Deepak Fertilisers and Petrochemicals Corporation Limited Taloja

8/11/2019 Deepak Fertilisers and Petrochemicals Corporation Limited Taloja

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CII 13th National award for'Excellence in Energy

Management -2012 '



Deepak Fertilisers and Petrochemicals Corp. LtdISO 9001:2008, ISO14001:2004, OSHAS 18001:2007 Certified

• Year of establishment : 1979

• Manufacturing Facility : At Taloja, Maharashtra

• Turnover ( 11-12 ) : Rs. 2342.81 Cr

• Products :

ANP ( 24:24:0 )

Isopropyl Alcohol

Weak Nitric Acid ( 59.2% )

Concentrated Nitric Acid ( 98.3% )

Strong Nitric Acid ( 72% )

Ammonium Nitrate

Methanol

Liquid CO2



Reformation PurificationNH3

Synthesis

Natural Gas

Air

Steam

Methanol AN ANP

MethanolPlant

Purification

Synthesis

Reforming

Compression

Liquid CO2Plant

Purification

Liquefaction

Liq. Co2

WNA Plant Ammonia

Oxidation

Absorbtion

WNA CNA

C.N.A.Plant

AN PlantReactor

Evaporation

PrillingCoating

Reactor

Evaporation

PrillingCoating

Phos Acid

RGP

IPAPlant

ANP Plant

RGPPurification

Reaction

Purification

IPA

Ammonia

Process Flow



Plants

Plant Original Cap. Current Cap.

Ammonia 272 TPD 380+10 TPD

Methanol 300 TPD 300 TPD

Liquid Carbon dioxide 100 TPD 120 TPD

Isopropyl Alcohol 210 TPD @ BOR 250 TPD @ BOR

Weak nitric Acid 3 X 300 TPD 3 X 300 TPD

Weak nitric Acid 1 X 450 TPD 1 X 450 TPD

Concentrated Nitric Acid 1 X 100 TPD 3 X 120 TPD

Ammonium nitrate melt 520 + 300 TPD 520 + 300 TPD

Ammonium Nitrate Prills 120 TPD 400 TPD

A N P ( Mahadhan Power) 765 TPD 1000 TPD

Steam 2712 TPD 2712 TPD

Captive Power Plant 2 X 4.5 MW2 X 4.5 MW1 X 7.2 MW



Plant Technologies

Plant Technologies

Ammonia Fish International Engineers

Methanol Davy McKee ( UK )

Isopropyl Alcohol British Petroleum

Weak Nitric Acid One : Weatherly Inc.

One : Uhde Medium Pressure

One : Uhde Dual Pressure

Concentrated Nitric Acid Adolf Plinke

Ammonium Nitrate One : Stamicarbon

One : Grand Paroisse

Ammonium Nitro Phosphate Stamicarbon



Energy Saving Projects Implemented:

Year

2009-10 8 1157.78 447.33 8437.27 5.30

2010-11 6 1002.21 712.57 11697.36 6.09

2011-12 3 55.17 216.48 14426.71 1.50Total 17 2215.16 1376.38 34561.33 3.98

Schemes

Implemented

Investment Made

(Rs. Lakhs)

Savings Achieve

(Rs. Lakhs/year)

Energy Cost

( Rs. Lakhs/year)

%Savings of

Energy Cost



Schemes Implemented In 2009-10

Details

http://localhost/var/www/apps/conversion/tmp/scratch_5/Annex-A%20Schemes%20Details%202009-10.pdf

http://c/Documents%20and%20Settings/pathakka/Desktop/financial%20report/CII/CII%20Presentation/Annex-A%20Schemes%20Details%202009-10.pdf





Details

http://localhost/var/www/apps/conversion/tmp/scratch_5/Annex-A%20Scheme%20Details%202010-11.pdf


http://localhost/var/www/apps/conversion/tmp/scratch_5/Annex-A%20Scheme%20Details%202010-11.pdf




Details






Magnetic Resonator on fuel

line of Boiler A & D



VFD for IPA CT fan motor



Pump replaced to match with

process requirement

• After



•100 Nos of 2 x 40 W Ferromagnetic Ballast &

Normal tube light replaced to 1 x 36 W with

Electronic Ballast & High Lux tube light

55 nos ,1 x 125 W HPMV Rusty Lamp Fitting at

ANP plant are replaced to 1 x 70 W New Metal

Halide Fitting.• After



Energy Management

System in place



• Initially the technical service department, apart from its routine jobs,

was also looking after the plant performance & energy conservation.

