2 Compressors with interstage intercoolers and separators. The compressed CO2 gas is then fed to Urea Reactors in each stream for the synthesis of urea. The drive for CO2 Compressor is extraction cum condensing turbine using HP steam as inlet steam.

A Vapour Absorption Machine (VAM) shall be installed to generate chilled water required for CO2 Gas chiller to be installed at the suction of CO2 Compressor of Urea plant. This shall cool inlet CO2 gas of CO2 Compressor from 45°C to 20°C, resulting in saving of steam consumption in CO2 Compressor turbine of Urea plant. The heating medium in VAM machine shall be LP steam. Expected Saving: HP steam saving: 1.7 MT/hr Energy saving: 0.015 Gcal/MT Urea

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Description of Energy saving schemes to be implemented in Phulpur-II Ammonia plant Scheme-1: Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section for less energy requirement Existing system Modified system In CO2 removal section of Ammonia-II plant, GV solution is used to absorb CO2 from process gas in CO2 Absorber. CO2 rich GV solution is regenerated in two stage i.e. in 1st Regenerator and then in 2nd Regenerator. CO2 gas separated from GV solution, is sent to Urea plant for the production of urea. The source of regeneration energy is process gas and LP steam. Regenerated GV solution is again sent to CO2 Absorber to absorb CO2 from process gas. CO2 content in the process gas at the exit of CO2 Absorber: 500 ppm Regeneration energy required: 830 kcal/NM3 In reforming section, superheated MP steam is mixed with feed natural gas to meet steam requirement for reforming reactions in Primary Reformer and Secondary Reformer. Steam to Carbon ratio at Primary Reformer inlet is maintained around 3.3. Higher steam to carbon ratio is maintained to meet energy requirement of CO2 removal section for the regeneration of GV solution. Steam to carbon ratio at Primary Reformer inlet: 3.3

The existing GV solution based CO2 Removal section shall be replaced by aMDEA solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in aMDEA solution from process gas. CO2 rich aMDEA solution shall be regenerated in three stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The source of regeneration energy shall be only process gas. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated aMDEA solution shall be again sent to CO2 Absorber to absorb CO2 from process gas. CO2 content in the process gas at the exit of CO2 Absorber: <= 500 ppm Regeneration energy required: 500 kcal/NM3 Expected Saving: HP steam saving: 20 MT/hr Electrical power increase: 2.0 MW Energy saving: 0.18 Gcal/MT amm With decreased regeneration energy requirement in CO2 Removal section and better CO2 removal in CO2 Absorber, steam to carbon ratio at Primary Refomer inlet can be decreased from existing 3.3 to 3.0. This shall reduce front-end pressure drop and also save steam. Expected Saving: HP steam saving: 8 MT/hr NG Saving: 250 Sm3/Hr Energy saving: 0.088 Gcal/MT Ammonia

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Scheme-2: New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge Existing system Modified system Synthesis gas from Methanator is compressed in three stages of Synthesis Gas Compressor with interstage coolers and separators and then sent to upstream of 2nd Ammonia Chiller in syn loop to remove oxygenated compounds (H2O, CO and CO2). These oxygenated compounds are detrimental for the catalyst of Synthesis Converters. In Syn loop After 2nd Ammonia Chiller, condensed ammonia in the mixture of synthesis gas and make up gas, gets separated in Ammonia Separator. Ammonia produced is sent to Let Down Vessel, from where it is sent to Urea plant for the production of urea. Uncondensed gas, known as recycle gas, is warmed in heat exchangers and then compressed in fourth stage of Synthesis Gas Compressor. The compressed gas is fed to 1st Ammonia Synthesis Converter and 2nd Ammonia Synthesis Converter alongwith Waste Heat Boilers for the synthesis of ammonia and to utilise generated heat to produce HP steam. After Converters and Waste Heat Boilers, the recycle gas is cooled to temperature of around 11°C through series of heat exchangers and then sent to Ammonia Separator.

In order to increase the energy efficiency of the synthesis loop, a syngas dehydration system based on liquid ammonia washing shall be introduced at Synthesis Gas Compressor second stage discharge. The oxygenated compounds (H2O, CO and CO2) available in Syn Gas shall be separated in ammonia wash system. With this modification, Syn Gas Compressor 3rd stage discharge which is free from oxygenated compounds, can be mixed directly with re-circulator discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st Ammonia Synthesis converter. With this modification, there shall be reduction in power requirement in tubine drive of Synthesis Gas Compressor by around 900 KW. Expected Saving: HP steam saving: 4 MT/hr Power saving in compressor: 900 kw Energy saving: 0.03 Gcal/MT Ammonia

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Scheme-3: Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency. Existing system Modified system Syn Gas Compressor consists of two case LP case and HP case with each case having two stages. The first three stages of Syn Gas Compressor is used to compress mixture of make-up coming from Methanator and recyle hydrogen coming from Purge Gas Recovery Unit. The fourth stage is used to compress syn gas coming from Ammonia Seperator of Syn loop. The drive for Syn Gas Compressor is Extraction cum condensing turbine using inlet steam as HP steam. Existing Syn Gas Compressor stages efficiencies:

