MAJOR ACHIEVEMENTS:

Milestone :

(a) IFFCO Kandla achieves the milestone of 50 Million MT of Bulk Production

of NPK/DAP/MAP/NP fertilizers since inception of the plant on

25.06.2013.

(b) IFFCO Kandla achieves the milestone of 50 Million MT of Bulk Despatch

of NPK/DAP/MAP/NP fertilizers since inception of the plant on

29.06.2013.

IFFCO Kandla Unit has produced 3436.140 MT of 100% Water soluble NPK

18:18:18 at R&D level and dispatched 3383.400 MT during the year.

IFFCO Kandla achieved highest ever daily production of the following products

during the year 2013-14.

Products Production (MT)

Water soluble fertilizer Urea Phosphate

(17:44)

42.000 on 14.08.2013

Water soluble fertilizer NPK 18:18:18 32.840 on 23.08.2013

Zinc Sulphate Monohydrate 72.500 on 22.11.2013

IFFCO Kandla achieved highest ever monthly production & dispatches of the

following products during the year 2013-14.

Products Production (MT)

Dispatches (MT)

Water soluble fertilizer Urea Phosphate

(17:44)

- -

Water soluble fertilizer NPK 18:18:18 745.860 during

Aug.-13

491.480 during Jul-

13

Zinc Sulphate Monohydrate 1136.510 during

July-13

1256.320 during

July-13

MAJOR AWARDS

During 2014-15, IFFCO Kandla unit has won following major awards:

IFFCO - Kandla wins "Idea Champion award" at 15th National Summit of INSSAN, New Delhi during 26th -27th July 2013.

IFFCO Kandla had been selected by Dynamic CIO as one of the top 30

innovative heroes compendium IT Award held on 8th August,2013 in Mumbai.

IFFCO-Kandla employee have won safety competition-2013 held by Gujarat

Safety Council, Vadodara.

IFFFCO Kandla won the best Unit Trophy for implementation of suggestion

scheme at third Inter Unit Innovation & Creativity Meet organised at FMDI,

Gurgaon during 15-16th May-2013.

TECHNICAL DEVELOPMENTS AT IFFCO KANDLA

Kandla Unit has taken various measures for technological development, retrofitting & revamping projects. A brief summary of the same is shown below: Sr.No. Title Benefit/ Annual Saving

1 Coating of DAP/ NPK granules with coating agent & furnace oil.

Quality improved

2 Fortification of NPK product with 0.5% Zinc

Quality improved

3 Modification in Granulator Pipe Reactor(GPR)

Quality improved

4 Installation of DPR in C train

Quality improved

5 Installation of separate vibrators for decks of

vibrating screen of B train.

Quality improved

6 Installation of Agitator in Reaction Holding

Tank(RHT) of Zinc Sulphate Plant.

Quality improved

7 Screening operation

Quality improved

8 Modification in Preneutraliserspargers.

Quality improved

9 Bagging quality improvement

Quality improved

10 Utilizing Heat of Compression of Ammonia

compressors / air compressors to heat Ethylene

Glycol for Heating Ammonia to save steam.

2.74 crore

11 Power Trading 8 crore 12 Delumping arrangement for Product Handling

System 1.75 crore

13 Heating Ammonia by using Air Heating Units (AHU) at IFFCO Kandla.

3crore

15 Removal of Recycle conveyor of E & F train. 5 lakhs 16 Common scrubber liquor supply pump in D train

23 lakhs

17 Installation of VFD at primary air blower and Quench air fan

2.7 lakhs

18 Installation of LED/ Induction lights/ light pipes 12.42 lakh 19 Usage of DM Water for boiler in place of Soft

water 63 lakhs

20 Installation of new PN tank with increased agitator length in B Train

21 Modification in Zinc Sulphate Plant for Zn

Recovery(addition of sulphuric acid to SMWT)

23 lakhs

22 Installation of Rotary Dryer for Water Soluble

Urea Phosphate Plant

Stability for full plant

capacity production has

been achieved.

23 Saving of ammonia due to installation of spray

nozzles in Granulator discharge duct, PN &

Granulator ammonia sparger modification,

maintaining low mole ratio of scrubber liquor in

K-I Plant.