• To become more focused & proactive, it has been restructured in the

month of June-08 & formed the energy cell named as PI & EnCon,

i.e. Productivity Improvement & Energy Conservation Cell.

• The group has been lead by professional who is in the field of

improvement of plant performance & better management of energy

for more than 15 year and also the BEE's designated Energy Manager.

• The group Head is directly reporting to unit head.

About PI & EnCon Dept.:



•

This group has two wings , one engineering & one implementation.Each wing has full fledge team of engineers.

• In totality, there are three BEE's Certified Energy Managers.

Company also sponsoring selected candidates for BEE's energy

manager examination on yearly basis.

• Apart from this, we are having nominated as energy managers (14

Nos ) from each stream of plants( like- production-each plant,

maintenance-each stream )

Company has energy policy which reflect



Company has energy policy which reflect

the top management commitment towards

Energy Conservation.



Techniques used for energy

conservation:

•We use software like Aspen plus, HTFS etc.

•Daily plant monitoring and carry out internal energy audit of

all plants once in a year

•We also carry out the energy audit from external parties

using recent methodology / technologies.

•We do circulate the knowledge sharing literature , conductseminars related to new developments etc which help for idea

initiation from shop floor person

S F



Shop Floor

Nominated Energy Manager from

Production & Maintenance ( 15 Nos )

PI & ENCON Department

Energy Conservation

Awareness

Energy Week

Celebration

CirculationLiterature

Seminars

Skills

Internal &

External

Trainings

Interactions

Daily With

Shop floor

personsMonthly with

Nominated

Energy Manager

Motivation &

Recognition

Prizes for

Best Schemes

Display Board with

name of Idea Initiator

Support From

Top Management



Awareness creation in the employees

& their involvement in energy

conservation program

• Display Boards for Energy Slogans

• Arranging Presentations, lectures, seminars on latest developments

& good practices in industries

• Circulating literature on weekly basis

• Booklet containing relative information of Energy Conservation

along with the case studies.

• Display boards for implemented & under implementation schemes

with idea initiators name & details of schemes



• Celebration of Energy Week during which different programs

related to EC are arranged.

• Also the prize distribution to idea initiator for implemented

schemes.

















Product wise specific energy consumption for last

four years



Graphical representation of Sp. Consumption for

energy intensive plants

Ammonia

2008-09 2009-10 2010-11 2011-12

0.83

0.84

0.85

0.86

0.87

0.88

Ammonia ( MTOE / Ton of product )

Ammonia





IPA

2008-09 2009-10 2010-11 2011-12

0.20

0.25

0.30

0.35

0.40

0.45

IPA ( MTOE / Ton of Product )

Iso Propyl Alcohol



World wide Benchmarking of Plants

• Ammonia Plant Benchmarking through Plant Survey International ( PSI )

• Net Specific – DFPCL 37.0 GJ / mt at 23 rd rank

- World best 24.7 GJ /mt

- World Avg. 37.4 GJ / mt

The world best plant is hydrogen based.

In 2011-12 , the yearly net specific consumption is Brought down to 35.17 GJ /mt even with converter catalyst at EOR condition which ranked at 15th

• Nitric acid plant Benchmarking through PDC, The Netherlands

• AN plant capacity augmentation and energy conservation through process

licenser M/s Grand Paroisse.

http://localhost/var/www/apps/conversion/tmp/scratch_5/Ammonia%20Benchmarking.ppt

http://c/Documents%20and%20Settings/pathakka/Desktop/financial%20report/CII/Presentation/Ammonia%20Benchmarking.ppt

http://localhost/var/www/apps/conversion/tmp/scratch_5/Ammonia%20Benchmarking.ppt



Future Road Map.....

•

Acid Plants : Incorporation of modified type of cooler condenser torecover the waste heat

• Ammonia Plant : To fire the waste process gas in Boiler , there by

recovering the energy.

