Pls send me iffco fulpur urea plant project training report pdf........

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Summer training report iffco fulpur plant

Summer training report iffco fulpur plant

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Pls send me iffco fulpur urea plant project training report

IFFCO - PHULPUR UNIT

1. IFFCO‘ IFFCO‘S MISSION “To enable Indian farmers to prosper through timely supply of reliable, high quality agricultural inputs and services in an environmentally sustainable manner and to undertake other activities to improve their welfare" IFFCO- IFFCO-PHULPUR UNIT Honorable Members of Jury and Delegates IFFCO-PHUL PUR UNIT A Profile Phulpur-I Process Licensor Annual Ca pacity •Ammonia Plant MW Kellog, U.S.A 322400 MT •Urea Plant Snamprogetti, Italy 551100 MT FM 534418 ( ISO 90 01:2000 certified ) Phulpur-II Process Licensor Annual Ca pacity •Ammonia Plant HTAS, Denmark 501600 MT •Urea Plant Snamprogetti, Italy 864600 MT EM S 534419 •Com mercial Producti on ( ISO 14 001: 2004 certi fied ) •Phulpur-I Urea Mar. 28, 1981 •Phulpur-II Urea Dec. 22, 1997 ANNUAL UREA CAPACIT Y : 1415700 M T H9104243 (OHSAS18001:1999 cer tifie d) ( Design) ANNUAL TURNOV ER ( 07-08) : Rs. 1765 Crores ( Includi ng s ubsidy) 1
2. ISO 14001:2004 ISO 9001:2000 OHSAS 18001:1999 IFFCO-PHUL PUR PRO DUCTION O UTL INE POWER POWER COAL RLNG RLNG Co al - Base d RL NG/LS HS ( Support Fuel ) Boilers Boiler TG – I TG – II ( 3 X 125 MTP H ) ( 1 X 20 0 MTPH ) 12.5 MW H 18.0 MW H HIGH PRESS U RE STEAM AIR AMMONIA P LAN T ( 977 AN D 1 52 0 MTPD) ( N 2 + O2 ) (C+ H) CO 2 Synthes is Refor mi ng Shift N aphtha Co nvers io n Rem ova l N 2+ 3H 2 2NH 3 / R LNG CO 2 Am mo nia Flue Gas to C DR Pla nt for C O2 Recov er y (NH 3) Hig h Pr essur e POWER Secti on Med ium P ress ure Secti on UREA PL AN T (167 0 A ND 2 62 0 MTP D) Vacu um Co nce ntrati on (Designed) Prill in g 429 0 MTP D , 858 00 BAG S Trans port PER D AY UREA Bagging 2
3. Major Water Recycle /Reuse Schemes during 2004-2008 Phulpur Unit Sr. Water Recycle / Reuse Investment Annual Pay back no. Schem e (Rs. in w ater Lakhs) Saving (m 3) 1. Increase in C ycle of -- 603662 Im medi- C oncentration of C ooling ately Tower ( from 6.0 to 9.0) 2. Direct Recycling & Re use 0.92 23100 4.3 of Turbine C ondensa te in m onth Amm. – II Pla nt 3. Recycle of C DR effluent 0.44 118800 3.86 for process use as coo ling m onth Tower make-up through Water Sof tening Plan t Major Water Recycle / Reuse Schemes during 2004-2008 Phulpur Unit Sno. Water Recycle / Reuse Investment Annual Pay Schem e (Rs. in w ater back Lakhs) Saving (m 3) 4. Installa tion of Rain 13.14 3600 -- Water Harvesting System 5. C ollection and re use of 316.72 3900 -- rain wa ter in proces s throug h Mist C ooling System 6. Installa tion of Wa ter 5.50 32200 17.1 Spraying System in m onth Ammonical G uard Pond 3
4. RAW WAT ER CONSUMPTION FO R UREA PRO DUCTION Fresh water (Borewell) Industrial effluent Recycle Process & Turbine Condensate Treated Sewage Water Reuse 4% 24% 58% 14% Des cription Year 20 04-05 Year 20 07-08 Urea Produ ction, MT 14,29,078 15,53,980 Raw Water, M3 95,29,997 94,62,926 Raw Water Consu mpti on 6.67 6.00 per MT Urea Specific Raw Water Consumption 20 2 .0 18 18 CPCB Benchmark : 10 m3/MT Raw Water (M3 / MT of Urea) National Benchmark : 7.3 m3/MT 16 Raw Water Saving in Year 2007-08 : 10,41,0 00 m3 . 95 (as compared to year 2004-0 5) 13 14 12 .14 ` . 10 10 10 10 0 7.8 8 3 8 7.0 6.6 10 6. 00 6. 6 2 4 8 2 6 8 4 6 0 -9 -9 -9 -0 -0 -0 -0 -9 -0 93 97 05 91 95 99 01 03 07 4
