- 1 -

Efficiency Improvement at IFFCO Paradeep

S.K. Gandhi, Executive Director
and
Navin Nath, Chief Manager (Process)
Indian farmers Fertiliser Cooperative Limited,
Paradeep Unit
Distt. J agatsinghpur,
Paradeep, Orissa
Abstract
In view of high cost of energy it is imperative to conserve
energy to reduce the cost of production. Level of energy
consumption of an operating plant can also provide the insight
of its physical and financial health. Article gives an insight on
how IFFCO Paradeep Unit is continuousl y improving its
performance in the areas of energy efficiency and
environmental improvement. The measures implemented
invol ves modification in the existing process and equipments,
changes in the equipment layout, recycl ing of material and
water, reduction of wastage and use of renewable energy. The
details of these measures and resultant savings in energy and
water consumption and improvement in environment etc are
elaborated.

1.0 Introduction
IFFCO Paradeep Unit operates two streams of Sulphuric acid plant (2 x 3500
MTPD), one stream of Phosphoric acid (2650 MTPD as 100% P
2
O
5
) and three
streams of complex fertilizer plant (3x2090 MTPD). The main raw materials
such as Rock Phosphate, Sulphur, Sulphuric Acid and Ammonia are imported
from various countries. The electric power requirement is met through Captive
Power Plant (CPP) having two nos. turbo generator (TG) sets, each having
capacity of 55 MW. In addition to the waste heat boilers in Sulphuric Acid
Plant, there are two coal fired 110 TPH capacity Atmospheric Fluidized Bed
Combustion boilers generating steam at a pressure of 61 kg/cm
2
(g) used for
power generation and other utility requirements.


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The raw materials are transported from J etty to the plant through 5 kms long
belt conveyors/pipelines. Water required for the plant is supplied from
Taladanda Canal 2 km away from the plant site. Unique Features of Paradeep
Unit :
1) Largest Phosphatic fertilizer complex in India.
2) Worlds largest single stream phosphoric acid plant: 2650 MTPD.
3) Largest Sulphuric acid plants in India: 2 x 3500 MTPD.
4) Captive power generation, hence self reliant.
5) Own jetty for unloading imported raw materials without delays.

2.0 Efficiency Measures Implemented since 2005
Though the Paradeep plant was commissioned in the year 2000 but it was
under closure by Pollution Control Board when IFFCO took over in 2005.
There were various design and operational drawbacks in the plant. IFFCO
took various systematic measures to improve its operation and energy
efficiency. With the continuous improvement, Electrical as well as thermal
energy has been brought down to the level of just half of its previous levels.
Water consumption of complex has been reduced from 35000 m3/day to
25000 m3/day. Some of the improvements made in the plant are described.

3.0 Efficiency Improvement in Sulphuric Acid Plant

3.1. Installation of Heat Recovery System (HRS)
Lot of heat is generated in the Sulphuric Acid Plant in acid dilution and
absorption. But a large amount of this heat is discarded in the cooling tower.
However in the Heat Recovery System, the low level heat discarded to the
cooling tower is used to generate the LP (4.0 kg/cm2g) steam.

HRS operates at the upstream of existing Intermediate Absorption Tower
(IAT). The HRS consists of a steam injection chamber, a packed heat recovery
tower, a horizontal steam boiler, heater, preheater, diluter, an acid circulating
pump, and two acid drain pumps. The schematic of sulphuric acid plant with
heat recovery system is shown in Figure 1.
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Figure 1: Schematic diagram of Sulphuric acid plant with heat recovery system

The additional steam of about 65 MTPH produced by the heat recovery system
has reduced the steam required from the coal fired boilers. Since the heat
recovery system was installed, coal consumption has decreased by 35%. In
addition to this it has reduced the heat load on cooling tower by 45 Gcal/hr.
Which in turn have stopped the operation of 1 cooling water pumps, two cooling
tower fans and have reduced the evaporation loss from cooling tower. Total
savings attributable to the heat recovery system project are estimated at Rs 25
crore per year.

