Plant: Phulpur

SrGM Shri D.K.Gupta

Address IFFCO, P.O.Ghiyanagar, Phulpur, Allahabad (U.P.),-212404

Phone (05332) 51256 (Direct Office No.)

PABX (05332)51250, 51251, 51333, 51334(0532) 282365, 282373
STD Code 05332 (Phulpur), 0532 (Allahabad)
Fax (05332) 51253, 51252, 51258, 51263, 51332
E-mail dkgupta@iffco.nic.in

Phulpur Unit - Environment

IFFCO PHULPUR UNIT " AN INDUSTRY IN HARMONY WITH THE NATURE"

Waste Management, Natural Resource Conservation, Environment Protection and its enrichment
has always been of paramount importance to IFFCO Phulpur Unit. We have adopted eco-friendly
technology wherever possible. Due care is taken at the design stage itself, to select the best
available technologies that produce low or negligible waste, conserve resources, and reuse
treated effluents to the maximum possible extent. ‘Prevention is better than cure’ has been the
basis of the Society’s pollution control programme. Environment monitoring and control at
IFFCO Phulpur is efficiently met by providing all necessary instrumentation and pollution
control measures for effluents, emissions, domestic sewage, and solid wastes.

With continuous efforts and its endeavours towards waste management IFFCO Phulpur has
achieved Zero liquid effluent discharge from premises - a rare performance achievable by any
similar industry. An effluent treatment cum recycle plant based on Reverse Osmosis Technology
has been installed to treat industrial effluent. The product water is reused in process as cooling
water make up. The domestic sewage water is treated in a well - designed sewage treatment cum
recycle plant. The treated sewage water is fully reused in plant process and sewage sludge thus
produced is utilized as manure in the farm lands of our Farmers Training Institute.

For monitoring the quality of ambient air, water and stack IFFCO has a monitoring laboratory
equipped with most sophisticated and modern instruments. The monitoring staff is experienced
and well qualified. This laboratory is recognized by the State Pollution Control Board because of
its good monitoring capability. Our R & D unit is also recognized by Ministry of Science and
Technology, Government of India.

Due to our excellent track record and well - established Environment Management System at
IFFCO Phulpur, we have been granted consent from State Pollution Control Board continuously
since Plant commissioning till date.

IFFCO Phulpur has an elaborate system for solid waste handling and utilization. Our strategy has
been to reduce the pollutants at source by adopting appropriate technology and to convert waste
into useful material.
Substantial Green Belt has been developed around the factory and Township to keep the
environment quality in its most natural condition.

AWARDS / APPRECIATIONS ON ENVIRONMET & POLLUTION CONTROL:

IFFCO Phulpur Unit has won prestigious Environmental Awards from time to time, which are
ample testimony of its excellent Environment Management System. Some of these awards are
listed here under :

In recognition of its outstanding performance in Environment Management, Phulpur Unit has

won the "BEST ENVIRONMENTAL AWAR" three times from Fertiliser Association of
India, i.e., for the Year 1993-94, 1996-97 and 1997-98.

2nd Jawahar Lal Nehru Memorial National Award for best organization in implementing
"POLLUTION CONTROL MEASURES" from International Green Land Society, Hyderabad.

IFFCO Phulpur has bagged "ENVIRONMENT AWARDS" for its excellent work in the
field of Environment Management, by Rotary Club of Allahabad Midtown, for the year 1993-94.

The Regional Director, Ganga Project Directorate, Ministry of Environment & Forests, New
Delhi has issued appreciation letters for the good Environment control at IFFCO Phulpur.

"First Position in Fertiliser Sector of Indo German Greentech Environment Excellence

Award" New Delhi in Year 2002.

"TERI Corporate Environmental Award" from Tata Energy Research Institute, New
Delhi in Year 2000-01 (in the category of companies having turnover more than Rs.500 crores
per annum).

ENVIRONMENT MANAGEMENT SYSTEM AT IFFCO PHULPUR.

LIQUID EFFLUENT MANAGEMENT:

All the liquid effluents generated from the various plants are subjected to extensive treatment to
ensure that the treated water quality conforms to the specification laid down by the UPPCB and
MINAS. For liquid effluent control, deep hydrolyser, distillation column, stripper and ETP based
on steam stripping, disc. oil separator, treatment cum recycle plant on Reverse Osmosis
technology, pH neutralization facility , guard pond, etc. have been installed and are operating
efficiently. Adoption of Non-Chromate cooling water system in process plants has been done
away with and menace of hazardous heavy metals like chromium has been eliminated.

ZERO EFFLUENT TECHNOLOGY:

IFFCO Phulpur has presently in operation, a single stream 1670 MT/Day Urea Plant
commissioned in 1980 and a twin stream 2x1310 MT/Day Urea Plant commissioned in 1997,
based on Snamprogetti’s patented Ammonia Stripping Process. Both the units have in-built
waste water treatment section, where the urea bearing waste containing 1.25% Urea and 0.5%
Ammonia is treated in deep urea hydrolyser with 35 ata steam. Product of hydrolysis, i.e.,
Ammonia and Carbon Dioxide are recycled back to process for increased production of Urea.
The water is purified for reuse as boiler feed water after passing through Ion Exchange polisher
unit. There is no effluent discharge from Urea plant.

977 MTPD and 1520 MTPD Ammonia Plants have been engineered and constructed by MW
Kellogg (USA) and Haldor-Topsoe (Denmark), respectively and are based on naphtha as the feed
stock. To achieve zero effluent discharge from the plant, it has process condensate stripper,
condensate polishing unit to recycle process and turbine condensate for steam generation. About
180 M3 / Day jacket cooling water of Ammonia Plant - I is recycled into Ammonia cooling
tower as cooling water make-up. Scheme has been implemented to reuse about 270 M3/day RV
sealing water of Ammonia plant-I into cooling tower.

WATER CONSERVATION MEASURE:

IFFCO Phulpur is very conscious and careful towards resource conservation. Several water
conservation schemes have been adopted right since inception of the plant for careful utilisation
of the precious commodity, i.e., water. The entire effluent generated in the factory is recycled /
reused after adequate treatment in plant process and irrigation of farm lands. The various water
conservation measures adopted at IFFCO Phulpur are as follows:
i. Treatment and reuse of process condensate and turbine condensate from Ammonia Plant:
In Ammonia Plant, process condensate, i.e., about 2980 M3/day, is treated in the stripper
for removal of its ammonical content. Further it is allowed to pass through a polisher unit
to remove all dissolved salts contained in the process condensate. The polished
condensate is pumped to plant and reused as boiler feed water.

Turbine condensate from Ammonia Plant is also sent to condensate polisher unit of D.M.
Plant for polishing in Ion Exchange units. The treated water is recycled and reused as
boiler feed water for steam generation in Ammonia plant itself and steam generation
plant.

ii. Reuse of Steam Condensate from Urea Plant:

About 950 M3/day of steam condensate from surface condensate of turbo driven CO2
compressor system and approximately 2100 M3/day of steam condensate from process of
Urea Plant-I & Urea - II are recycled to steam generation plant as a make up to boiler
feed water.

iii. Treatment and Reuse of waste water of Urea Plant (Deep Urea Hydrolyser):
In order to recover the valuable Urea and Ammonia from effluents and make the effluents ( 2200
M3/ Day ) reusable, the deep urea hydrolyser (operating at 35 Ata and 230 deg. C) has been
installed and operated.

BENEFITS:
Following benefits have been achieved :
i. Recovery of ammonia and carbon dioxide from waste water for reuse in the process.
ii. Reduction in DM water production & saving of required chemical for regeneration of
equivalent water.
iii. Reduction in quantity & improvement in quality of the effluents.
iv. Treatment and reuse of Off Spec. Ammonical & Deoiled Effluent.
Off spec. Ammonical effluent and deoiled water from Ammonia and Urea Plant is treated
in Ammonia stripper of effluent treatment plant. This treated effluent water is recycled &
reused in water softening plant.

v. Quench water / cooling water from I.G. Plant is directly pumped to water softening plant.
This saves equal quantity of raw water.
vi. About 180 M3/day of jacket cooling water of Ammonia Plant-I is recycled into Ammonia
cooling tower as cooling water make-up.
vii. About 100 M3 / day of flash tank condensate which comes out from Power Plant-I is
pumped into Ammonia cooling tower as cooling water make-up.
viii.About 150 M3/day pump house ejector discharge is presently being recycled into water
softening plant.
ix. About 270 M3 / day R.V. sealing water of Ammonia Plant - I is recycled in to Ammonia
cooling tower-I.
x. About 350 M3/day blow down water from boilers is recycled into power cooling tower.
xi. Total recycle of effluent through reverse osmosis effluent treatment plant:
An effluent treatment cum recycle plant with a cost of Rs.8.8 crores based on Reverse
Osmosis Technology has been installed to treat the Industrial liquid effluent e.g.
regeneration effluent of D.M. Plant, cooling water blow down and surplus effluent water
of Guard Pond. R.O. section is designed to give 85% recovery of product water. The
product water is reused in process as cooling water make-up. The R.O. modules are made
up of thin spirally wound composite polyamide membrane. This plant is a unique and
pioneer effluent treatment plant in India Fertiliser Industry. Its Technology has been
provided by M/s Hydranautics, California, U.S.A. The plant has been supplied by M/s
Ion Exchange (India) Limited.

xii. Installation of sewage treatment cum recycles plant for treatment and reuse of treated
sewage water into plant process.

We have installed a sewage treatment plant of 3000 M3/day capacity for treatment of township
sewage water which is generated from our residential township. The treated sewage water is
pumped to water softening plant and utilized as make-up water in our cooling towers. Treated
sewage water is also utilized for irrigation of 150 acres of farm land of Moti Lal Nehru Farmers
Training Institute, Phulpur.

Snaps of R.O. Plant ..

Snaps of Sewage Treatment Plant...

AIR POLLUTION CONTROL:

For Air emission control electrostatic precipitators, scrubbers for gaseous emissions, cyclone
dust collectors, natural draft prill towers of substantial height, flare stacks, chimneys of adequate
height for steam generation units have been installed and operated efficiently.

Adequate arrangement has been made for stack sampling and monitoring of pollutant level in
flue gases. The stack emissions are always well with-in the prescribed limits stipulated by State
Pollution Control Board & MOEF. Following stacks are regularly monitored for SPM, SO2,
NOx, Ammonia etc.

Name of Stack Height of Stack from G.L.

Power Plant Stack (2 nos.) 100 m and 120 m
Urea Prilling Tower (2 nos.) 96 m and 104 m
Primary Reformer Stack (2 nos.) 33.528 m and 30 m
Hydrotreater Stack (1 no.) 49.20 m
Desulphurizer feed preheater 58.5 m
Raw Naphtha super heater 35.8 m
Naphtha feed stack super heater 34.2 m
HRU Stack 37.7 m

Five ambient air quality monitoring stations have been installed in consultation with U.P.
Pollution Control Board. Ambient is monitored at the following stations:
• Bore well No.-8
• Railway Gate
• Moti Lal Nehru Farmers Training Institute, Phulpur (CORDET)
 • Central School Ghiyanagar
• Township Gate No.-4

The Ambient air quality is always well within the limits prescribed by statutory authorities.

