Records and Achivements
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Transcript of Records and Achivements
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.