Figure 2 and 3 shows block diagram illustration of steam balance of the
complex before and after HRS respectively.
Furn
ace
I
II
SH 2
SH 1
IV
III
HRS
Heater
ME

HRS Tower
Demister

FAT
Circulation

DT Circulation
Tank
Boiler
Converter 1
Converter 2
Venturi
Scrubber
Hot HE
450
o
C
341.
o
C
248.
o
C
Cold HE
Steam Drum
HP Steam to export
Stack

Strong acid from IAT tank required
during high humidity only
IAT Circulation
Tank
240
o
C
DT
FAT
IAT
Sulphur
CW
CW
CW CW
Air
Blow Down
IP Steam
Economizer
HRS
Pre
Heate
r
Boiler feed water

To deaerator

Treated water
from existing
system
0.7 barg steam


HRS
Diluter
HRS Boiler
Steam
injection
Strong
Acid to
common
acid tank
N




New HRS
Product
acid
Blower
Process water
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Figure 2 Steam & Power balance PRE HRS-1



Figure 3 Steam & Power balance Post HRS-1



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3.2. Reduction of Catal yst preheating time during Cold Start-up of Sulphuric
Acid Plant & simultaneous reduction of diesel consumption.

This schemes was designed in-house to preheat the catalyst by utilizing HP
steam from coal fired boilers in the waste heat boiler of Sulphuric Acid Plant
and also providing an interconnection between 1
st
bed outlet duct to 4
th
bed
inlet duct in order to achieve 4
th
bed temperature early, during the cold start-
up. After implementation of the above scheme, diesel consumption has been
reduced from 100 KL to 60 KL thus saving 40 KL per startup per stream and
Cold start-up time has been reduced from 36 hrs to 24 hrs thus saving 12 hrs
of production. Total investment was just Rs. 1.0 lakh. The schematic of
scheme is shown in Figure 4.

Figure 4 Schematic diagram Modification of Start up in Sulphuric acid Plant



3.3. Al kali Scrubber to arrest SOX emission during start-up
Sulphuric acid plant is equipped with an Alkali Scrubber unit for scrubbing
1,20,000 NM
3
/hr of gas. The scrubbing system controls SO
3
concentration in
the stack during the plant start-up. Sodium hydroxide solution (15%) is used
as scrubbing media. After absorption of SO
3
, sodium hydroxide solution gets
converted into sodium sulphite and sodium bisulphate. The tail gas from final
absorption tower enters at the bottom of the scrubber and rises to the top
through polypropylene packing beds.
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The moisture of the gas is removed by 20 Nos. of PPE fiber beds mist
eliminators installed before the packing. The gas leaving the scrubber is
vented in to atmosphere through the stack. The pH of the circulation solution is
maintained at 6.8. A bleed off is taken from the circulating liquor to the final
effluent tank where the aeration takes place. The solution is aerated for 120
hours by a surface aerator to convert sodium sulphite and sodium bisulphate
to sodium sulphate.

3.4. Caesium promoted catal yst

Caesium promoted catalyst has been added to the 4th bed (248 m3) of the
converter bed in Sulphuric Acid Plant. Out of the 248 m3 catalyst 50% is the
caesium promoted catalyst. The conversion temperature with caesium
promoted catalyst is as low as 340C where for normal catalyst its about 400-
420 C. Because of low reaction temperature conversion of SO2 to SO3
during cold start up is attained relatively faster, reduces the plant start-up
duration and also reduces the emission of SO2 during start up.

3.5. Utilization of vent steam from condensate receiver and CBD tank

In sulphuric acid plant, the flash steam from condensate tank and boiler
continuous blow down tank (CBD) were vented to atmosphere. To recover the
loss of energy the flash steam was diverted to the nearby deareator tank with
an investment on Rs 2.6 Lakh. The recovery of steam resulted in subsequent
reduction of 7 ton of LP steam input to deareator. The block diagram of the
scheme is shown in Figure 5.
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Figure 5: Schematic showing Utilisation of Vent Steam

3.6. Reduction in Boiler feed water pump discharge pressure from 105
kg/cm
2
g to 90 kg/cm
2
g in Sulphuric Acid pant

Though the boiler feed water header pressure requirement was about 90
kg/cm2g, discharge of Boiler Feed Water Pumps was maintained at 105
kg/cm2g to with a view that it provides operation flexibility. The detailed review
of the boiler feed water system established that there is no need of keeping
such a high discharge pressure. Reduction in the discharge pressure has
resulted in the stoppage of one pump which was made stand-by, thereby
resulting in power savings of 900 kW.

