K M Tandon

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Efficiency improvement and cost optimization inFertiliser Plant- Case Study

K M Tandon

Session III III/

Efficiency improvement and cost optimizationin Fertiliser Plant- Case Study

Shriram Fertilisers & Chemicals : Kota

Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Fertilisers & Chemicals Shriram Cement Works Shriram Cement Works Shriram Cement Works Shriram Cement Works

Fenesta Building Systems Fenesta Building Systems Fenesta Building Systems Fenesta Building Systems Shriram Polytech Shriram Polytech Shriram Polytech Shriram Polytech

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Location

475 km fromDelhi on themainwesternbroad gaugeline linefrom Delhi toMumbai

235 km fromJaipur onthe NH 12From Jaipurto Jabalpur

Location

Manufacturing FacilitiesPLANTS / PRODUCTS UNIT CURRENT

PRODUCTION LEVELS

Power MW 133

Fertiliser - Ammonia- Urea

TPDTPD

7001200

Chlor Alkali - Caustic Soda- Chlorine Liquefaction- HCl- SBP

TPD

325180175

35

Plastics - Calcium Carbide

- PVC Resin

TPD

340

200Cement TPD 1200

Shriram Polytech - PVC Compounds TPD 60

Fenesta - Window and Door profiles TPA 3000

Common Services Rly. siding, Mech. Workshop, CentralStores, HR, Adm., IT, Accounts etc.

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Fertiliser Plant

Fertiliser Plant

Commissioned in 1969 with a capacity of 450 TPD Ammonia / 700 TPD Urea

Expanded in 1974 to 600 TPD Ammonia / 1000 TPD Urea

Present Operation level is 700 TPD Ammonia / 1200 TPD Urea

Ammonia Plant based on Haldor Topsoe Steam Naphtha reforming process

Urea plant based on Stamicarbon's total recycle process with crystallisation route

for urea finishing

Ammonia plant modified to use Natural gas and naphtha in any proportion in 2006

Plant started using gas from Sep.07

Plant running fully on natural gas since May,2009

Focused on reducing energy consumption

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Philosophy of improving energy efficiency

Identification of process bottlenecksIncreasing capacity utilisation

Incorporation of available retrofits

Systematic equipment replacement plan

Reduction in shutdown frequency and duration

Relook into original design of equipmentModifications in compression equipment

Redesign of boilers and exchangersSimplification of piping and replacement to decrease PChange of packings

Philosophy of cost reductionSteam conservation

Reuse and recycle of water

Cooling water treatment

Water conservation

Use of right temperature

Trap management

Online leak sealing

Better procurement strategies for cooling water chemicalsBenfield system chemicals

Reoxidation cooler for V2O5Better house keeping and maintenance practices.

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Philosophy of cost reduction

Compressor partsImport substitution

Vendor development

In house NDT

Vibration monitoring

Reclamation and reuse of old parts

Replacements on condition monitoring results

Reclamation of Lubricating Oil

Recycle tank for Urea solutionUse of Aspen for process analysis and design

Ammonia Plant

Reforming section

Modifications / upgradations

Reformer catalyst tubes MOC changed from original HK 40 toManuarite in 2000. With this ID of tubes increased from 115 mmto 131.6 mm

A water spray tower was installed in 1980 at the downstream ofthe waste heat boilers to maintain HTS inlet temperature byadding BFW

The primary reformer induced draft fan was also replaced with ahigher capacity one so that proper excess air of 2.5% O2 couldbe maintained

In order to reduce the heat duty of fired preheater upstream ofprimary reformer, a steam fired heater was installed

A convection section was added in direct fired preheaters toutilise waste heat from flue gases

Additional heat recovery from the Reformer convection zoneby addition of extra rows of tubes in air and steam coils

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Carbon dioxide removal and beyond

25 mm Metallic (SS) Pall rings were installed in the top twobeds and 38 mm rings were installed in the bottom two beds inplace of ceramic rings