SOLID WASTE MANAGEMENT:

Our strategy has been to reduce the pollutants at source by adopting appropriate technology and
to convert waste into useful materials based on the key concept "Wealth from Waste". Gainful
utilization of waste material has always been of paramount importance to IFFCO Phulpur Unit.

Adoption of non-Chromate System:

We have adopted non-chromate cooling water treatment, which has completely eliminated the
menace of hazardous heavy metals like chromium.

Utilisation of Coal Ash Generated From Steam Generation Plant:

About 1.5 Lakh tonnes per year Ash is generated from coal fired boilers of IFFCO Phulpur. Fly
ash generated in pulverised coal - fired boilers is disposed off to cement industries in eco-
friendly closed tankers, for which a dry ash collection system, i.e., the Dense Phase Pneumatic
Conveying system has been installed. With this mechanised system, it has been possible to load
and despatch total fly ash generated from our coal-fired boilers to bonafide end users.

Following are the areas where coal ash is utilised as useful material :-
A. Usar Land Reclamation
B. Manufacture of fly ash bricks and clay-fly ash bricks.
C. Manufacture of Portland Pozzolana Cement by Cement Industries.
D. Back - filling of low -lying areas.

IFFCO Phulpur is also involved in following Environmental Programme / initiative related to

solid waste utilization.
A. Use of fly ash as a soil reclaimant alone or in combination with other soil reclaiming
agent - IFFCO Phulpur along with Department of Science and Technology, New Delhi
under Fly Ash Mission.
B. Use of spent catalyst as source of micro nutrient for soil - IFFCO Phulpur along with
Allahabad Deemed Agricultural University, Allahabad.

ENVIRONMENTAL MONITORING FACILITY:

An environment laboratory well equipped with all necessary sophisticated instruments and
equipments have been established in the factory to monitor the liquid effluent, stack emissions,
ambient air quality, solid waste and Meteorological data. The major equipments include high
resolution chromatographs, absorption spectrophotometers, U.V. and visible spectrophotometer,
optical instruments, flame photometers, gravimetric analysis equipments, wind velocity and
direction monitors and recorders, high volume samplers, duct flow velocity measuring
instruments, isokinetic sampling device from ducts and other necessary equipments.

We also have a microbiology Lab. for microbiological analysis. In addition, we have also
established testing facility for toxicity test of effluent with fish in our laboratory itself. The
toxicity test of effluent of existing plant with fish is regularly done.

In addition to Environment Laboratory, IFFCO Phulpur is having an Environment and Pollution

Control Section to fulfill statutory requirements laid down by various authorities and co-
ordinating activities relating to environment among various sections.

GREEN SURROUNDING DEVELOPMENT:

The land provided for the factory and township was originally 'USAR' land and was lying
unutilized from long time. IFFCO had taken a challenge to reclaim this usar land and it has been
converted into a green land. 50 to 200m wide green belt has been developed around the complex.
Today, the entire area is full of trees and vegetation.

About 2.8 Lakh trees of wide variety of about 30 species including some of medicinal species
imparts scenic beauty besides providing suitable habitat for birds and other flora and fauna. The
greenery and the scenic beauty of Sanjivani Vatika, Buddha Vihar, Nandan Udyan, Saras Kunj,
etc. are remarkable and imparts healthy environment. The species of plants planted are Peepal,
Neem, Shesham, Pakad, Jamun, Guava, Arjun, Amla, Bel, Kanji, Ashok, Casurina, Gulmohar,
Amaltas, Harre, Bahera, Karenj, Bottlebrush, etc.

ENVIRONMENT MANAGEMENT SYSTEM (ISO-14001 Accreditation ) :

IFFCO Phulpur has established and implemented Environment Management System as per
International Organisation for Standardization. The system has been audited by Indian
representative of M/s British Standards Institution, U.K. and the Unit has been accredited with
ISO 14001 : 1996 Certification. IFFCO Phulpur has received ISO 14001 Certification for :
A. Factory Premises.
B. Residential Township, Ghiyanagar.
C. IFFCO Hospital, Ghiyanagar.
D. Moti Lal Nehru Farmers Training Institute, Phulpur located nearby the factory.

IFFCO Phulpur is having a well defined environmental policy. The policy states:

IFFCO Phulpur is conscious of its responsibility towards maintaining a safe and clean
environment and is committed to :
• Ensure Ecological balance and prevention of pollution.
• Comply with relevant laws, regulations and society’s requirements.
• Minimise waste by recycling / reutilization and optimize natural resource consumption.
 • Motivate the employees and community for betterment of environment through
awareness programme.
• Create Environment consciousness amongst the external agencies associated with
Society’s activities.
• Promote green surrounding through planting of trees around manufacturing and living
areas.

ENVIRONMENTAL OBJECTIVES:
• To plant minimum 8,000 trees in current year (2004-05).
• To maintain zero effluent discharge from the premises (Except rainy season).
• To keep SPM level below 200 ug/M3 in ambient air.
• To keep raw water consumption below 7.0 M3/MT of Urea.
• To dispose 200% of total coal ash generation (100% of day to day generation plus equal
quantity disposal from ash ponds)
• To develop new lawns (Minimum 1000 Sq.M) wherever space is available in plant
premises.

ENVIRONMENTAL AWARENESS PROGRAMME AND SUSTAINABLE

DEVELOPMENT MEASURES TAKEN:

To create awareness among people of surrounding area, several mass awareness programmes e.g.
Kisan Mela, World Environment Day Celebration, lectures, etc. are organised by IFFCO Phulpur
Unit time to time. These programmes encourage participation by all constituents of the society,
e.g. farmers, technocrats, students and business community of surrounding area.

IFFCO’s philosophy does not end with manufacture of fertilizer only–it has unstinted
commitment towards the upliftment of the surrounding community also.
i. Distribution of sapling for forestry to the near-by villagers.
ii. Provision of clean drinking water in surrounding area.
iii. Construction of approach roads, culverts over nullahs, construction of class rooms /
science rooms & boundary walls in schools.
iv. Organise various community development and welfare programmes like Kisan Mela,
Pashu Mela, medical assistance, eye camps, health and family lanning camps, etc. In
these camps free treatment and operation is done by a team of qualified doctors.
v. Agricultural extension programmes e.g., balance fertilisation programme, soil testing,
Seed treatment, Veterinary medical check-ups camps, Animal husbandry and Pisciculture
campaigns.
vi. Organise training classes for handicraft, literacy programmes, computer awareness,
artisan skills training programmes in surrounding villages. Computers have been donated
in some of the nearby schools to educate the students on computer applications.
vii. IFFCO's Jan Kalyan Samiti in association with state innovation in family planning
 project services agency (SIFPSA) has done a lot of work for family welfare in 63 village
of Phulpur Block e.g. family planning operation, cut insertion, distribution of oral pills,
condoms and children vaccination.
viii. IFFCO's Mahila Chetna Club is also involved in social upliftment of the women of
nearby villages. Training programmes on Silai Shiksha Kendra were organised in nearby
villages to make them self sufficient for day to day house hold requirement girls / women
were benefited in such training programmes.

Marketing Network

Products - Urea

IFFCO's Urea is not merely a source of 46% of

nutrient nitrogen for crops, but it is an integral part
of millions of farmers in India. A bag of IFFCO's
urea is a constant source of confidence and is a
trusted companion for Indian farmer.

When farmers buy IFFCO's urea, they know that

what they get is not just a product but a complete
package of services, ably supported by a dedicated
team of qualified personnel. More importantly, they
are aware that it is their own urea, produced and
supplied by a cooperative society owned by
themselves.

About Urea
Urea is the most important nitrogenous fertiliser in
the country because of its high N content (46%N).
Besides its use in the crops, it is used as a cattle feed
supplement to replace a part of protein
requirements. It has also numerous industrial uses
notably for production of plastics.
 Specification of urea as Control Order
per Fertiliser
1. Moisture % by weight, 1.0
maximum
2. Total N % by weight 46.0
(on dry basis) minimum
3. Biuret % by weight, 1.5
maximum
4. Particle size 90% of the material shall
pass through 2.8 mm IS
sieve and not less than
80% by weight shall be
retained on 1 mm IS
sieve.
If urea is applied to bare soil surface significant quantities of ammonia may be lost by
volatilisation because of its rapid hydrolysis to ammonium carbonate. The hydrolysis of urea can
be altered by the use of several compound called urease inhibitors. These inhibitors inactivate the
enzyme and thereby prevent the rapid hydrolysis of urea when it is added to soil. The rapid
hydrolysis of urea in soils is also responsible for ammonia injury to seedlings if large quantities
of this material placed with or too close to the seed. Proper placement of fertiliser urea with
respect to seed can eliminate this difficulty.

Products - BIO – FERTILISERS

A biofertiliser unit was established at

Cooperative Rural Development Trust,
Phulpur (Uttar Pradesh) in 1996 - 97
and other at Kalol (Gujarat) in 2003-04
with an annual capacity of 75 MT and
165 MT respectively of different
cultures such as Rhizobium,
Azotobacter, PSM, Azospirillium and
Acetobacter.
 Phosphate Solubilising Rhizobium - It is the most
Micro Organism - Several important nitrogen fixing
soil bacteria and fungi organism. It live
possess the ability to bring symbiotically in the root
insoluble phosphates into nodules of leguminous plants
soluble forms by secreting and supply nitrogen to the
organic acids. They can be plant through nitrogen
applied to and recommended fixation. Besides, supplying
for all crops nitrogen to the crop, nitrogen
fixed by legume - Rhizobia
association would also leave
residual nitrogen for the succeeding crops. The
beneficiary crops are Groundnut, Soybean,
Red-gram, Green-gram, Black-gram, Lentil,
Cow pea, Bengal-gram and Fodder legumes.
Azotobacter - It is non Acetobacter - It is a
symbiotic nitrogen fixing symbiotic bacteria capable of
bacteria recommended for fixing atmospheric nitrogen
non leguminous crops like by living within the sugar
Paddy, Wheat, Millets, plant. They are found in all
Cotton, Tomato, Cabbage, parts of plant body. It is
Mustard, Safflower and suitable for sugarcane
Sunflower. The Azotobacter cultivation.
performs well if the soil
organic matter content is
high.
Azospirillium - It is an
associative microaerophilic
nitrogen fixer is commonly
found in association with the
roots of cereals and forage
grasses. The beneficiary crop
include Sugarcane,
Vegetables, Maize, Pearl
millet, Rice, Wheat, Fodders
and Oil seeds.

PRODUCTION OF BIO – FERTILISERS

CORDET - PHULPUR & KALOL (Annual Capacity 75 MT & 165 MT) (Qty in MT)
STRAIN 2000-01 2001-02 2002-03 2003-04 2004-05
Rhizobium 5.07 3.81 5.50 5.39 7.37
Azotobacter 45.72 55.37 56.22 56.73 120.20
PSM 51.80 72.07 71.17 71.24 172.77
Azospirillium 0.01 0.37 0.34 3.14 8.36
Aectobacter 0.00 0.00 0.00 0.00 30.43
Total 102.60 131.62 133.23 136.50 339.13
Production
Capacity 136.80 175.49 177.64 182.00 141.30
Utilisation (%)
CORDET- KALOL commissioned w.e.f. 16.02.2004 with annual capacity of 165 MT.