46 lakhs

QUALITY IMPROVEMENT MEASURES AT IFFCO KANDLA

1. Coating of DAP/ NPK granules with coating agent & furnace oil

IFFCO Kandla Unit is producing NPK/DAP fertilisers using phosphoric acid as

one of the major raw materials. The quality of phosphoric acid affects the quality

of the product. To give an identity and marketability of IFFCO NPK/DAP

fertilisers, a system has been developed for coating of NPK/DAP fertiliser

product which should be compatible for storage and agronomic suitability and

also impart shining appearance to NPK/DAP fertilisers.

The coating spray was done at cooler feed conveyor discharge (or product

cooler inlet) with coating agent namely INFER 5625K .Intimate contact and

mixing of the coating agent over granules was possible due to rolling of material

in the product cooler.

It has been observed that the dust formation was reduced as observed in

product cooler discharge and bagging plant. Shining appearance of granules

was observed. Coating will also help in preservation of fertilizer for longer time.

The scheme has been implemented from Jan-14.

The overall target is to make product sieve size of -2 mm & +4 mm nil. Product

analysis is also being monitored. Physical appearance of product are important

for good product brand in market and same shall be targeted for IFFCO DAP/

NPK fertilisers.

The additional cost for coating with 1.5 kg of surface coating agent & furnace oil

in 50:50 ratio per MT of the product worked out to be Rs. 85 with contributing

cost of furnace oil at Rs. 31.50 and surface coating agent at Rs. 52.50.

2. Fortification of NPK product with 0.5% Zinc To meet the increasing demand of fortified fertilizers, it is proposed to fortify the

existing NPK fertilizer by addition of Zinc Sulphate Monohydrate slurry in the

scrubber effluent tank in K-I & K-II Plants for achieving 0.5% zinc in the final

product. A trial run has been carried out for NPK 12:32:16 dated 19/02/2014 in

F-train of K-II plant. The trial run has been successfully done to achieve the

product with 0.5% Zn.

For production of 7000 - 7500 MTPD NPK fertiliser, the zinc sulphate mother

liquor requirement is 250 - 275 MTPD. In zinc sulphate plant the capacity of

mother liquor storage tank is just 60 kl. Therefore, it is required to have adequate

storage facility with reliable handling facilities & control systems. Two storage

tanks with rubber lining have to be installed in K-I & K-II plants. Pipeline of about

1.5 km is required for transfer of mother liquor. It is also proposed to ensure

accurate dosage system to avoid variation in zinc content. Hence the operation

control loop is being incorporated which will be linked to the phosphoric acid

being fed to each plant separately and also a control setting with recycle load

and zinc content in liquor is being provided. For proper operation, reliable and

robust system with good automation is required. This has been developed and

will be executed in the plant. The procurement & erection activities will take 3 - 4

months time for completion.

The per MT cost of Rs. 620 shall be increased due to fortification of NPK grades

with 0.5% zinc .

3. Modification in Granulator Pipe Reactor(GPR) (a) Diameter of Granulator Pipe Reactor (GPR) in E and F train has been increased

from 3" to 4".This has improved the quality and granulometry of the product.

(b) Length of Granulator Pipe Reactor (GPR) in E and F train has been increased by

2 meters and 1 meter.

The main reason has been the improvement in reaction efficiency due to higher

reaction time.

4. Installation of DPR in C train: A DPR (Dryer Pipe Reactor) has been installed in C train in addition to PN which

is a CSTR (continuous stirred tank reactor) process. This will increase the plant

capacity by 10 MTPH. Also the MAP produced will help in following:

i. Improvement of granulation by providing granulating nuclei.

ii. Saving in Furnace oil(it has been observed that for same plant load, the inlet

dryer temp. is reduced by 50-60 deg C .

iii. Also the draft has improved in the dryer system resulting in no escape of hot

gases to surrounding.

5. Installation of separate vibrators for decks of vibrating screen of B train.

Separate vibrator for upper and lower decks has been installed in Vibrating

Screen of B train which has improved screening operation and product quality.

6. Installation of Agitator in Reaction Holding Tank(RHT) of Zinc Sulpahte Plant. Agitator has been provided in Reaction Holding Tanks (RHT) of zinc sulphate

plant. This has improved thorough mixing of the slurry and prevention of settling

of mud in RHTs.This helped in improving the zinc efficiency by reducing mud

wastage.

7. Screening operation

Maintenance of screen cloth, proper vibration and uniform distribution of material

on various screens of each train is being ensured. Polishing screen in K-II has

been converted to single deck and is working well.

It is also proposed to install polishing screen in K-I. Procurement activity for

installation of polishing screen in K-I plant is under progress.