5. SPECIFIC EFFLUENT DISCHARGE Zero discharge since 1994-95 1 7.0 CPCB Ben chmark: 5.0 m3 /MT of Urea 6. 3 Effluent discharge, M3/MT Urea 6.3 5.6 Nati onal Ben chmark:0.6 m3 /MTof Urea 1 4.9 4. 3 4.2 4 2. 9 3.5 2.8 9 2 1.8 1.8 2.1 1.4 0 0 0 0 .0 0 0 0.00 0 0 0 0 0 0 0 0.7 0.0 0.0 0.0 0 0.0 0. 0 0. 0 0 .0 0.0 0. 0 0. 0 0. 0 0.0 0.0 92 02 03 04 05 06 07 08 98 99 00 01 90 91 93 94 95 97 6 95 - 9 01 - 02 - 03 - 04 - 05 - 06 - 07 - 91 - 89 - 90 - 92 - 93 - 94 - 96 - 98 - 99 - 00 - 97 - EFFLUENT DISCHARGE PER MT OF UREA Per capita Domestic Water consumption Industrial Colony water consumption Year Consumption Average Per capita Consumption No of Per capita m3 / day No. of consumption m3 person consumption emplo yee (Ltr per (Ltr per per day person per person per day) day) 2004- 05 350 1185 295 3800 4000 950 2005- 06 350 1118 313 3800 4000 950 2006- 07 300 1063 282 3800 4000 950 2007- 08 300 1967 281 4100 4500 911 5
6. INNOVATIVE PROJECT No.-1 ETP cum Recycle Plant based on Steam Stripper Off-spe cification Ammonical effluent and deoiled water from Am monia and Urea Plant is treated in stripper of ETP vEarlier treate d wate r was dischar ged into Gu ard Po nd. vPresently this effluent water is recycled and reused in pr ocess as Cooling Water make-up. This sav es 742 M3/day of Raw water. Year of Implementation: 2004-0 5 Water Quality ( mg/l) Paramet er Before After (Designed). Treat ment Treat ment Amm. - N 2000 < 50 Effluent Treat ment Plant Cost : Rs. 203 Lakh Tr eated Wat er R ec yc led as C W make-u p INNOV ATIV E PROJ ECT No.-2 Blo w-do wn re duct io n due w- to im proved COC from 6 to 9 Cooling Blow-dow n Blow -dow n Cooling Evaporation, Make up Make up Pl ant Water fl ow, COC = 6 , CO C = 9 , Range, deg.C m3/ hr COC = 6 CO C = 9 m3/hr m3 /hr m3/ hr Ammonia C. T- I 13000 12 279 334 313 56 35 Urea C.T. - I 10000 10 179 214 201 36 22 Power C. T. - I 3200 5 29 34 32 6 4 Ammonia C. T- II 20000 7 250 300 281 50 31 Urea C.T. - II 17000 7 213 255 239 43 27 COC = 6 Power C. T. - II 4800 5 43 51 48 9 5 Total 68000 991 1189 1115 198 124 Benefits: v Reduction in Blow-down = 1776 m3/day v Ye arly Raw water saving = =60 366 2 m3 v Reduction in Hydrated lime consumption in Cold lime softening process due to reduced make up water requirement. COC = 9 vYear of Implementation: 2004-0 8 6
7. INNOVATIVE PROJECT No.– 3 Recycle of CDR Effluent Water in to Plant Process Year of Implementation: 2006-0 7 Raw Water Saving (1188 00 m3 per year) Cost : Rs. 0.44 Lakh. v Reduction in quantity of the effluent Paybac k: 3.86 months (1188 00 m3 per year) vSaving of Electrical energy (39204 KWH per annum) S.N. Composition Design Value CDR Fresh Effluent Raw Water Actual 1. Na 2SO3 0.02 –0.03 0.012 % - Wt% 3. Na 2CO3 0.04 –0.05 0.10 % - Wt% 5. pH 7.0 7.80 7.6 6. Colour None None None 7. Total Amm.-N 0 25.0pp nil (as N) m 8. TKN (as N) <50 mg/L 29.5 nil ppm 10. COD <50 mg/L 55 ppm - 14. TDS 800 360 ppm INNOVATIVE PROJECT No.– 4 Recycle of Turbine Condensate in Ammonia Plant -II Year of implementation :2006-0 7 Cost : Rs. 0.92 Lakh Benefits: v Raw Water Saving (23100 m3per year) v Reduction in quantity and improvement in quality of the effluent (2310 0 m3per year) vSaving of required chemical (HCl – 100 MT per Annum and NaOH – 89 MT per annum) for regeneration of condensate Polisher Unit for this condensate water. vSaving of Electrical energy (8075 0 KWH per annum) 7