3.7. Candle Filter to arrest acid mist in sulphuric acid plant

In Sulphuric acid plant at the top of Inter pass Absorption Tower and Final
Absorption Tower, trickling candle filters have been installed. The candle filter
helps in arresting acid mist or droplets present in the outlet gases. The gas
leaving the final absorption tower has an acid mist concentration of 40 mg/Nm
3

of SO
3
as against the norm of 50 mg/NM
3
, which is discharged through to tail
gas stack of 131 meters height.
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4.0 Efficiency Improvement in Phosphoric Acid Plant

4.1. Modification of evaporators barometric condenser by installation of
single sieve type distribution tray and removal of steam ejector system.
In evaporators, phosphoric acid is concentrated from 28% to 54 % P
2
O
5
.There
are seven evaporators. Each evaporator is single stage, forced circulation unit
consisting of rubber lined flash chamber, axial flow circulation pump and
vertical shell and tube Heat Exchanger with impervious graphite tubes. Acid is
re circulated at a high rate by the pump through the heat exchanger and into
the flash chamber where an absolute pressure of about 66 mmHg is
maintained to keep the acid at its boiling point. The vapours from the flash
chamber flow under vacuum to the entrainment separator. From the separator
phosphoric acid is returned to flash chamber and the vapour flow continues to
fluorine scrubber. Vapours from the fluorine scrubber will come under direct
contact with cooling water in the barometric condenser and the remaining non
condensable gases are extracted.


Figure 6: Barometric Condenser Before and After Modification



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Earlier System:
In the earlier system the vapors from the fluorine scrubber are condensed in
baffle type barometric condenser where a large amount of cooling water
condenses the partial amount of water vapor. Remaining water vapor and any
non condensable gases are extracted by a two stage Vacuum jet steam
ejector system consisting of two nos. of medium pressure (MP) steam (15
kg/cm2g) ejectors and a water cooled inter condenser. MP Steam
consumption in each ejector system was 2 MTPH. Total MP Steam
consumption in all the seven evaporators was 14 MTPH.

Modified system:
In the modified system, baffle trays of barometric condenser were replaced
with a single sieve tray where cooling water passes through the sieve at the
top and condenses condensable vapours and extracts all the non condensable
gases without vacuum jet ejection system. The modification was carried in-
house with an investment of Rs 84.894 lakh, with savings of 14 TPH of MP
steam equivalent to annual savings of about Rs. 5 crore.

Figure 6 shows the schematic before and after modification.

4.2. Installation of pre scrubber for improving Fluorine scrubbing efficiency

Earlier reactor fumes were scrubbed in a single stage scrubbing system with
pond water. This system was not adequate and was not meeting the norms
fixed by the Pollution Board. After conducting in-house study a pre-scrubber is
installed at the up-stream of the existing scrubber (Figure 7). Additional pre-
scrubber vessel along with an additional scrubber exhaust fan and new stack
with higher diameter was installed. This has improved the scrubbing efficiency,
reduced the fluorine emission to the atmosphere from 20-25 mg/NM3 to 4-5
mg/NM3.
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Figure 7 Fluorine Scrubbing Unit

4.3. Retrofit of Fluorine recovery uni t
Earlier Hydro Fluorosilisic acid recovery system was bypassed. Hydro
fluorosilicic acid produced in evaporator section was not recovered in the
Fluorine Scrubber instead it was getting recovered in the barometric
condenser which in turn lead to rise in the fluoride content in cooling tower and
release of free fluorine in to the atmosphere. Fluorine recovery system was put
into operation by major revamping viz brick lining of the scrubber, installing
reliable pumps, circulation MSRL lines replaced with Poly-propylene lines etc.
Presently about 20 MT / day hydro flurosilisic acid (18% - 20% H
2
SiF
6
) is
recovered which in turn reduces emission of Fluorine to the atmosphere. The
schematic in Figure 8 shows the modification.

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Figure 8: Fluorine Recovery Unit

4.4. Provision of a Single cloth wash tank in Phosphoric Acid Plant.
There are seven (7) nos. of belt filters in Phosphoric Acid Plant. Each belt filter
was having its individual cloth wash tank and cloth wash pump. All these 7 cloth
wash tanks and pumps were replaced with common cloth wash tank and pump.
This has reduced the power consumption by 27.5 kW and has also improved
the accessibility & approach to the equipments and house-keeping of the entire
area.

Figure 9: Schematic Diagram of Modification in Wash Tank



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5.0 Efficiency Improvement in Complex Fertiliser Plant

5.1. Steam Air heater in DAP:
To evaporate the moisture of fertilizer, hot gases are supplied into the dryer
through a duct which is lined with refractory. The hot air was generated by firing
fuel oil through a burner and a combustion chamber with supply of inlet air.