8. Modification in Preneutraliserspargers. Preneutraliser (Main Reaction vessel for reacting ammonia & phosphoric acid)

spargers have been modified. Besides reducing ammonia loss, it has also

helped in better reaction resulting in slurry with good plasticity which helps in

granulation.

9. Bagging quality improvement Quality of bag is strictly checked and accepted with CaCO3 limit of 8%. Beyond

8% content of CaCO3, bags are accepted on penalty basis up to 12% and

penalty is directly proportional to invoice value. Beyond 12% content of

CaCO3,whole lot is rejected. Bags consumption is based on FIFO basis.

Drop test is carried out to ensure that filled bags do not fail.

Usage of 25 no. needle has been implemented which has improved stitching

quality. Procurement for new Polypropylene (PP) bags of required strength is

under progress.

ENERGY SAVING/ COST REDUCTION MEASURES AT IFFCO KANDLA

1. Utilizing Heat of Compression of Ammonia compressors / air compressors to heat Ethylene Glycol for Heating Ammonia to save steam.

Phase 1: IFFCO Kandla Unit has successfully implemented innovative scheme

of saving steam (making it zero) for heating ammonia required for process in

NPK/DAP plant operating on pipe reactor technology i.e. K-II plant. With this,

annual saving of Rs. 2.74 crore will be realized. The scheme is successfully

commissioned on 01/09/2013.

Before modification:

Ammonia is stored in atmospheric tanks at -33 deg C and it is required to heat

up to -5.0 deg C to +5.0 deg C for use in pipe reactor. For that we are using

Ethylene Glycol as heating medium. First Ethylene Glycol is heated with steam

and then this hot Ethylene Glycol is used to heat ammonia to achieve the

desired temperature. Heat energy was fulfilled by steam.

After modification:

The existing Ethylene Glycol-ammonia heating system is modified to Ethylene

Glycol-cooling water system. Ethylene Glycol which was heated earlier by steam

is now heated by return cooling tower water. This hot Ethylene Glycol is used to

heat ammonia for use in pipe reactor.

Benefits/savings:

Steam & Power saving (I D Fan stop, compressor amps.)

Cooling tower make up water saving

Easy & Safe operation

Reduce maintenance work.

Phase 2: IFFCO Kandla unit is having Air Heating Unit (AHU) for providing

centralized Air Conditioning system for various office buildings of the plant. The

AHU is consisting of chilled water unit for cooling the air for using in centralized

Air Conditioning system. Chilled water is generated by vapor compression

refrigeration cycle.

Ammonia is heated by return chilling water of all AHU of plant and generated

chilling water is used in centralized Air Conditioning System for various office

buildings. All compressors has been stopped which results saving in electrical

power (about 600 kWH) equivalent to monetary saving of Rs. 3 crore.

2. Power Trading

IFFCO kandla Unit has entered into power purchase agreement through Indian

Energy Exchange (IEX) and Power Exchange India Ltd. (PXIL) under provisions

of short term open access.

Kandla Unit has started drawing power through the new system w.e.f. 7th

December, 2013. Saving achieved by purchase of power through trading from

7thDec. 2013 to Feb. 2014 is:

Month Dec-13 ( 7th to 31dec)

Jan-14 Feb-14 Total saving in three months.

Saving in Rs. (Lakhs)

69 86 68 223

The expected annual saving is around Rs. 8 crore.

3. Delumping arrangement for Product Handling System

The scheme is to install delumpers at 107 A/B and 107 C/D conveyor discharge

at K-I silo.

Initially the scheme was for the installation of two elevators with delumping

arrangement at the discharge of Conveyors 108 and 112 (new conveyor). This

job required major civil modification and structure modification in screen house.

Later the scheme was modified and the delumpers was installed at 107 A/B and

107 C/D conveyor discharge at K-I silo. The total cost incurred for the project is

in tune of Rs 27 lakhs as against sanctioned budget of ` 202 lakhs. Hence

Kandla unit saved ` 175 lakhs approximately. This modification shows IFFCO

Kandla units commitment towards the cost saving measures. The scheme was

implemented in April-2013.

Also installation of delumperat conveyor 107 G/H discharge for K-II silo has been

successfully commissioned in December-2014 and installation of Delumper at

108 B conveyor dischargeat K-II silo shall be installed shortly. This helps in

avoiding lumps which effect the operation of bagging machines causing weigh

variation to large extent. With lump free material, the accuracy of bagging

machine will increase.