IFFCO's Chief Executive Officer

The Chief Executive Officer of IFFCO, designated as Managing

Director, is vested with the overall responsibility of the affairs
of IFFCO's day to day activities. Dr. Udai Shanker Awasthi is
Managing Director of IFFCO since 1993.

Dr. Awasthi is n internationally renowned chemical engineer

and has about four decades of experience which is completely
dedicated to the fertiliser industry. Dr. Awasthi enjoys the
unique distinction of serving private, public and cooperative
sectors of the industry in India. He is acclaimed as a manager
par excellence in India, particularly, in the area of project
management. He has played crucial role in setting up a number
of Ammonia-Urea, SSP and NPK/DAP projects in the country.

Ever since taking over as the Managing Director of IFFCO in

Dr. U.S. Awasthi February 1993, Dr. Awasthi has instilled new dynamism into
IFFCO. He was the architect of "VISION 2000", a strategic
road map for IFFCO, to make it a global leader in fertiliser
production. The organisation has made rapid strides on all
fronts under the aegis of this plan. New records and milestones
were created in projects, production, energy conservation,
environmental protection and sales. Four major expansion
projects were completed and new projects in India and abroad
are initiated. With the completion of Kandla-II on Aug 5, 1999,
all the major projects of Vision 2000 have been achieved. A
testimony of Dr. Awasthi’s project management skills are
evident from the fact that these projects were completed without
time and cost overruns. A hallmark of Dr. Awasthi’s tenure at
the helm of IFFCO are the high levels of growth & and
excellent financial results which are unsurpassed in the history
of IFFCO. He was also instrumental in diversification forays of
IFFCO such as IFFCO-Tokio General Insurance Company
Limited (ITGI), power project in Chattissgarh titled IFFCO
Chattisgarh Power Limited (ICPL). Similar objectives have
contributed towards joint venture agreement with Jordan
Phosphates Mines Company (JPMC) for setting up Phosphoric
acid plant in Jordan. This initiative facilitate in steady supply of
phosphoric acid to IFFCO's plants in India. His vision of
extending the benefits of emerging technologies for the welfare
of the farmers is evident from IFFCO's forays into NCDEX &
NCMSL. Dr Awasthi’s modernisation plans of IFFCO include
aggressive penetration of Information Technology at all levels
of the organisation. In order to meet the challenge of
communication requirements of villages of India and to provide
them with most appropriate information to equip them to take
right decisions, a unique joint venture "IFFCO KIsan Sanchar
Limited (IKSL) was launched. Dr Awasthi is the inspiration and
leading force in all these unique ventures of IFFCO.

Dr. Awasthi's deep rooted concern for Indian agriculture is

evident from some of the special agriculture projects he has
visualised in the areas of drip irrigation, bio-pesticides, bio-
fertilisers, use of plastic in agriculture, agricultural
mechanisation, farm forestry etc. He has also galvanised the
farmers’ education programmes to make them more effective.
Every year, a large number of farmers from all over India
benefit from the agricultural extension activities of IFFCO. He
initiated IFFCO's ICT Initiatives for farmers and cooperatives
to extend the benefits of computers and communications to
rural India. He takes keen interest in evolving appropriate
content for farmers & cooperatives as well as effective delivery
mechanism through a well conceived farmers kiosk network.
He is an enthusiastic and active cooperator and takes keen
interest in the growth of cooperative movement in India. He
was also instrumental in promoting "IFFCO Foundation" to
strengthen cooperative movement in the country.

Dr. Awasthi has held several positions in various bodies. He

was elected president of International Fertiliser Industry
Association (IFA), during 1997-99, which is an organisation of
457 member companies from 80 countries. He was the first
Asian to occupy the coveted position of IFA. He was the
Chairman of Fertiliser Association of India (FAI) during 1994-
96.

He is on the Boards of several Indian as well as international

companies:
Chairman, Industries Chimiques du Senegal (ICS), Senegal
Deputy Chairman, Jordan India Fertiliser Company, Amman,
Jordan

Director on the Boards of:

IFFCO-Tokio General Insurance Company Limited (ITGI)
IFFCO Chattisgarh Power Limited (ICPL)
IFFCO Kisan Sanchar Limited, (IKSL)
IFFCO Kisan SEZ Limited
Fertiliser Association of India (FAI)
Indian Potash Limited (IPL)
Oman India Fertiliser Company (OMIFCO), Oman, Muscat
Kisan International trading (KIT), Dubai
Agricultural Cooperative Development International (ACDI),
USA
Legend International Holdings Inc, Australia

Dr Awasthi had the honour of having represented the Industry

Point of View at High Level Segment in the 6th Session of
United Nations Commission on Sustainable Development and
delivered a speech at ECOSOC Chamber, United Nations
Headquarters, New York on Wednesday 29 April, 1998.

Prior to joining IFFCO, Dr. Awasthi was the Chairman and

Managing Director of Pyrites, Phosphates and Chemicals Ltd.
(PPCL). During this tenure, he had managed to bring stability
and viability to PPCL. He also headed Rashtriya Chemicals and
Fertilisers Ltd. (RCF) for one year. Prior to this, he held
important positions in several prominent fertiliser companies
and was a key person in execution of Aonla and Hazira
Projects. Dr Awasthi had been dedicated to Indian fertiliser
industry since 1967 after completing his graduation in Chemical
Engineering from Banaras Hindu University.

Dr Awasthi is a recipient of several honours and awards for his

outstanding contributions and achievements in the fertiliser
industry and Indian agriculture. Dr Awasthi was conferred
Honourary Doctorate during the 20th Convocation of
University of Agricultural Sciences, Dharwad held on Apr 25,
2006. He was also conferred the Doctor of Science (D.Sc.) by
Vikram University, Ujjain, Madhya Pradesh, on March 2, 2008
at Ujjain. Other eminent awards include, Uttar Pradesh Gaurav
Award by the Society of Environment & Agricultural
Advancement, Distinguished Alumnus Award by Benares
Hindu University and Eminent Chemical Engineer Award by
Indian Institute of Chemical Engineers. He was conferred with
Honorary Fellowship of Indian Institute of Chemical Engineers
(I.I.Ch.E) during the Indian Chemical Engineering Congress
(Chemcon - 2001) held at Chennai. Dr Awasthi is a honorary
visiting Professor in Department of Chemical Engineering,
Institute of Technology, BHU, Varanasi. . He was decorated
with Golden Jubilee Award by Indian Institute of Chemical
Engineers for his distinction in leadership and contribution to
Chemical Industry. Dr. Awasthi has been awarded the
prestigious "CEPM-Dr. Davidson Frame Award” on 11th
December, 2000. The Award recognises international leaders in
the discipline of project management. He is the recipient of
 “Best Chief Executive of the Year 2002” from Minister for
Shipping, Government of India during the Global Corporate
Convention-2002 held in September 2002. Dr. Awasthi is a
Member, Center for Management in Agriculture, IIM,
Ahmedabad and Fellow, Indian National Academy of
Engineering (INAE), New Delhi. National Cooperative Union
of India (NCUI) honoured him in November, 1997 for his
distinguished services to the cooperative sector. Dr Awasthi
was conferred Alumni Award of Excellence 2007-08 by BHU
for achievements in Projects Management and developments in
fertiliser sector of India. He was awarded IBC Leading
Engineers of the World - 2007 by International Biographical
Centre, Cambridge, England.

Widely travelled, Dr. Awasthi has more than 25 papers to his

credit and has co-authored a book 'Fertiliser Industry in India'.
In addition to professional interests, Dr. Awasthi is an avid
follower of fine arts with special taste for paintings.

IFFCO Phulpur
Situated near Allahabad in Uttar Pradesh , IFFCO Phulpur complex has two production units –
Phulpur unit-I and Phulpur unit-II and is the world’s largest fertiliser complex based on naphtha
as feed stock. Shown here in the upper left part is the plant, nd in the right side is the township
where the employees of IFFCO live. The township Ghiyanagar (212404) is ISO14002 certified
and is a very state of the art township with all the necessary facilities like hospital, schools,
clubs, theatres and even petrol pump.
[edit] IFFCO PHULPUR UNIT " AN INDUSTRY IN
HARMONY WITH THE NATURE"
Waste Management, Natural Resource Conservation, Environment Protection and its enrichment
has always been of paramount importance to IFFCO Phulpur Unit. We have adopted eco-friendly
technology wherever possible. Due care is taken at the design stage itself, to select the best
available technologies that produce low or negligible waste, conserve resources, and reuse
treated effluents to the maximum possible extent. ‘Prevention is better than cure’ has been the
basis of the Society’s pollution control programme. Environment monitoring and control at
IFFCO Phulpur is efficiently met by providing all necessary instrumentation and pollution
control measures for effluents, emissions, domestic sewage, and solid wastes.
With continuous efforts and its endeavours towards waste management IFFCO Phulpur has
achieved Zero liquid effluent discharge from premises - a rare performance achievable by any
similar industry. An effluent treatment cum recycle plant based on Reverse Osmosis Technology
has been installed to treat industrial effluent. The product water is reused in process as cooling
water make up. The domestic sewage water is treated in a well - designed sewage treatment cum
recycle plant. The treated sewage water is fully reused in plant process and sewage sludge thus
produced is utilized as manure in the farm lands of our Farmers Training Institute.
For monitoring the quality of ambient air, water and stack IFFCO has a monitoring laboratory
equipped with most sophisticated and modern instruments. The monitoring staff is experienced
and well qualified. This laboratory is recognized by the State Pollution Control Board because of
its good monitoring capability. Our R & D unit is also recognized by Ministry of Science and
Technology, Government of India.
Due to our excellent track record and well - established Environment Management System at
IFFCO Phulpur, we have been granted consent from State Pollution Control Board continuously
since Plant commissioning till date.
IFFCO Phulpur has an elaborate system for solid waste handling and utilization. Our strategy has
been to reduce the pollutants at source by adopting appropriate technology and to convert waste
into useful material.
Substantial Green Belt has been developed around the factory and Township to keep the
environment quality in its most natural condition.
[edit] AWARDS / APPRECIATIONS ON ENVIRONMET
& POLLUTION CONTROL:
IFFCO Phulpur Unit has won prestigious Environmental Awards from time to time, which are
ample testimony of its excellent Environment Management System. Some of these awards are
listed here under :
In recognition of its outstanding performance in Environment Management, Phulpur Unit has
won the "BEST ENVIRONMENTAL AWAR" three times from Fertiliser Association of India,
i.e., for the Year 1993-94, 1996-97 and 1997-98.
2nd Jawahar Lal Nehru Memorial National Award for best organization in implementing
"POLLUTION CONTROL MEASURES" from International Green Land Society, Hyderabad.
IFFCO Phulpur has bagged "ENVIRONMENT AWARDS" for its excellent work in the field of
Environment Management, by Rotary Club of Allahabad Midtown, for the year 1993-94.
The Regional Director, Ganga Project Directorate, Ministry of Environment & Forests, New
Delhi has issued appreciation letters for the good Environment control at IFFCO Phulpur.
"First Position in Fertiliser Sector of Indo German Greentech Environment Excellence Award"
New Delhi in Year 2002.
"TERI Corporate Environmental Award" from Tata Energy Research Institute, New Delhi in
Year 2000-01 (in the category of companies having turnover more than Rs.500 crores per
annum).
[edit] ENVIRONMENT MANAGEMENT SYSTEM AT
IFFCO PHULPUR.
LIQUID EFFLUENT MANAGEMENT:
All the liquid effluents generated from the various plants are subjected to extensive treatment to
ensure that the treated water quality conforms to the specification laid down by the UPPCB and
MINAS. For liquid effluent control, deep hydrolyser, distillation column, stripper and ETP based
on steam stripping, disc. oil separator, treatment cum recycle plant on Reverse Osmosis
technology, pH neutralization facility , guard pond, etc. have been installed and are operating
efficiently. Adoption of Non-Chromate cooling water system in process plants has been done
away with and menace of hazardous heavy metals like chromium has been eliminated.
ZERO EFFLUENT TECHNOLOGY:
IFFCO Phulpur has presently in operation, a single stream 1670 MT/Day Urea Plant
commissioned in 1980 and a twin stream 2x1310 MT/Day Urea Plant commissioned in 1997,
based on Snamprogetti’s patented Ammonia Stripping Process. Both the units have in-built
waste water treatment section, where the urea bearing waste containing 1.25% Urea and 0.5%
Ammonia is treated in deep urea hydrolyser with 35 ata steam. Product of hydrolysis, i.e.,
Ammonia and Carbon Dioxide are recycled back to process for increased production of Urea.
The water is purified for reuse as boiler feed water after passing through Ion Exchange polisher
unit. There is no effluent discharge from Urea plant.
977 MTPD and 1520 MTPD Ammonia Plants have been engineered and constructed by MW
Kellogg (USA) and Haldor-Topsoe (Denmark), respectively and are based on naphtha as the feed
stock. To achieve zero effluent discharge from the plant, it has process condensate stripper,
condensate polishing unit to recycle process and turbine condensate for steam generation. About
180 M3 / Day jacket cooling water of Ammonia Plant - I is recycled into Ammonia cooling
tower as cooling water make-up. Scheme has been implemented to reuse about 270 M3/day RV
sealing water of Ammonia plant-I into cooling tower.
WATER CONSERVATION MEASURE:
IFFCO Phulpur is very conscious and careful towards resource conservation. Several water
conservation schemes have been adopted right since inception of the plant for careful utilisation
of the precious commodity, i.e., water. The entire effluent generated in the factory is recycled /
reused after adequate treatment in plant process and irrigation of farm lands. The various water
conservation measures adopted at IFFCO Phulpur are as follows:
1. Treatment and reuse of process condensate and turbine condensate from Ammonia Plant: In
Ammonia Plant, process condensate, i.e., about 2980 M3/day, is treated in the stripper for
removal of its ammonical content. Further it is allowed to pass through a polisher unit to remove
all dissolved salts contained in the process condensate. The polished condensate is pumped to
plant and reused as boiler feed water. Turbine condensate from Ammonia Plant is also sent to
condensate polisher unit of D.M. Plant for polishing in Ion Exchange units. The treated water is
recycled and reused as boiler feed water for steam generation in Ammonia plant itself and steam
generation plant.
2. Reuse of Steam Condensate from Urea Plant: About 950 M3/day of steam condensate from
surface condensate of turbo driven CO2 compressor system and approximately 2100 M3/day of
steam condensate from process of Urea Plant-I & Urea - II are recycled to steam generation plant
as a make up to boiler feed water.
3. Treatment and Reuse of waste water of Urea Plant (Deep Urea Hydrolyser): In order to
recover the valuable Urea and Ammonia from effluents and make the effluents ( 2200 M3/ Day )
reusable, the deep urea hydrolyser (operating at 35 Ata and 230 deg. C) has been installed and
operated.
Vision - 2015