System was retrofitted with steam heated air system for utilizing the captive
steam of the plant by connecting the hot air duct of this new steam air heater to
the existing discharge duct of combustion chamber as shown in Figure 10.

Total expenditure for all the three trains was Rs. 6.78 crore and with the annual
FO saving of 12150KL total monetary savings are about Rs. 51.22 crore.


Figure 10: Steam Air Heater



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5.2. Individual scrubbing system for Dust and Fumes in DAP/NP Plant
There was a common dust and Fume Scrubbing System for scrubbing dust
generated from conveyor, elevators, crushers & screens and Fumes from Pre-
neutralizer and Granulator. Dust being heavier and system not designed for
the combined scrubbing of fumes and dust, it was not able to suck the dust
properly. To overcome the problem separate dust scrubbing system was
installed from the scrap equipment and material (Figure 11). This modification
improved dust scrubbing efficiency reduced the dust escape to the
atmosphere and reduced the ammonia loss to atmosphere from 350 mg/NM3
to 150 mg/NM3.

Figure 11: Dust and Fumes Scrubbing Unit in DAP Plant

6.0 Efficiency Measures in Utilities and Offsite

6.1. Energy savings due to installation of new BFW line from AFBC boiler to
Energy Center

Earlier a dedicated pump of 300 kW motor was supplying Boiler feed water to
PRDS in Energy center. A new line from the discharge of BFW pump of coal
fired boiler was provided to supply the required de-superheating water to this
PRDS. This has stopped the operation of 300 kW motor thus saved 300 kW
power.
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6.2. Installation of lower capacity Pump at Canal pump house
The Canal pump house, which is the source of water supply to Paradeep Unit is
at distance of about two kilometres. From the underground tank of canal pump
house water is pumped to the plant through centrifugal pump of 3000 m3/hr
capacity drive by 450 kW motor. On studying the water supply system, it was
observed that the process requirement could be met with a pump of lower
capacity of 1500 m3/hr only. Pump was replaced with lower capacity pump
driven by motor of 160 kW thus saving 290 kW power.

6.3. Replacement of Cooling Tower fan blades from solid FRP to Hollow FRP
Fan blades of cooling tower in Sulphuric Acid Plant and Energy Centre were
replaced from Solid FRP to Hollow FRP. Seven numbers of Fan blades were
replaced in Sulphuric Acid Plant and 10 nos. of fan blades were replaced in
Energy Centre Cooling Tower. Total reduction in power consumption was 300
kW.

6.4. Energy savings in Coal Handling Plant (CHP)
There were 11 nos. of conveying belts were operated in the earlier layout.
However with careful study the conveyor belts have been reduced to 7. This
resulted in a power saving of about 200 kW.

6.5. Trimming of Filter water pump impeller
The filter water pumps are used to pump process water to different plants inside
the complex. Each of the three pumps was designed to give a flow of 1800
m
3
/hr at a discharge pressure of 6.90 kg/cm
2
. After an in-house study as per the
requirement of the plant it was observed that the impeller of one pump can be
trimmed for lower flow without any change in the discharge pressure. The
impeller dia. of the pump was trimmed form 540 mm to 520 mm. This resulted in
the power saving of 75 kW.

6.6. Installation of De dusting unit for Product Handling Conveyors
De-dusting units are installed at various locations in the product handling
system to extract the dust and keep the environment dust free Figure 11). The
system was designed in-house using scrap equipment & material.

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Fig-11: De-dusting system for Product Conveyer and Bagging Plant


6.7. Energy savings due to reduction in discharge head of Ammonia transfer
pump
A scheme was implemented to reduce the discharge head thus reducing the
power consumption of Ammonia transfer pump by reducing the impeller from
four stage to three stage. After implementation of the scheme, power
consumption has been reduced from 71 kW to 59 kW, thereby saving 12kW of
power consumption.

6.8. Installation of Capacitor banks to increase Power factor
Power factor at Paradeep unit was just 0.71. Capacitor Banks were installed
and power factor improved to 0.90.

6.9. Installation of Steam traps and Condensate recovery system
A total of 387 nos. steam traps were installed in all the plants of the entire
complex. This scheme has resulted in steam savings of about 5%.