4. Usage of DM Water for boiler in place of Soft water:

IFFCO Kandla has commissioned two streams of 25m3/hr DM plant on

22.02.2013.

The DM water has replaced the soft water which was used in the boilers. Due to

usage of DM water, blowdown frequency has been reduced resulting in

reduction of fuel oil consumption and water consumption in the boiler. Scaling

inside the tubes has decreased which has helped in increasing the boiler

efficiency. Approximately saving is 0.5 KL FO/day equivalent to monetary saving

of Rs. 63 lakhs per annum.

5. Removal of Recycle conveyor of E & F train: Recycle conveyor in E and F train which carried fines from polishing screen to

fines conveyor has been removed and replaced with direct chute for transferring

fines to fines conveyor by gravity flow. This has reduced the maintenance cost

and energy consumption by 66500 units equivalent to monetary saving of Rs. 5

lakhs.

6. Common scrubber liquor supply pump in D train :

In D Train, dust scrubber liquor pump is replaced with new high capacity pump and

its discharge line is interconnected with scrubber effluent pump and fumes

scrubber liquor pump which results in non- operation of scrubber effluent pump

and fumes scrubber liquor pump and reduces energy, inventory and

maintenance cost.This has reduced the maintenance cost and energy

consumption by 302400 units equivalent to monetary saving of Rs. 23 lakhs.

7. Installation of VFD at primary air blower and Quench air fan

One 60 HP & 100 HP VFD were installed at Primary air Blower & Quench air fan in

D train in order to conserve energy by operating the fans at desired speed

thereby reducing the energy consumption by 5% equivalent to monetary saving

of Rs. 2.7 lakhs.

VARIOUS PLANT MODIFICATION/SAFETY AND PLANT HEALTH

1. Installation of new PN tank in B Train: New PN tank of MOC SS 904 L having eight ammonia spargers has been

installed in B train. The new MOC is suitable for using higher quantity of 98%

sulphuric acid in PN in order to achieve the balance Ammonical nitrogen, thereby

reducing the urea consumption. Also, agitator length has been increased. After

the evaluation of performance of B train agitator, remaining agitators shall be

installed in 6 months for A, C and D trains.

2. New Centrifugal Air Compressor IFFCO Kandla unit successfully commissioned Centrifugal air Compressor of IR

make of capacity 5000 Nm3/hr. With this the use of existing reciprocating

compressor, which are high maintenance prone shall be reduced. Also overall

maintenance cost of the plant shall reduced

3. New Sulphuric acid unloading station

A new 98% concentrated Sulphuric acid unloading station has been

commissioned on 16/09/2013. From this unloading station, the sulphuric acid is

directly transferred to the NPK/DAP plants. Earlier the sulphuric acid from main

storage tank was first transferred to day tanks and consumed in the process . By

direct supply of sulphuric acid to plant from unloading station, the day tanks have

been eliminated and this has reduced the idle time of pipelines. With continuous

sulphuric acid handling, the corrosion to pipe and pipe fitting is less. This has

increased the safety and leakages are nil. The MOC of the Sulphuric acid line

has also been upgraded with SS316L. This improves the safety and reliability of

the plant and employees.

4. Modification in Zinc Sulphate Plant for Zn Recovery The major raw material in Zinc sulphate plant is Zinc ash and Sulphuric acid. In

the designed system the Zinc content in the final zinc mud is high i.e., 7-8 %

which increased per MT Zinc ash consumption and ultimately the plant level Cost

of production of the product. Various in-house modifications have been taken,

and Sulphuric acid has been used in secondary mud washer tank to react with

unreacted Zinc. With this, the Zn % in final mud has been reduced by 2-3%. The

scheme has been implemented from Aug-13 and equivalent monetary saving of

Rs. 23 lakhs is realized on annual basis.

5. Installation of Rotary Dryer for Water Soluble Urea Phosphate Plant:

Rotary dryer for 50 MTPD 100% Water Soluble Urea Phosphate plant has been

commissioned on 18.04.2013.It has been installed to reduce the moisture content

of product from 2-3% to 0.5%. It is rotating with 2.5 rpm with the slope less than

10 (almost close to 0.50) which provides the sufficient residence time to product to

dry. With this, it is possible to have full plant capacity production as and when

required.