In pursuit of its growth and development, IFFCO had embarked upon and successfully
implemented its Corporate Plans, ‘Mission 2005’ and ‘Vision 2010’. These plans have resulted
in IFFCO becoming one of the largest producer and marketeer of Chemical Fertilisers by
expansion of its existing Units, setting up Joint Venture Companies Overseas and Diversification
into new Sectors. :
IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’ which will be guided by
the following objectives:
 Production of fertilizers through expansion of existing units.
 Setting up of fertilizer production facilities in India and outside the country through joint
ventures.
 Diversification into other Profitable Sectors.
 Strengthening its raw material sourcing through Strategic Joint Ventures in India and
abroad.
 Strategic Alliances through IFFCO Consortium.
The salient features of the ‘Vision-2015’ document are as under:
○ To stand as a Global Leader in Fertilisers Production to cater to the food security need of
the nation.
○ Maximizing the synergies of the Core Business through Downstream Value Additions
and Forward/ Backward Integrations.
○ Enhancing presence in International Markets through Strategic Joint Ventures and
Synergistic Acquisitions.
○ Diversification into other profitable businesses to maximize returns to our stakeholders.
○ Leveraging State of the Art Technologies and Global best practices to retain its global
competitiveness.
○ Promoting Integrated Nutrient Management to improve efficiency of Fertilizer use and
promoting location specific research on efficient fertilizer practices.
○ To bring in Sustainability and Strategies to prevent Climate Change by reducing Energy
Consumption, better Resources Management and promoting Renewable Energy sources.
○ To help the Cooperative Societies become economically strong, professionally managed
and to equip the Farming Community with advanced agricultural practices for improved
Productivity, to ensure an Empowered Rural India.
○ Achieve Fertilizers Production / Marketing target of 15 million Tonne per annum with an
annual turnover of Rs. 30,000 crores.

IFFCO is the leading player in the Indian fertiliser industry. It represents over 40,000 farmer co-operatives
which equate to over 50,000,000 individual farmers and their families. IFFCO supplies the necessary
IFFCO branded products to the marketplace to increase food grain production. They are a highly trusted
name throughout all Indian States.
In July 2008 a principal off-take agreement was signed between Legend and IFFCO. Based on favourable
market conditions Legend will supply, and IFFCO purchase, up to 4Mtpa of phosphate rock and an
additional 1Mtpa for IFFCO to market to other potential customers. IFFCO also has 15.2% stake in the
Legend business.

A direct dialogue exists between IFFCO and the Indian Government. In April 2009, alongside IFFCO
Managing Director and Legend Board Member Dr. U.S. Awasthi, the Secretary to the Government of
India (Ministry of Fertilisers) visited the Legend project and associated facilities. The Indian Government
subsidise the production of fertilisers to ensure the nation's famers have the necessary agricultural means
to support their families and the developing Indian economy.

Legend aims to be an integral part of India's development economic and agricultural development through
the provision of phosphate fertiliser products.

Our Executive - Mr. N. P. Patel

IFFCO's Chairman

Mr. Natwarlal Pitambardas Patel is the Chairman of IFFCO. Mr. Patel is a distinguished cooperator from
India and is associated with the movement for about four decades. He had been involved with the
growth and development of IFFCO for a long time. He was a delegate to IFFCO for about three decades
and has been on the Board of IFFCO for about 15 years.

Mr. Patel held several state and national positions in reputed cooperative societies. The Societies that
have benefited from his services on the Board of Directors include Krishak Bharati Cooperative Limited,
National Agricultural Federation (NAFED), Indian Tourism Cooperative, National Cooperative Bank of
India.

Mr. Patel was instrumental in promoting several primary cooperative societies in the state of Gujarat.

Besides IFFCO, Mr. Patel is also on the Boards of the following :

IFFCO Kisan Sewa Trust

 National Agricultural Coop Marketing Fed., Ltd.

Gujarat State Cooperative Marketing Fed. Ltd.

Gujarat State Cooperative Bank Ltd.

Gujarat State Cooperative Union

Mehasana Distt. Centre Bank Ltd.

Agricultural Produce Market Committee

Mr. Balvinder Singh Nakai| Vice-Chairman

Mr. Balvinder Singh Nakai is an eminent farmer - cooperator who has been deeply involved in providing
strength to Indian Cooperative Movement for the last three decades.

Read More...

Dr. U.S. Awasthi | Managing Director & Chief Executive Officer

The Chief Executive Officer of IFFCO, designated as Managing Director, is vested with the overall
responsibility of the affairs of IFFCO's day to day activities.

Read More...

Mr. Rakesh Kapur | Jt. Managing Director & Chief Financial Officer

Mr. Rakesh Kapur holds the position of Joint Managing Director & Chief Financial Officer in IFFCO. Mr
Kapur is also responsible for the Finance Division of IFFCO.

Read More...

Objectives
To serve the cause of IFFCO’s mission as stated in the mission document available on the homepage of
IFFCO. To make strategic use of IFFCO’s website to promote the mission of the organisation to improve
the welfare of Indian farmers.
 Provide information on all aspects of IFFCO to visitors from both within and outside the country.

Extend IT enabled services to farmers and cooperatives to promote IT penetration and improve IT
comfort levels in rural India.

To evolve appropriate dissemination strategies for effective use of IT Enabled Services in Rural India.

To extend e-services to cooperative members of IFFCO and in a phased manner, extend e-commerce
through the website.

Provide latest and reliable information and extend other services to all those actively involved in the
development of Indian agriculture and rural development.

Provide necessary information / services for suppliers to IFFCO and achieve e-procurement in a phased
manner.

About IFFCO

During mid- sixties the Co-operative sector in India was responsible for distribution of 70 per cent of
fertilisers consumed in the country. This Sector had adequate infrastructure to distribute fertilisers but
had no production facilities of its own and hence dependent on public/private Sectors for supplies. To
overcome this lacuna and to bridge the demand supply gap in the country, a new cooperative society
was conceived to specifically cater to the requirements of farmers. It was an unique venture in which
the farmers of the country through their own Co-operative Societies created this new
institution to safeguard their interests. The number of Co-operative Societies associated with IFFCO
have risen from 57 in 1967 to 39,824 at present.

Indian Farmers Fertiliser Co-operative Limited (IFFCO) was registered on November 3, 1967 as a Multi-
unit Co-operative Society. On the enactment of the Multistate Co-operative Societies act 1984 & 2002,
the Society is deemed to be registered as a Multistate Co-operative Society. The Society is primarily
engaged in production and distribution of fertilisers. The byelaws of the Society provide a broad frame
work for the activities of IFFCO as a Co-operative Society.

IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP plant at Kandla both in the
state of Gujarat in 1975. Another ammonia - urea complex was set up at Phulpur in the state of Uttar
Pradesh in 1981. The ammonia - urea unit at Aonla was commissioned in 1988.

In 1993, IFFCO had drawn up a major expansion programme of all the four plants under overall aegis of
IFFCO VISION 2000. The expansion projects at Aonla, Kalol, Phulpur and Kandla were completed on
schedule. All the projects conceived as part of VISION 2000 had been realised without time or cost
overruns. All the production units of IFFCO have established a reputation for excellence and quality.
Another growth path was chalked out to realise newer dreams and greater heights through Vision 2010.
As part of this vision, IFFCO has acquired fertiliser unit at Paradeep in Orissa in September 2005. As a
result of these expansion projects and acuisition, IFFCO's annual capacity has been increased to 3.69
million tonnes of Urea and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its growth and
development, IFFCO had embarked upon and successfully implemented its Corporate Plans, ‘Mission
2005’ and ‘Vision 2010’. These plans have resulted in IFFCO becoming one of the largest producer and
marketeer of Chemical fertilisers by expansion of its existing Units, setting up Joint Venture Companies
Overseas and Diversification into new Sectors.

IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’ which is presently under
implementation.

IFFCO has made strategic investments in several joint ventures. Godavari Fertilisers and Chemicals Ltd
(GFCL) & Indian Potash Ltd (IPL) in India, Industries Chimiques du Senegal (ICS) in Senegal and Oman
India Fertiliser Company (OMIFCO) in Oman are important fertiliser joint ventures. As part of strategic
diversification, IFFCO has entered into several key sectors. IFFCO-Tokio General Insurance Ltd (ITGI) is
a foray into general insurance sector. Through ITGI, IFFCO has formulated new services of benefit to
farmers. 'Sankat Haran Bima Yojana' provides free insurance cover to farmers along with each bag of
IFFCO fertiliser purchased. To take the benefits of emerging concepts like agricultural commodity
trading, IFFCO has taken equity in National Commodity and Derivative Exchange (NCDEX) and National
Collateral Management Services Ltd (NCMSL). IFFCO Chattisgarh Power Ltd (ICPL) which is under
implementation is yet another foray to move into core area of power. IFFCO is also behind several other
companies with the sole intention of benefitting farmers.

The distribution of IFFCO's fertiliser is undertaken through over 39824 Co-operative Societies. The entire
activities of Distribution, Sales and Promotion are co-ordinated by Marketing Central Office (MKCO) at
New Delhi assisted by the Marketing offices in the field. In addition, essential agro-inputs for crop
production are made available to the farmers through a chain of 158 Farmers Service Centre (FSC).
IFFCO has promoted several institutions and organisations to work for the welfare of farmers,
strengthening cooperative movement, improve Indian agriculture. Indian Farm Forestry Development
Cooperative Ltd (IFFDC), Cooperative Rural Development Trust (CORDET), IFFCO Foundation, Kisan
Sewa Trust belong to this category. An ambitious project 'ICT Initiatives for Farmers and Cooperatives' is
launched to promote e-culture in rural India. IFFCO obsessively nurtures its relations with farmers and
undertakes a large number of agricultural extension activities for their benefit every year.

At IFFCO, the thirst for ever improving the services to farmers and member co-operatives is insatiable,
commitment to quality is insurmountable and harnessing of mother earths' bounty to drive hunger away
from India in an ecologically sustainable manner is the prime mission. All that IFFCO cherishes in
exchange is an everlasting smile on the face of Indian Farmer who form the moving spirit behind this
mission.
 IFFCO, to day, is a leading player in India's fertiliser industry and is making substantial contribution to
the efforts of Indian Government to increase foodgrain production in the country.

Iffco Phulpur Images: Phulpur I - Plant Ammonia/Urea

Phulpur Unit - R & D

1. FLY ASH FOR BRICK MAKING

IFFCO, Phulpur Unit utilises approx. 1200 MTPD of coal for its 12.5 MW thermal power plant
and produces, in turn, approximately 400 - 450 MT per day which was disposed off as water -
ash slurry in ash ponds acquired by IFFCO.However, after twenty years of continuous running,
the ponds are now saturated and new ash pond is being utilised for ash disposal.
In order to solve the above problems and to utilise this huge quantity of fly ash, a project for fly
ash brick making was taken up at the behest of IFFCO Phulpur Research and Development
laboratory and was successfully completed.

Finally, a pilot plant of capacity 3000 bricks per day was installed and was inaugurated on 2nd
October 1993.
The raw materials for production of fly ash bricks are Fly ash, Lime and Sand.
The important constituent of fly ash is silica which reacts with lime in the presence of saturated
steam at elevated temperature and pressure to form Calcium Silicate Hydrate.Aluminium Oxide
of fly ash reacts with lime to form Calcium Alumino Hydrate and hydrogarnates with some
bonding properties.

SiO2 + Ca(OH)2 + (n-1) H2O --> CaO.SiO2. n H2O

Silica Lime Steam Calcium Silicate Hydrate
The process involves four main operations.
i. Preparation of raw materials.
ii. Mixing
iii. Shaping or pressing.
iv. Curing.

One part by weight each of Hydrated Lime and Sand are added to 8 parts by weight of fly
ash.The material is then fed to a Counter Current Mixer. Water is added in the CCM and the
material is made homogeneous . The mixture is allowed to stand overnight. The material is then
directly fed to the hydraulic press through a hopper where it is pressed at 180 - 200 Kg/cm2 to
get moulded green bricks.These green bricks are air dried for 24 hours. The green bricks are then
stacked on a trolley to be cured in a curing chamber called Autoclave and subjected to steam
curing at 10 - 12 Kg/cm2 for 6 hours.

2. FLY ASH MIXED CLAY BRICKS:

Government of India has made the use of fly ash mandatory in the clay brick manufacture in
brick kilns situated in a radius of 50 kms of the Thermal Power plants..In spite of the order , the
brick manufacturers are not keen in the use of fly ash.In order to motivate the local brick
manufacturers in the use of fly ash in clay brick manufacture and maximize the utilization of fly
ash in brick making, a study was undertaken .
Fly ash was made available at the doorstep of the kilns of a few local manufactures.Fly ash was
mixed in different proportions with clay under the supervision of IFFCO and bricks were made.
Bricks without fly ash addition were also made simultaneously for comparison.These bricks
were tested for weight,compressive strength and water absorption. The results show that fly ash
addition to the extent of 40 % are comparable to normal clay bricks.

3.APPLICATION OF OZONE IN COOLING WATER SYSTEM

At IFFCO Phulpur, non - chromate cooling system has been adopted. Some chemicals for
corrosion control, pH monitoring and microbial controls are being added in the cooling system.

In order to achieve better results and control, an R&D project based on oxidative and disinfecting
properties of ozone has been taken for study. All the necessary facilities have been arranged and
we have started conducting experimentation on the efficiency of the ozone system.

Ozone is an environment friendly disinfectant and finds its use in innumerable applications
where disinfection and oxidation are required. It kills all the bacteria, fungi, viruses, parasites
and other micro-organisms present is cooling water system. It oxidises all the organic matters
and reduces itself to oxygen. This unique phenomenon of the oxidation - reduction is called
'Redox Tension’.The total destruction of micro-organisms and organic matter is controlled by
this Redox tension.

A considerable number of technical literature on cooling tower ozonation for refrigeration

system, potable water disinfection etc. are available but industrial cooling tower ozonation
literature is not available. Hence, this R&D project was undertaken for detailed studies.Presently,
the pilot plant ozone system have been installed and trial runs are in progress.
The major benefits of ozone application system are follows:
1. ELIMINATION OF CHEMICALS - which means no purchasing, handling, discharge
liabilities or storage equipment for cooling water chemicals used for monitoring.
2. REDUCED ENERGY CONSUMPTION - because of the elimination of biofilm build up
on condenser tube surfaces, resulting in improved fouling factor and elimination of scale
build up on lower surfaces.
3. REDUCED WATER CONSUMPTION AND SEWAGE COSTS - due to change in blow
down rate (Cycle of concentration nearly 12).
4. REDUCED LABOUR REQUIREMENTS - by eliminating twice - daily tower water
testing, logging and servicing, annual cleaning, and condenser cleaning.
5. NO TOXIC EFFECTS - Ozone is a non - poisonous gas so the blow - down from the
ozone system will not be toxic.

4.Use of fly ash as soil reclaiming agent alone or in combination with gypsum
Fly ash is very good conditioning material for agriculture use. To study the efficacy of fly ash for
reclamation of alkaline soil and to enhance bulk utilization of fly ash in the field of agriculture,
IFFCO Phulpur has undertaken an R&D project with Fly Ash Mission, TIFAC, Dept. of Science
& Technology, Government of India, New Delhi. Fly ash, on application in waste land / usar
(alkali soil) improves soil fertility,lowers soil pH,changes soil texture,improves soil porosity and
soil density,increases water holding capacity; releases some of the plant nutrients in soluble form
and improves fertilizer use efficiency of soil.

Fly Ash, grey in colour, abrasive and refractory in nature, is finely divided residue resulting from
the combustion of pulverized coal in furnaces of thermal power plants (TPPs). It contains mainly
silica (SiO2), alumina (Al2O3) and iron oxide (Fe2O3)0. In addition, it has the primary nutrients
like phosphate and potash and secondary nutrients like calcium, magnesium and sulphur as well
as micronutrients like zinc, copper and manganese etc. Thus, fly ash may be regarded as a source
of essential nutrients to the plants.

Seven demonstration sites have been selected which are situated within 5 to 15 kms. from
IFFCO, Phulpur site. Pond ash has been used for alkali soil reclamation of these sites. Each site
has been subjected to fly ash, gypsum and FYM addition as per recommended experimental
design.

Data recording and photography/videography at various growth levels till harvesting were
carried out. Detailed analysis of fly ash, FYM, gypsum, grain, straw, irrigation water etc. are also
performed to evaluate toxic levels of trace and heavy metals and radioactive effects.

5.Evaluation of Manurial value of Spent Zinc Oxide catalyst

In ammonia plant, Zinc Oxide is used as a catalyst for desulphurisation of naphtha. Sulphur
present in naphtha is adsorbed on Zinc Oxide surface. The catalyst cannot be reused once it loses
its activity due to adsorption of sulphur.Thus the spent catalyst is lying with us unused as a waste
whose disposal of is difficult.An R&D effort has been made to make use of the exhausted
catalyst in the form of a mixture of Zinc Oxide and Zinc Sulphide in agriculture.

A project in coordination with Allahabad Agricultural Institute was started in July 2000. Zinc is
the key element in production of field crops, specially because of its enzymic activities. Zinc
Sulphide is chemically an inactive material and cannot release Zinc in available form for the
plants uptake until it is oxidised. After its oxidation, it will be a miracle material of immense
utility for production of crops. The oxidation process is regulated by several factors like soil,
crop, water and other associated factors like organic matter content in the soil, inorganic
materials like fertilizer etc. It is, therefore, of great importance to find out the actual factors
responsible for oxidation and thereby mineralisation of the Zinc and Sulphur from Zinc Sulphide.

In the first Kharif season (2000) field experiments were conducted in the Agronomy Farm of
Allahabad Agricultural Institute .The size of the plot for field trial was maintained at 50 M2. The
trials included three different dosages of the Spent ZnO catalyst viz. 20, 30 & 40 Kg/ha
.Different organic manures are tried in combination with these three types of catalyst application.
Recommended dosages of inorganic fertilizers such as Urea,DAP and MOP were used for each
crop.Groundnut, Urad, Moong, Maize, Jowar, Bajra and Arhar crops were taken for
experimentation in Kharif season.. While Arhar is an annual crop,others are seasonal.

In the Rabi season of 2000, the trials for second set of crops were conducted. In this season also,
the same experimental parameters were retained. The six crops selected for the experiment were
Pea, Lentil, Wheat, Barley, Linseed and Safflower.
The yield data obtained for both these crops indicate that there is a tremendous increase in the
yield with the application of spent catalyst in comparison with the application of inorganic
fertilizer alone or in combination with other organic manures.

6. GYPSUM PILOT PLANT

Gypsum is a proven usar soil reclaimant. A simple method has been devised for its preparation
by reaction of sulphuric acid with waste lime sludge which is produced from cold lime softening
of water . Laboratory trials have been completed and pilot plant installation is will be taken up in
future.