In order to reduce gas velocities at the CO2 Absorber outlet anadditional Separator was installed in 1979 itself . This helped inavoiding liquid carryover to the methanator

To reduce the temperature of the bottom to top potassiumcarbonate solution a larger size HPC cooler had to be installedin 1983

The synthesis gas compressors which are motor drivenreciprocating machines posed a bottleneck in achieving fullplant loads. The cylinder bores of 1st stage were increasedfrom 289 to 305 mm as there was some margin in the motor.This enabled a capacity increase of 9 %


Period between turnarounds

Earlier the plant turnarounds were taken on annual basis.However, the IBR later allowed operation of waste heat boilersupto two years.

With judicious planning of the overhauling of the reciprocatingcompressors the turnaround are now taken up once in two years.

This has improved availability of plant


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Installation of a radial ammonia convertorThe original TVA Type Axial Flow Ammonia Converter Basket wasdue for replacement in 1992

A radial flow converter was installed as replacement of old axialflow basket

This has made the running of smaller 120 TPD AmmoniaSynthesis loop unnecessary

Since the loop did not have any waste heat boiler, the energy wasbeing wasted to the cooling tower. This could be avoided with theinstallation of the radial converter


Feed stock conversionfrom

Naphtha to Natural Gas

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Why change to Natural gas

Energy cost constitutes about 80% of total cost of production of urea

After removal of APM from naphtha, its prices touched a very highvalue of Rs. 55,000/MT

Gas is a clean fuel as compared to naphtha

Gas is cheaper as compared to naphtha

Reduced cost of production leads to improved competitiveness

Favourable government policy for feedstock changeover

Reduced subsidy outgo

Conversion to Natural Gas

Modifications done in the plantto enable it

touse natural gas


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Replacement of all 252 burners from self aspirating naphtha firedburners to forced draft Natural gas / Naphtha fired burners

Installation of a Combustion Air preheater

This was necessary as the reformer furnace was originally designedfor 450 TPD only and it was difficult to fire sufficient heat withoutthe preheating of combustion air

Installation of a new feed Natural Gas preheater

Installation of new FD Fan and ID Fan at ground floor

Installation of fuel NG preheaters

Replacement of Steam Naphtha Coil and inlet distribution headersfor steam naphtha mixture going to the catalyst tubes

Removal of BFW Coil from convections section of primary reformerfurtnace


Control system upgradation

35 year old pneumatic controls required frequent maintenance andwere facing obsolescence

More accurate control helps in better optimization of plant parameters

Temperature scanner was also error prone and inaccurate

Plant interlocks were relay based

Old pneumatic controls replaced by state of the art Digital control System

This has enabled

Centralised Operation MonitoringProcess behaviour analysisMonitoring of Alarm managementProcess history storage


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DCS Chosen isEmersons Delta V system

Plant safety interlocks have been implemented in integrated Delta - V SISwhich is TUV approved system for SIL3 applications.

Salient features are

1100 Nos I/OsEase of operationTrends , process history, alarms available.Built on commercially available personal computers as work station andengineering satations.Windows platformProven ethernet communication technologyScalable to add more controllers and operating stations as required


SIL safety system

Foundation field bus

Latest technology foundation field bus has been used for temperatureSignals and few pressure and flow monitoring requirements.

Asset management system

Delta V AMS suite has been installed for centralised configuration ,diagnostics, maintenance and history record for HART and FF fielddevices.

Operator interface

5 Operating stations with 19 LCD monitors in a control roomScreens interchangeable in all respectsOperator can scroll through the entire plant seamlessly.


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Redundancy

100% plant availability ensured

Controller 1 HDS, Gas Purification and synthesis sections

Controller 2 Primary and Secondary reformer and LNG system

All critical Inputs/outputs are connected to redundant modules

Hazardous area interface

Input cards are Delta V inherently safe . However, as a precaution

i/o isolators for all hazardous ares have been instal led.