• Replace the old energy inefficient pump with efficient one



Innovative Projects...1

• Innovative change over to total energy integration

strategy

• A back pressure turbo alternator has been installed as

part of the overall steam network to recover energy from

steam as it is let down from 40 to 3.5 bar. This steamturbine along with alternator can produce 3 MW of

electricity.

•

Also we have put additional 7 MW gas based co-generation power plant to improve the energy

integration and power reliance.





Alternator with Exciter



Innovative Projects.......2

Modifications in CO2 Removal Section•In June 2009 solvent changeover from @MDEA to @MDEA –

HiCap

•Also the additional LP flash column is added in-between

absorber and stripper

Benefits Envisaged:

• Plant capacity is enhanced from 354 to 380 TPD

• Energy consumption is reduced from 56.1 Mbtu/lbmole to 39.3 Mbtu /lbmole, 31166 to 21833.33 kcal/Kmol i.e. 30 % energy reduction

LP Flash Column in ammonia plant



LP Flash Column in ammonia plant

CO2 removal section



Environmental Projects



Environmental Projects• Scheme for recycling 15 m3/hr water from IPA plant effluent is

successfully implemented in June 2011

• We have successfully implemented the CDM project for two plants of weak

nitric acid. This has substantially reduced the greenhouse gas emission to

atmosphere.

– Also , we are in process of implementing the CDM project for another

three weak nitric acid plants.

• Nox scrubbing scheme is implemented and same is under commissioning ,

this will reduce the Nox emission from acid storage tanks.

• Online ambient air monitoring & online display at main gate

WNA-1 WNA-3 Total

CERs Issued NIL 21448 21448

CERs verified 224678 72336 297014

Deepak CER 224678 93884 318562

B i e t the dified



Basic concept on the modified

energy plan related to specific

measures

• Design Stage : Each and every modification in DFPCL is

reviewed by energy cell during design stage. Energy cell

evaluate and compare the energy efficiency of equipments

involved in the modification. According to the cost benefit

analysis, recommends the best energy efficient equipment.

• In Operation : Energy cell monitors the energy consumption

of each plant on daily basis. The deviations with respect to

design being addressed with corrective actions. This cell also

carry out complete plant energy audit once in a year. Also thecomplex energy audit is being carried out once after every two

years from external competent agency.

Monitoring & Reporting format




M i i & R i f




Future Projects



Future Projects

• Zero discharge effluent project.

• CDM projects for WNA 3 & 4 plant

• De-Bottlenecking of AN melt plant.

• Replacement of old conventional motors with energy efficient 1 type

motor

• Implementation of recommendation of complex water pump audit.

• IPA & Ammonia Plant waste gases firing in Boiler to eliminate the

flaring

• Complex energy audit from external agency

ISO 9001 ISO 14001 and ISO 18001



ISO 9001 , ISO 14001 and ISO 18001

audits of Energy Saving Projects

Year No Of NC

Major

No Of

NC

Minor

No Of Corrective

actions

No Of

Preventive

actions

2011 0 0 0 -

2012 0 0 0 -

U f R bl E S



Use of Renewable Energy Sources

• Company has 8 nos of wind mill of 1.25 MW each , i.e. 10 MW in Dhule

district of Maharashtra.

• Generation Data:

• We have installed the solar water heater for canteen which has stopped

the 6 KW electrical heating system.

Through windmill 2009-10 2010-11 2011-12

Unit generated(Millions

kWh/year)19.285 15.297 16.017

Awards & Accolades:



Awards & Accolades:

• MEDA State Award for Energy Conservation : 2008-09 ( 2nd ) &

2009-10 ( 1st )

Awards & Accolades:



Awards & Accolades:

• ICC award for Excellence in Energy Conservation and

Management : 2010

Thank You!!!



Thank You

Mr.R.S.Sankhe : GM ( PI & ENCON )

Deepak Fertilisers and Petrochemicals Corp. Ltd.

K-1 , Taloja MIDC Industrial area, Raigad – 410208, Maharashtra, India

www.dfpcl.com

Thank You!!!

http://www.dfpcl.com/