Production of biogas from biodegradable wastes

Organic solid wastes mainly consist of cooked food, fruit & vegetable waste, agricultural and
horticultural green wastes.A study is undertaken to convert this organic soild waste into bio-
fertiliser and obtain biogas with biomethanation technologies which convert carbon in the waste
to methane gas by the action of bacteria under anaerobic condition and leave the nitrogen and
other compounds unaffected. Hence both fuel and fertiliser can be obtained from the same waste
making the technology superior to either composting or incineration .
The process is carried out in two stages. The first one being the acidification of the wastes with
the mesophilic (reacting at ambient temperature) group of microorganisms and carried out in a
Acidification Reactor. This is followed by the methanantion process with the aid of thermophilic
( reacting at above ambient temperatures) microorganisms in the Methanator.

The biodegradable waste material, separated from the solid waste is loaded into the Reactor
(around 100 Kg) from the top opening.Water is sprinkled over the waste material with the help
of a perforated sprinkler located in the door of the top opening.The liquid percolates through the
bed of the waste and collects in the reservoir through the filter. The collected leachate is
circulated into the Reactor through a small pump. The circulation of the leachate on the waste
bed is carried out in intervals so that the mass does not get dry . This process of extraction is
continued till the extraction of the organic matter from waste into the leachate is complete.Dried
digested solid waste is an excellent manure .

The leachate collected from the Reactor is treated in an UASB ( Upflow Anaerobic Sludge
Blanket Reactor) which under the influence of microbial consortia gets converted to a gaseous
mixture.The conversion take place at 45 - 55 deg C .The temperature is maintained by heating
the Methanator from the bottom.

Production Unit - Phulpur

 Ammonia-Urea Complex
commissioned in 1981

Re-assessed Production Capacity

Ammonia - 0.824 million TPA
Urea - 1.416 million TPA

Head of the Unit

Mr. Surjit Singh - Executive Director,

ADDRESS
IFFCO, PHULPUR, (P.O.) Ghiyanagar,Allahabad - 212404
(Uttar Pradesh), INDIA
Phones : 91-5332-251250 , 91-5332-251251, 91-5332-251252
Fax : 91-5332-251252, 91-5332-251253,

News & Events

It is a matter of great Pride that IFFCO Phulpur Unit has achieved the Prestigious Certificate
for its Energy Management System, EN 16001:2009 from Certification body - BSI India.

Phulpur Unit is the first Unit in Indian Fertiliser Sector who has the achievement of
Registration to Energy Management System i.e. EN 16001:2009-Certificate.

Copy of the Certificate is attached herewith:

इइइइ इइइइइइ इइइइ इइइ इइइइइइइ इइइइइइ इइ इइइइ इइइइइ

OFFICIAL LANGUAGE CELEBRATION - IFFCO PHULPUR UNIT

Restoration of Ammonia-II Plant Cooling Tower

Ammonia-II Cooling Tower has been successfully and safely restorted to its full operational
capacity on May 29,2006.
The Site Activities were carried out in a record time of 45 days (Contract for Supply and
Erection Work was for 70 days starting from April 15,2006) .
Distribution Header (East Side) has also been brought down and is laid on the Sump Roof.
Six Nos. of Risers along with its Structure have been Erected. The Main Riser of 52" feeding
1st cell water has also been Erected.

Enclosed please find glimpses of restoration of Ammonia-II Cooling Tower to full capacity .
Ammonia-II CT (East Side) in Operation after Restoration

Phulpur-II: Ammonia Cooling Tower Failure

Event
At around 11:23 hrs on 11th April 2206, entire East side wooden structure including nozzle
deck of Ammonia Cooling Tower covering the seven cells collapsed along with Distribution
header. West side nozzle deck, distribution header & all Fans,along with its structure of the
cooling tower were intact.

Photographs of Cooling Tower after the failure are attached below.

Possible Reasons of Failure
Sudden failure of main supporting wooden columns (supplied by M/s Paharpur)

Distribution header having diameters reducing from 52" in the first cell to 30" in last cell.
Distribution header is supported on nozzle deck of wooden saddles mounted directly on
main wooden columns.

Failure of main supporting wooden columns causes breaking of distribution header in parts
due to its own hydraulic weight of 90 MT (approx.)

Action Plan to Restore Ammonia CT operation

Inter connection between Ammonia-II Urea-II CT is being provided for following:
• Return Header of Ammonia CT is being connected with Return Header of Urea CT to
divert part of Hot Water from Ammonia-II CT to Urea-II CT for cooling.
• Discharge header of Ammonia CW pump & Discharge header of Urea CW pump is
being connected by a 30" header to divert cold water from Urea CW header to
Ammonia CW header.
• A 36" header is being installed to connect the sump of Ammonia CT with Urea CT.
Safe Maintenance Practices to be adopted for Cooling Towers:

During Commissioning:

1. Water is to be charged in Cooling tower keeping a watch on Pipelines vibration.

2. Fans are to be started one by one after vibration measurement of fans.
3. Daily monitoring of Vibrations of fans and pipelines.
4. Daily monitoring of water loading on hot water distribution decks & their uniformity

Operation & Maintenance:

1. Vibration measurement of Fans on daily basis.

2. Vibration measurement of Return headers and distribution headers on daily basis. Dumpy level of
header to be taken once in a month.
3. Annual Preventive maintenance of Fans, Gear boxes, Motors.
4. Annual Inspection & repair of Cooling tower timber structure by PCT personnel.
5. Distribution Headers, Valves should be checked for proper operation. Any leakages or inoperative
valves should be attended immediately.
6. Distribution headers have to be checked for thinning, corrosion etc.
7. Need based painting of distribution headers.
8. Developing internal skills for Cooling tower inspection to reduce dependence on PCT personnel.
9. Developing checklist for inspection of Tower Timber structure and in-house inspection in running by
isolating cells one by one.
10. Wood samples have to be sent for analysis for strength checking.

57th Republic Day Celebrated at Phulpur Unit...

57th Republic Day was celebrated at Phulpur Unit with gaity and cheers . General Manager
Shri M Rajashekharaiah unfurled the National Flag and took salute from the contigents . A
snap on the occasion...
 IFFCO Phulpur Unit has bagged the Prestigeous National Award for " Excellence in Water
Management-2005" and " Innovative Project Award" by Confederation of Indian Industry (CII) - Sohrabji
Godrej Green Business Centre - Hyderabad on 20th December, 2005.

The award was given by Dr. K.S. Jawahar Reddy, I.A.S., Managing Director, Hyderabad Metropolitan
Water Supply & Sewerage Board.

The images of the certificate, plaque and Photo are attached below.
 IFFCO Phulpur Unit has bagged the prestigious "National Energy Conservation Award - 2005"
(Certificate of Merit in the Fertiliser Sector) on December 14, 2005.

The award was given by Honourable President of India Dr. A.P.J. Abdul Kalam in a glittering function
organised by Bureau of Energy Efficiency, Ministry of Power, Govt. of India at Vigyan Bhavan, New Delhi.
During his address at the INAUGURATION OF 58TH ANNUAL SESSION OF INDIAN INSTITUTE
OF CHEMICAL ENGINEERS CHEMCON-2005, Dr. A.P.J. Abdul Kalam has appreciated IFFCO-
Phulpur unit for its efforts towards Energy conservation. Some excerpts in his speech on Energy
Efficiency in Fertilizer Industry is reproduced below. . . . . . .
-------------------------------------------------------------------------------------------------------------------------------------------

Energy Efficiency in Fertilizer Industry

Let me illustrate this with one example. Indian Farmers and Fertilizers Co-
operative Organization (IFFCO), is a Cooperative owned by more than 37000
cooperative societies (50 Million farmers) and is the largest producer of
fertilizers in the country. It produces over 60 lakh tonnes of fertilizers
annually.

IFFCO, in their Phulpur-I plant situated in Allahabad have adopted the

following strategies for operating its plants in an energy efficient way. This
Plant started its commercial production from March 1981 with overall
Specific Energy Consumption of 10.40 Million Kilo calories per Metric Tonne
of Urea.
With continuous efforts, the operating efficiency has been increased.
Increasing the efficiency of mechanical equipment was carried out by
updating of plant and machinery, by replacing earlier technology devices
such as turbines, pumps etc. Improving the efficiency of electrical and
electronic systems was carried out by installation of a distributed control
system by using which the plant was operated closer to optimal design
operating parameters. Process heat losses were cut down by micro-level
reengineering such as use of better thermal protection insulation of pipelines
and vessels, plant effluents have been recycled and used for horticultural
and process purposes, thus saving on the overall requirement for process
water.
Through the combined action on all these areas the specific energy
consumption has been reduced to 7.62 Million Kilo calorie per Metric Tonne
Urea by the year 2004-05, amounting to more than 25% reduction in Energy
Consumption. This reduction in Energy consumption has saved around 1.5
lakh MT Naphtha per year costing more than Rs. 375 crore per year based
on present Energy costs.

The Unit has undertaken more reforms to further lower the Energy
consumption to achieve 7.22 Million Kcal/MT urea by May 2006 and is
considering the use of renewable energy sources for further reducing
dependency on thermal power from fossil fuel sources.
In the area of better material utilization, the Unit shall be switching over
from high cost Feedstock Fuel namely Naphtha Fuel Oil to low cost Re-
gasified Liquid Natural gas (RLNG). This shall make the Plant further Energy
efficient and also reduce the Government subsidy outgo by Rs. 270 crore.
The total reduction in subsidy outgo due to above measures shall amount
Rs. 645 crore per year. In addition, IFFCO is installing a Carbon Di-Oxide
Recovery (CDR) Plant of 450 MTPD capacity to recover CO2 from flue gases,
emission of Green House Gases (GHG) to atmosphere thus protecting the
environment. The Carbon thus saved shall be traded under Kyoto Protocol to
generate additional revenues.
--------------------------------------------------------------------------------------------------------------------
-----------------------
ADDRESS DURING THE INAUGURATION OF 58TH ANNUAL SESSION OF INDIAN INSTITUTE
OF CHEMICAL ENGINEERS CHEMCON-2005

14-12-2005 : Delhi

Energy Efficiency Leads to Economic Growth

I am delighted to participate in the inauguration of 58th Annual Session of Indian Institute
of Chemical Engineers (CHEMCON-2005) organized by the Indian Institute of Chemical
Engineers. I greet the organizers, chemical engineers, scientists, academicians,
industrialists and other participants on this occasion. I am glad that the theme of CHEMCON
2005 is "Sustainable Technologies for Efficient Energy Utilization in Process Industries"
which is most timely and essential in the current energy scenario of the nation. Sustainable
Energy Solutions comes out of Energy Independence. I would like to discuss on the topic
"Energy Efficiency Leads to Economic Growth".

As you are aware, our industries and service sectors account for nearly 60% of total energy
used in the country and the current national energy shortage is around 7 to 9%. Hence,
major innovations are needed for reducing the energy intensity in manufacturing process
and reduce the overall energy consumption and emission of pollutants in process industry
while increasing the overall efficiency of the process. Such action will save the energy usage
by the industry and improve its productivity and profitability, facilitate the electricity boards
to meet the demands of the citizens without undue shortage and also help in minimizing the
atmospheric pollution.