6.10. Installation of screw type un-loader
Earlier, there were two Grab type un-loaders each of 1500 TPH capacity at
J etty for unloading Rock Phosphate & Sulphur from Ship. Unloading the
materials through grab un-loaders, lot of dust was generated.
- 16 -
Now an additional Screw Type Enclosed Un-loader of 1800 TPH capacity has
been installed to avoid the dust generation and any spillage (Figure 12). This
system was commissioned in J uly 2013.

Figure 12 Screw Un-loader
















6.11. Renewable Energy Measures
As a part of green initiative; lighting of Administrative Building is done by
installing the solar panels of 30 kW (3x10 kW) with an investment of Rs.70 lakh

6.12. Measures for Water Conservation
6.12.1. Water conservation measures in Phosphoric Acid Plant
a) Reduction in Fresh Water Consumption
Previously, around 200 m
3
/h of fresh water was used in the lubricating oil
coolers of the gypsum pump and ball mills. These coolers are now connected
to the sulphuric acid plant closed loop cooling water circuit, thereby reducing
fresh water consumption.
b) Utilization of Waste Water from utility/offsite
The waste water generated during back wash of resin in DM plant, tower blow
down of sulphuric acid and power plant cooling towers of about 350 m3/hr are
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being used in 7 nos. of belt filter condensers, vacuum ring pumps and for rock
phosphate wet grinding. Thus saving about 9000 m3/day of fresh water.
c) Use of pond water as pump seal water
All the centrifugal pumps in phosphoric acid plant, except the pumps in ball
mill section are designed to handle acidic solution; this made us possible to
use acidic pond water as pump seal water instead of fresh process water thus
saving 20 m3/hr of fresh water.

The above modifications lead to zero consumption of process water in
phosphoric plant with only minor consumptions for safety showers and
cleaning purpose.

6.12.2. Water conservation measures in Sulphuric Acid Plant
a) LP steam condensate recovery
About 25 TPH of low pressure steam is used for melting of sulphur, molten
sulphur storage tank and molten sulphur pipeline. All the steam condensate
from the sulphur melting and storage area earlier drained to the storm water
channel. This condensate is now sent to DM plant polishing unit. As a result of
this about 20 m
3
/h of DM water is saved.

b) Waste heat boiler blow down recovery
Earlier blow down from waste heat boilers of around 10 m3/hr was drained in
the storm water channel. This is diverted to Intermediate absorption tower and
Final absorption tower dilution tanks for sulphuric acid dilution thus reducing
the consumption of water by 10 m3/hr.

7.0 Impact of Improvements
Figure 13 and 14 clearly indicate how Electrical Energy and thermal energy
consumption of the plant improved over the years respectively. Specific
consumption of electivity has been reduced from about 958 kWh/ MT of P2O5
in 2006-07 to 568 kWh/MT of P2O5 in 2012-13. In the year 2013-14, it is
expected that this shall be about 500 kWh/MT of P2O5. The water
consumption has reduced significantly.
- 18 -
958
833
806
718
620
616
568
400
500
600
700
800
900
1000
K
W
H

/

M
T

o
f

P
2
O
5

i
n

F
e
r
t
l
i
z
e
r
Overall Specific Consumption of Electricity

Thermal Energy Consumption was reduced from 2.99 Gcal/MT of P2O5 in the
year 2006-07 to 1.71 Gcal/MT of P2O5 in the year 2012-13. Lowest thermal
energy consumption of 1.07 Gcal/MT of P2O5 was achieved in the year 2011-
11. Thermal energy consumption in recent years has gone up due to stoppage
of Sulphuric Acid Plant for revamping the Absorption Towers. The overall
specific consumption of water has been brought down from 12.90 M3 per tonne
product in 2006-07 to 6.01 M3 per tonne of product in 2012-13 (Figure 15).
G
c
a
l
/
t
o
n
n
e
P
2
O
5
1.18
1.71
2.99
2.43
2.04
1.3
1.07
0
0.5
1
1.5
2
2.5
3
3.5
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
Thermal Energy Consumption per tonne of Complex fertilizer

- 19 -

Figure 15

8.0 Conclusion
With moderate investment in the energy conservation and environment
improvement measures as on-going process, there is steady decline of energy
consumption and reduction in emission of sulphur dioxide and fluorine.
Consumption of electric and thermal energy have come down from 568 kWh/MT
of P2O5 to 500 kWh/MT of P2O5 and 2.99 Gcal/MT of P2O5 to 1.71 Gcal/MT of
P2O5 respectively from 2006-07 to 2012-13. The water consumption has also
been reduced from 12.90 M3/MT of product to 6.01 M3/MT of product during
the same period.