Stages 1st 2nd 3rd 4th

Eff. (%) 79.2 76.1 68.8 75.6

Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced by new barrels for increasing the efficiency of Syn Gas Compressor. This shall result in saving in steam requirement in turbine drive of Synthesis Gas Compressor by around 10 MT/hr. Modified Syn Gas Compressor stages efficiencies:


Eff. (%) 81.3 75.29 73.70 78.62

Expected Saving: Power saving (without amm wash system): around 3 MW Power saving (with amm wash system): around 4 MW HP steam saving guaranteed: 9.5 MT/hr Energy saving: 0.15 Gcal/MT Ammonia

Scheme-4: Installation of Fuel Gas Expander with power generator Existing system Modified system NG supplied from GAIL at pressure of around 40 kg/cm2g, is used as feed and fuel in Ammonia-II plant. NG fuel is let down from 40 kg/cm2g to 5.5 kg/cm2g and then is used in burners of Primary Reformer

NG fuel which is let down in existing system from around 40 kg/cm2g to 5.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW. Expected Saving: Electricity generation: 1MW Energy saving: 0.02 Gcal/MT Ammonia

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Description of Energy saving schemes to be implemented in Phulpur-II Urea plant Scheme-1: Replacement of existing CO2 Compressors by new higher efficiency compressors Existing system Modified system CO2 from Ammonia plant is compressed in two streams 31 & 41 Unit of Urea plant through CO2 Compressors. CO2 Compressor consists of four stages with interstage coolers and separators. The compressed CO2 gas is then fed to Urea Reactor for the synthesis of urea. Existing CO2 Compressor stages efficiencies:


Eff. (%) 80.3 76.3 71.1 54.1

In both 31 & 41 Units of Urea plant, existing CO2 Compressor shall be replaced with new CO2 Compressor of higher efficiency. This shall result in saving in steam consumption in steam turbine drive of CO2 Compressor by around 9 MT/hr. Revamped CO2 Compressor stages efficiencies:


Eff. (%) 84.5 81.1 80.0 68.0

Expected Saving: HP steam saving guaranteed: 9 MT/hr Energy saving: 0.07 Gcal/MT Urea

Scheme-2: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion Existing system Modified system In Urea reactor, NH3 and CO2 gas are fed in the bottom and reacted at pressure of around 150 ata and temperature of around 1800C to form Ammonium Carbamate, a part of which dehydrates to Urea. The first reaction i.e. from ammonia and CO2 to ammonia carbamate, takes place in the bottom of Urea Reactor and dehydration of Carbamate to Urea takes place in the rest volume of reactor. For better mixing of liquid and gas mixtures to enhance 2nd reaction, there are 15 number of sieve trays in Reactor.

The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor. Expected Saving: MS steam saving: 66 kg/MT Urea HP steam saving: 6 MT/hr Energy saving: 0.02 Gcal/MT Urea

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Scheme-3: Installation of Ammonia Preheaters Existing system Modified system Ammonia from Ammonia plant is received in Ammonia Receivers of 31 & 41 streams of Urea plant. In each stream, from Ammonia Receiver, ammonia is pumped by Ammonia Booster Pump P-5 and then by Ammonia Feed Pump P-1 to feed ammonia to Urea Reactor. After synthesis reaction in Urea Reactor, the solution consisting of urea, carbamate and water is sent to HP Stripper for the recovery and recycling of NH3 and CO2 from carbamate solution. In HP Stripper, MS steam is used to meet the requirement of heat for the decomposition of carbamate to ammonia and CO2.

In both streams of Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce. Expected Saving: Ammonia temperature increase: from 23°C to 70°C HP steam saving: 6 MT/hr Energy saving: 0.01 Gcal/MT Urea

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Description of Energy saving schemes to be implemented in Steam & Power Generation Plant Scheme-1: New GTG-HRSG Package for Power and Steam Generation Existing system Modified system Presently, in Phulpur Unit, Electric Power is being generated in the Steam Turbo-Generators wherein the Exhaust Steam is condensed in Steam Condensers and latent heat of Exhaust Steam is taken away by Cooling Water under Circulation which finally dissipates it to Atmosphere.

The Proposed System, GTG-HRSG will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam.

In Phulpur Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is 12500 Sm3/Hr RLNG and 250 MTPD Coal. Whereas, the same quantity of Electric Power & HP Steam will be generated by only 9455 Sm3/Hr RLNG in GT-HRSG Expected Saving: NG Saving: 3045 Sm3/Hr Coal Saving: 250 MTPD Energy saving: 0.32 Gcal/MT Urea

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Annexure-XVIII Water Balance:

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Steam & Power Balance:

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