Now I would like to dwell on the topic of how economic prosperity for the industry and
nation can be achieved through the application of innovative energy efficiency measures in
India’s chemical process industry.

Strategies for Energy Efficiency

The potential for improvement in energy efficiency in industrial processes

depends on how closely such processes have approached their
thermodynamic limit. In industrial processes which require moderate
temperature and pressures we can introduce technologies for combined heat
and power for achieving overall higher efficiency. New process schemes,
substitution of material, changes in design and manufacture of products
result in less material use and increased recycling can lead to substantial
reduction in energy intensity. Certain technologies that can have strong
impact on efficient energy use are microwave processing, electro separation,
electro chemical synthesis, ozone disinfection and radio frequency drying. In
Pulp and Paper industries the use of membrane separation and bio-filtration
can be introduced. In food processing industries ozonation and ultra-violet
light for sterilization, electron beam processing and electronic pasteurization
for meat and poultry can enable large scale saving in energy and also make
the process clean.

In other words,

(a) Improving the efficiency of mechanical, electrical, electronic and

chemical plant, equipment, processes and materials,

(b) Reduction in process heat losses and

(c) Use of waste process heat for energy generation

These are the three conventional pillars for enhancing energy efficiency in process
industries. In addition, I would like to suggest
(d) A fourth pillar, namely the creative use of renewable energies such as solar and bio-fuel
combinations for production of high quality process water for use in boilers and other
auxiliary systems and applications thus making them less dependent on depleting resources
and increasing costs of oil and natural gas. I understand that a small technology
demonstrator "Suryajal" is functional at IIT, Chennai.

I would like to discuss a few case studies to illustrate these points.

Energy Efficiency in the Sugarcane Industry

As you are all aware, India is the second largest producer of sugar in the
world next to Brazil. There are 553 sugar mills operational in the country
producing 20 million tonnes per annum of sugar from 360 million tonnes of
sugarcane, cultivated by 45 million farmers. I shall now discuss how
enhancement of energy efficiency will benefit these major stakeholders in
the sugar industry, farming community and the nation.

The yield of crystalline sugar from unit mass of sugarcane is an important

parameter for maintaining the competitiveness of the sugar farmers and
industry. In the agricultural component of the sugar industry, development
of varieties of sugarcane to maximize the yield of crystalline sugar content in
a particular variety takes a large amount of time. The typical research
potential in sugarcane development is the following: (a) reduction of water
required for cultivation (b) reduction of growth cycle (c) minimizing the cost
of input for sugarcane cultivation and also sugar production (d) regulated
growth cycle of sugarcane so that sugarcane industries can get continuous
supply of sugarcane.
Our scientists have been able to evolve newer sugarcane varieties through micro-
propagation so that new transgenic varieties can be grown in States like Maharashtra.
Genetic engineering research has to be intensified on molecular characterization of the
sugarcane genome, molecular diagnosis of diseases and molecular biology of sugarcane
pathogens and nitrogen fixing micro-organisms. The molecular characterization of
sugarcane genome will be useful in early selection of desirable plants in the breeding
programme on the basis of molecular markets. It is also envisaged to isolate desirable
genes (for resistance to biotic and abiotic stresses) from the wild relative species of
sugarcane so as to transfer them in the cultivated varieties. Molecular characterization of
the disease causing organisms like viruses is useful in controlling the diseases.
Development of higher nitrogen fixing microbes will be useful in sustainable and low cost
sugarcane production.

So far, I have discussed how the basic bio-technology can lead to high
crystalline sugar yielding sugarcane. With this high yielding sugarcane the
overall energy requirement for extraction of sugar, per tonne of sugarcane
can come down dramatically.

In the sugar industry itself, the Sugar Technology Mission of TIFAC-DST has
identified and commercially evaluated equipment and systems to reduce the
existing captive power consumption from 35 kilowatts per tonne of
sugarcane to 25 kilowatts per tonne that is enhancing the energy efficiency
by about 28%. This is being done by improving mechanical efficiency of
pumps, compressors, crushers, electric motors, conveyors, continuous
centrifuges, continuous vacuum pans etc. New process innovation such as
using new Low Pressure Extraction process, flash recovery, recirculation of
condensates etc. have also contributed to overall energy savings. In
addition, saving in energy has also been accomplished through enhancing
the efficiency of electrical and electronic equipment such as variable
frequency drive, selective process automation, automation of condensing
and cooling systems etc.
The average production of a sugar plant in India is about 35,000 tonnes per
annum, with a sugarcane input of above 6.3 lakh tonnes for the plant. By
implementing such energy efficiency measures the industry can save about
63 million units of energy. This would result in financial saving of Rs. 32
crore for an average plant or about Rs.18,000 crore per annum for the
industry as a whole. This has direct bearing on the profitability of the
industry.
I would recommend such measures must be followed by every member of
the Indian sugar industry.
Impact of Process Yield Enhancement in the Bio-fuel Industry
Let me now take another example. The rise in oil prices and the dwindling
reserve of oil and natural gas makes the transportation sector of our national
economy highly vulnerable. However, we have nearly 63 million hectares of
wasteland available in the country, out of which 33 million hectares of
wasteland have been allotted for tree plantation. One of the bio-fuel
generating plant varieties Jatropha can grow well in this wasteland with
limited water and fertilizer inputs. The plant has fifty years of life. Fruiting
can take place in this plant in two years. It yields up to five tonnes of oil
seeds per hectares and presently produces around 1.5 tonnes of bio-fuel.
The challenge before our scientists and engineers is to enhance the yield of
bio-fuel from the present 1.5 tonnes to 2.5 tonnes per 5 tonnes of oil seeds.
Enhancing energy efficiency in the chemical, mechanical, electrical and
electronics engineering processes involved in bio-fuel production would
contribute to such an enhancement in the yield of bio-fuel plants. In India
we are currently importing the large size esterification plants. Our engineers
and R&D scientists and the industry should focus in designing, building the
energy efficient chemical reactors for small, medium and large esterification
plants for use by different segments of Jatropha producers.
This contribution that is enhancing the yield of bio-fuel from Jatropha seeds
and building energy efficient chemical reactors for esterification by our
scientists and chemical engineers will enhance the nation’s production
capacity of bio-fuel by 33 million tonnes. This would be a substantial
contribution to India’s oil economy in the era of dwindling supplies and
consequent high cost of oil. As you are aware, Government has authorized
use of 10% bio-fuel with diesel for small transport sectors. However, the
experiments established that 100% bio-fuel use for tractors, trucks, heavy
vehicles and diesel generators is technically feasible. A big movement has
started for cultivation of Jatropha in millions of hectares in states like
Chattisgarh, Andhra Pradesh, Jharkhand and our railways.
Energy Efficiency in Fertilizer Industry
Let me illustrate this with one example. Indian Farmers and Fertilizers Co-
operative Organization (IFFCO), is a Cooperative owned by more than 37000
cooperative societies (50 Million farmers) and is the largest producer of
fertilizers in the country. It produces over 60 lakh tonnes of fertilizers
annually.

IFFCO, in their Phulpur-I plant situated in Allahabad have adopted the

following strategies for operating its plants in an energy efficient way. This
Plant started its commercial production from March 1981 with overall
Specific Energy Consumption of 10.40 Million Kilo calories per Metric Tonne
of Urea.
With continuous efforts, the operating efficiency has been increased.
Increasing the efficiency of mechanical equipment was carried out by
updating of plant and machinery, by replacing earlier technology devices
such as turbines, pumps etc. Improving the efficiency of electrical and
electronic systems was carried out by installation of a distributed control
system by using which the plant was operated closer to optimal design
operating parameters. Process heat losses were cut down by micro-level
reengineering such as use of better thermal protection insulation of pipelines
and vessels, plant effluents have been recycled and used for horticultural
and process purposes, thus saving on the overall requirement for process
water.
Through the combined action on all these areas the specific energy
consumption has been reduced to 7.62 Million Kilo calorie per Metric Tonne
Urea by the year 2004-05, amounting to more than 25% reduction in Energy
Consumption. This reduction in Energy consumption has saved around 1.5
lakh MT Naphtha per year costing more than Rs. 375 crore per year based
on present Energy costs.

The Unit has undertaken more reforms to further lower the Energy
consumption to achieve 7.22 Million Kcal/MT urea by May 2006 and is
considering the use of renewable energy sources for further reducing
dependency on thermal power from fossil fuel sources.
In the area of better material utilization, the Unit shall be switching over
from high cost Feedstock Fuel namely Naphtha Fuel Oil to low cost Re-
gasified Liquid Natural gas (RLNG). This shall make the Plant further Energy
efficient and also reduce the Government subsidy outgo by Rs. 270 crore.
The total reduction in subsidy outgo due to above measures shall amount
Rs. 645 crore per year. In addition, IFFCO is installing a Carbon Di-Oxide
Recovery (CDR) Plant of 450 MTPD capacity to recover CO2 from flue gases,
emission of Green House Gases (GHG) to atmosphere thus protecting the
environment. The Carbon thus saved shall be traded under Kyoto Protocol to
generate additional revenues.
Conclusion
In conclusion, I suggest that the members of the Indian Institute of
Chemical Engineers may like to study and standardize and propagate such
models among all the fertilizers, sugar and other chemical process industries
within the country. This will enable the enhancement of the competitiveness
of India's chemical process industries in the international arena.

I have described four basic strategies for enhancing the energy efficiency of
chemical plants in a sustainable and profitable manner, through case studies
of success stories in sugar and fertilizer industries. These basic strategies
can be similarly applied to the entire spectrum of chemical process
industries, such as pharmaceuticals and drugs, petroleum refineries, etc.
Indeed these principles can be applied by other major engineering industries
with significant advantages, such as steel, cement and thermal power
industries among a few. Collectively they consume 50% of the total energy
consumption in India which is about 1000 billion units. An energy saving
target of even a modest 20% in the industrial sector will be a saving of 100
billion units which is worth about Rs. 50,000 crores annually. Look after the
small things, and the big things will soon take care of themselves.

I inaugurate CHEMCON 2005 and my best wishes to the participants in their

mission of generating sustainable technologies for efficient energy utilization
in process industry and lead India towards energy independence.

May God bless you.

IFFCO Phulpur Unit has bagged the prestigious "National Energy Conservation
Award - 2005" (Certificate of Merit in the Fertiliser Sector) on December 14, 2005.

The award was given by Honourable President of India Dr. A.P.J. Abdul Kalam in a
glittering function organised by Bureau of Energy Efficiency, Ministry of Power, Govt. of
India at Vigyan Bhavan, New Delhi.

The scanned images of Certificate and Photos are attached below.

 IFFCO Phulpur Unit has bagged the Prestigeous Rajiv Ratna National Award - 2005 for Excellence
in Indian Industries - "Best Pollution Control Gold Award" by What Hails Public Sector Today (National
Magazine) on 06th November, 2005 at New Delhi.