6. Ammonia saving on account of modification in Granulator, PN & Scrubber a) Spray nozzle successfully installed and operated in Granulator discharge

duct in B,C, and D trains (B,C,and D trains do not have inclined venturi)

which has controlled ammonia loss.

b) Lowering of ammonia spargers of granulator & PN tank.

c) Scrubber operated at lower mole ratio of 0.6 to 0.7 in K-I Plant.

Due to above modifications, ammonia loss has been reduced by 40 ppm per

train thereby saving of 0.5 MT per day (150 MT per annum) of ammonia

equivalent to monetary saving of Rs. 46 lakhs per annum.

7. Installation of isolation valve A separate isolation valve at ammonia tank - A pump discharge header has been

provided.This helps in depressurizing without affecting the ammonia lines from

tank B and tank C. Depressurizing is done faster and safely.

8. Air conditioning system has been installed for AB train MCC room which helps in

equipment protection and good working environment.

9. Two agitators have been installed in the central sump of NPK K-I which prevents

sludge settling at the bottom,ensures constant pump suction and it gives good

performance and saves nutrient in the washings which get collected in central

sump for reuse in scrubber.

10. Sulphuric acid is now added to tail gas scrubber which has improved scrubbing

and also reduced choking of demister pads and carry over in stack.

11. Horton sphere flare stack has been removed and now the connection has been

made for common flare stack which has capacity of 2.2 MTPH. With this safety

has increased and maintenance of low capacity old flare stack of Horton sphere

is not required.

12. Modification in orientation of ammonia spargers& lowering of ammonia spargers

at 0.3 m in B-train. This will help in larger contact time between the reactants

helping to increase reaction efficiency.

13. Lowering of ammonia spargers in Granulator for better sparging through the

material bed to improve granulation and reduce ammonia loss.

14. Repositioning of slurry nozzles in the slurry header to optimize the spray and

cover larger area for better granulation and ammoniation efficiency.

15. Use of 2.5 mm mesh product screen to ensure best size distribution in product.

16. Relocation of PN level indicator outside the PN and proper jacketing to ensure

continuous & reliable readings of PN level. Auto flushing arrangement is

provided. With 60% level on continuous basis, the ammonia efficiency increase

on account of sparging through the slurry maintained at this level.

17. Provision of two load cells in potash feeder to ensure accuracy even if potash

feeder is slightly off-centre. This has improved potash efficiency & also with

accurate feeding the grade quality is maintained.

18. The old conductors and clamps of 66 kV switch yard Kandla line were replaced

with ACSR conductors and Tee clamps of aluminium alloy A6.

19. Proximity switch has been provided in zinc sulphate spray dryer atomizer to

ensure that in case of failure of atomizer rotation, the mother liquor feed pump

trips. This has increased process safety and downtime of plant.

20. Renovation & strengtheningof Aged Equipments& Steel Structures is under

progress for safety &healthy of the plant. Nearly 60-70% of the strengthening job

has been completed.

21. Load cell boxes of B, E, G, H, P1, P2 modified and both machines load cells

taken in a common box & location also shifted for easy access.

22. Sack Grip boxes of all CRIL machines repaired by providing glanding,terminal

strips,new lugs, ferrules etc.

23. Sack grip assemblies for N, L, M machines modified.

24. Sack grip levers of Newlong machines modified

25. Load cell boxes of all 12nos. of Newlongmachines modified by the reduction the

length of load cell extension cables and providing new glands, lugs in it.

26. Local control panels of Newlong machines repaired, modified and old terminal

strips,selector switches, push buttons, indicators are same as in CRIL Panels.

27. New weighing scales platforms fabricated for Mettler scales (06 nos.) and

Weighing scale housing boxes replaced ( 06nos ).

28. Bunker level transmittersof F & H replaced.

29. Proper synchronisation of all weighing machines done i.e., mechanical parts with

electronics/sensors to minimise weight variation.

30. L1 proxy switch of O&P bagging machine eliminated and modified.

31. A new high angle (90 degree) belt type Steep conveyor of capacity 5MTPH has

been installed in Urea Phosphate plant in the month of april-2013, to convey the

dry product from Rotary dryer discharge to product Hopper. The steep conveyor

is suitable, where there is space limitation.

32. Replacement of Split Casing with Quarter casing of Fan in K-I Plant has been

done during Aug-2013 for ease of maintenance.

33. Coils have been installed in urea phosphate reactor for heating phosphoric acid

to 70 – 75 C with steam and then cooling the slurry to 45 C by passing water

through same coil. This has improved crystal formation and better quality urea

phosphate is obtained.