Old pneumatic controls replaced by state of the art Digital control System in 200



Systematic effort to optimise the operation and with use of Natural Gas ,the energy consumption has been reduced significantly

7.3257.447

7.7147.779

7.857.887.85

7.81

7.97

8 . 0 9

8. 28.15

8.19

8 . 4 3

8 . 2 5

8 . 3 5

8.53

8 . 3 8

8.52

9 . 0 2

7.3

7.5

7.7

7.9

8.1

8.3

8.5

8.7

8.9

9.1

9.3

9 1

- 9 2

9 2

- 9 3

9 3

- 9 4

9 4

- 9 5

9 5

- 9 6

9 6

- 9 7

9 7

- 9 8

9 8

- 9 9

9 9

- 0 0

0 0

- 0 1

0 1

- 0 2

0 2

- 0 3

0 3

- 0 4

0 4

- 0 5

0 5

- 0 6

0 6

- 0 7

0 7

- 0 8

0 8

- 0 9

0 9

- 1 0

1 0

- 1 1

MKCal/MT Urea

Energy performance of the plant

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Focus on reducing R & M Cost

12.24

13.85

12.312

12.33

14.84

5.25.8

4.7

7.5

5.7

10.7

7.5

10.0

8.3

11.0 10.5

12.911.5

9.7

12.9

13.1

8.0

0

2

4

6

8

10

12

14

16

18

20

8 8

- 8 9

8 9

- 9 0

9 0

- 9 1

9 1

- 9 2

9 2

- 9 3

9 3

- 9 4

9 4

- 9 5

9 5

- 9 6

9 6

- 9 7

9 7

- 9 8

9 8

- 9 9

9 9

- 0 0

0 0

- 0 1

0 1

- 0 2

0 2

- 0 3

0 3

- 0 4

0 4

- 0 5

0 5

- 0 6

0 6

- 0 7

0 7

- 0 8

0 8

- 0 9

0 9

- 1 0

1 0

- 1 1

( P )

Avg. inflation rate during last 7 years 5.18% per yearGrowth rate R & M Cost during last 7 years 0.5% per year

R & M Cost contained to below inflation rate Reduction in real terms

Rs.Crs/Yr.

Maintaining Plant Health with min. Capex

1.9

1.8

2.813.72

6.158.7

8.1

9.6

2.2

8.4

4.3

18.2

6.0

34.7

6.68.0

6.74.4

1.8

30.4

1.10.92.0

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

8 8

- 8 9

8 9

- 9 0

9 0

- 9 1

9 1

- 9 2

9 2

- 9 3

9 3

- 9 4

9 4

- 9 5

9 5

- 9 6

9 6

- 9 7

9 7

- 9 8

9 8

- 9 9

9 9

- 0 0

0 0

- 0 1

0 1

- 0 2

0 2

- 0 3

0 3

- 0 4

0 4

- 0 5

0 5

- 0 6

0 6

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0 7

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0 8

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0 9

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1 0

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( P )

R

s . C

r s

.

Average Capex Rs. 7.8 Cr./Year

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The way forward - Energy savings schemes

S.No.

Scheme Expected energysavings

MKCal/MT Urea

A. AMMONIA PLANT

1 Heat Exchange Reformer (KRES) 0.32

2 Additional cell in cooling tower 0.04

3 Chiller at synthesis gas compressor suction 0.02

B UREA :

1 High Efficiency Combined (HEC) process for Ureaor 1st stage heat recovery

0.16

2 Evaporation route for Urea Plant 0.073

3 Additional cell in cooling tower 0.04

4 Natural Draft prilling tower 0.02

5 DCS and N/C Metering for urea plant 0.01

Total (A+B) 0.683

Thank you

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Urea concession price

*

11771

8751 92809884

12183

18018

23178

19995

8000

10000

12000

14000

16000

18000

20000

22000

24000

SFC, Kota Pre-92 -gas

Post-92 -gas

Mixedfeed

Post-92 -Naph.

Imported FO/LSHS Pre-92 -Naph.

Rs./MT Urea

Comparison with other Indian plants and imported Urea

K M Tandon

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