The award was presented by Shri Oscar Fernandes, Minister for Statistics & Program Implementation,
Govt. of India.
Best Pollution Control Gold Award - Certificate and Plaque :

Chief Guest, Shri Oscar Fernandes, Presenting the Award

 IFFCO Phulpur Unit has been adjudged one of the 38 top "Energy Efficient Units" in India by
"Confederation of Indian Industry (CII) - Sohrabji Godrej Green Business Centre"-Chennai. The 38 top
"Energy Efficient Units" in India belong to various sectors such as Automobiles, Cement, Chemicals,
Engineering, Fertiliser, Glass, Metal, Paper, Petrochemicals, Pharmaceuticals, Power Plants, Refineries,
Textiles, Tyres etc.

Two out of 38 awards are in Fertiliser sector. The two fertiliser industries selected are :

1. IFFCO-Phulpur unit
2. NFL-Vijaipur unit

The Award ceremony will be held in Chennai during 6-7 October, 05.

IFFCO Phulpur Unit has bagged the 'Rajiv Ratna National Award - Best Pollution Control
Implementation Gold Award' from the organisation "Public Sector Today and AP Central
Public Sector Employees Federation Hyderabad".

The Award will be presented by senior Union Cabinet Ministers in the last week of
September 2005 at New Delhi.

In recognition to Phulpur Unit's Outstanding Performance in Environment Management

and Sustainable Development, TERI, New Delhi has Conferred TERI Corporate Environmental
Award 2003 - 04 ( Certificate of Participation ) to IFFCO Phulpur Unit. Award Ceremony took
place on 27th May 2005 at the India Habitat Centre New Delhi.

It may be noted that IFFCO Phulpur is the only Unit to bag TERI Award and 04 Years
Certificate of Participation. The Summary of TERI Awards (incl. Certificate of Participation) are
as under:

1. TERI Corporate Environmental Award 2003-04 (Certificate of Participation)

2. TERI Corporate Environmental Award 2002-03 (Certificate of Participation)
3. TERI Corporate Environmental Award 2001-02 (Certificate of Participation)
4. TERI Corporate Environmental Award 2000-01 (Award)
5. TERI Corporate Environmental Award 2000-01(Certificate of Participation also)

TERI Corporate Environmental Award 2000-01 being received by Sr. ED(Tech.)

TERI Corp. Environ. Award 2000-01 Certificate

 Electronic Governor for CO2 Compressor drive Turbine in Urea-I Plant has been Installed
in Annual Turn-Around, 2005. Following are the major advantages:

1. Precise control of speed : There were no direct control over the speed of compressor. The
speed was controlled by varying the secondary oil pressure manually which was causing speed
hunting of the order of 25 to 30 rpm. With the installation of Electronic governor, the speed
controlling is being done automatically, it can be increased or decreased in the small steps of 2 to
5 rpm. The speed variation is now reduced to 0 to 5 rpm.

2. Extraction pressure variation eliminated : There was variation in the extraction steam pressure
earlier. Now with the help of electronic governor, the extraction pressure can be kept on
automatic control which keeps the extraction pressure variation minimum.

3. Automatic startup and shutdown sequence : The startup and shutdown of the machine is now
taken through a software program, which allows the machine to run on the idle speed for pre-
specified time and then ramp-up or ramp down the speed in a controlled manner for the safety of
the machine.

4. Improvement in the steam consumption (start-up) : Through the automatic startup sequence,
the steam consumption during startup has come down.

The Electronic Governor was inaugurated on 10th May 2005, the photographs of which are as
under:
Shri Samar Pal Singh, Ex-Director, IFFCO, performing 'Pooja' in Urea-I Control Room

Shri V. K. Bali, Sr. E D (Tech.), performing 'Pooja' in Urea-I Control Room

Shri S. K. Mishra, E D (P&A), performing 'Pooja' in Urea-I Control Room

 Energy Saving Project (Phase-I) in Phulpur-I, comprising of Modification in CO2 removal
section and LTS Guard Scheme has been commissioned.

CO2 Removal System Modification to 'GV 2 stage Process' from 'Lo-Heat Benfield Process' in
Phulpur-I plant has been commisioned along with plant start-up. LT Guard System has been
taken in line on 12th May 2005.

Photographs of the same are as under:

Honorable Shri Samar Pal Singh (Ex-Director, IFFCO) performing 'Puja'

Honorable Shri V.K. Bali (Sr. ED, Tech.) alongwith Honorable

Shri S.K. Mishra (ED, P&A) at site
Honorable Shri S.K. Mishra (ED, P&A) performing 'Puja'

LTS Guard Scheme in Phulpur- I Commissioned on 12th May 2005. A view of the scheme is
shown below.
 • Phase-I of Energy Saving Project in Phulpur-II, comprising of LT Guard Scheme, has
been commisioned on 25th March 2005. A few Snaps..
• <¡òEòÉä ¡Úò±É{ÉÖ®ú ¨Éå 34 ´ÉÉì ®úɹ]ÅõÒªÉ ºÉÖ®úIÉÉ Ênù´ÉºÉ ºÉ¨ÉÉ®úÉä½þ -
04 ¨ÉÉSÉÇ 2005
• National Energy Conservation Award - 2004
• FAI award for Best performance for Ammonia Plant
• FAI First Prize for Paper from Phulpur Unit
• Hindi Pakhwada in Phulpur Unit celebrated on 14th Sep' 04 with gaity....
• Catalyst Pool Meet took off at Phulpur.....
• IFFCO-PHULPUR UNIT upgraded to ISO-9001:2000
• Honourable Managing Director Visited Phulpur Unit...
• Corporate level training programme on "e-Porcurement" held at Phulpur Unit

CHAPTER - 1

RATIONALE FOR THE STUDY

The project report on the ³Distribution Channel of IFFCO,Phulpur´ is just an attempt to find
out the overall distribution and marketing activities of the organization. For a better
understanding, the distribution strategy has been studied by me. Studying the distribution
channel strategy gave me a clear understanding of the specific funct ions of each section of
the distribution channel of IFFCO.

In the recent years, we have seen that the importance of studying any subject matter in an
analytical way has developed conceptually with the changing scenario. In a professional
course like M.B.A., it is very essential for a student to get sufficient exposure to the real
business situation where one can have some practical knowledge as how to the organisation
functions and works.

Fertilizer has been a major contributing factor to the growth of Indian agriculture over the
last five decades. The overall fertilizer consumption in the country has recorded
phenomenal growth in last few years. The marketing department controls the day to day
supply as per the fixed norms of government so that the farmers are benefited with good
quality Urea at a cheaper rate and at cooperat ive societies nearer to them.

With a view to find out the policy of distribution and movement of company¶s product i.e
UREA and DAP in the states like Uttar Pradesh. I have undertaken the study on the
distribution channel of the Indian Farmer Fertilizer Cooperative Limited, Phulpur . This
project also discusses about the role of farmer service centres (FSC) and the role of dealer in
the distribution channel. Since fertilizer distribution and movement are regulated by Govt. of
India under Essential Commodities Act (ECA), the company is expanding its marketing of
their product as per extent rule and regulations of the Government.

Urea at present being the only controlled fertilizer and having a major share of the entire
states and also a market leader in many countries, therefore , market potential of
company¶s product is very high.

In conclusion, this project will give a comprehensive idea about effective

utilization of the channel of the distribution and recommendations

offered would definitely help in increasing the sale of urea and dap etc.

CHAPTER - 2

OBJECTIVE OF STUDY
6

(2.1)Title of the Project:

³A Study of distribution channels of Indian Farmer Fertilizer Cooperative Ltd.

(IFFCO), Phulpur, Uttar Pradesh.´

(2.2)Scope:

1.The project will act as a broad straightforward guide to the management

for further expansion and improvement of distribution channels.

2. The study will encourage the marketing officials and the dealers to take

sufficient measures to overcome the limitation of the channel of distribution.

(2.3)Objectives :

1. To study the existing distribution channel of the organisation.

2. To find out the satisfaction level of farmers of Allahabad district regarding

IFFCO fertilizer.

3. To study the sales promotion activities being undertaken by IFFCO

Phulpur Unit.

CHAPTER - 3

PROFILE OF THE COMPANY

8

(3.1)INDIAN FARMERS FERTILIZER COOPERATIVE LIMITED

(IFFCO)

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"
9

APPROACH

³To achieve their mission, IFFCO as a cooperative society, undertakes several

activities covering a broad spectrum of areas to promote welfare of member
cooperatives and farmers. The activities envisaged to be covered are exhaustively
defined in IFFCO¶S Bye-laws´.
10

COMMITMENT

³Their thirst for ever improving the services to farmers and member co-operatives is
insatiable, commitment to quality is insurmountable and harnessing of mother earths'
bounty to drive hunger away from India in an ecologically sustainable manner is the prime
mission´.
11

(3.2)IFFCO VISION 2015

Successfully implemented its earlier Corporate Plans namely ³VISION 2000´, ³MISSION 2005´
and µVISION 2010¶ which resulted into becoming one of the largest producer and marketer
of Chemical Fertilisers by expansion of IFFCO¶s existing units, setting up joint venture
companies overseas and diversification into new sectors.

IFFCO has now visualised a comprehensive Plan entitled µVISION -2015¶

having objectives of :-

Production of fertilisers through expansion of existing units .

Setting up of additional fertiliser production facilities in India and Abroad

through joint ventures.

Diversification into other profitable sectors .

Strengthening raw material sourcing through Strategic joint ventures.

Formulation of Strategic Alliances through IFFCO consortium .

Become Global Leader in Fertilisers Production to cater to Food Security

needs of the Nation.

Enhance presence in International markets through strategic joint ventures

andSynergisticAcquisitions.

Promote Integrated Nutrient Management to improve efficiency of fertiliser

use and to promote location specific research an efficient fertiliser practices .

12

During mid- sixties the Co-operative sector in India was responsible for distribution of 70 per
cent of fertilizers consumed in the country. This Sector had adequate infrastructure to
distribute fertilizers but had no production facilities of its own and hence dependent on
public/private Sectors for supplies. To overcome this lacuna and to bridge the de mand
supply gap in the country, a new cooperative society was conceived to specifically cater to
the requirements of farmers. It was an unique venture in which the farmers of the country
through their own Co -operative Societies created this new institution to safeguard their
interests. The number of co-operative societies associated with IFFCO has risen from 57 in
1967, 39862 on 31st march 2010.

1968-69 1975-76 1981-82 1987-88 1993-94 1999-00 2006-07 2008-09 2009-10

57

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13

Indian Farmers Fertilizer Co -operative Limited (IFFCO) was registered on November

3, 1967 as a Multi-unit Co-operative Society. On the enactment of the Multistage
Cooperative Societies act 1984 & 2002, the Society is deemed to be registered as a
Multistate Cooperative Society. The Society is primarily engaged in production and
distribution of fertilizers. The byelaws of the Society provide a broad frame work for
the activities of IFFCO as a Cooperative Society.

IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP plant at Kandla
both in the state of Gujarat in 1975. Ammonia - urea complex was set up at Phulpur in the
state of Uttar Pradesh in 1981. The ammonia - urea unit at Aonla was commissioned in
1988.

In 1993, IFFCO had drawn up a major expansion programme of all the four plants under
overall support of IFFCO VISION 2000 . The expansion projects at Aonla, Kalol, Phulpur and
Kandla have been completed on schedule. Thus all the projects conceived as part of Vision
2000 have been realized without time or cost overruns. All the production units of IFFCO
have established a reputation for excellence and quality. A new growth path has been
chalked out to realize newer dreams and greater heights through 2015 which is presently
under implementation.
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