Development of Energy

Consumption Norms
for
Ammonia/ Urea Plants for
Implementation of EA-2001
R V Nesari

5/14/2008 Fertilizer Sector Workshop, 1

Mumbai
 Energy Conservation Act-2001
Objectives
• Bridging the gap between energy
demand & supply.
• Reducing environmental emissions
through energy saving and
• Reduction in the energy import bill.
• The Act provides the much needed
legal framework and institutional
arrangement for embarking an energy
efficiency drive.
5/14/2008 Fertilizer Sector Workshop, 2
Mumbai
 Provisions of EA-2001 Act
• Energy intensive industries/ establishments
have been identified and specified as
Designated Consumers of energy.
• Establish and prescribe energy consumption
norms for Designated Consumers.
• The study is being conducted for setting up
Energy Norms for Fertilizer Industry as one
of the designated consumers.

5/14/2008 Fertilizer Sector Workshop, 3

Mumbai
 Fertilizer Industry as Designated
Consumer
• Any fertilizer unit having annual energy consumption
equal to or more than 30,000 metric tonnes of oil
equivalent (MTOE) per year.
• Evaluation of energy consumption levels and notification
of norms for specific energy consumption by BEE.
• The limit of annual energy consumption in terms of
MTOE shall be reviewed every three years.
• A high powered technical committee represented by
senior officials/executives from ministry, FAI and
fertilizer units shall be constituted for evaluation of
recommended energy consumption norms.

5/14/2008 Fertilizer Sector Workshop, 4

Mumbai
 Factors Affecting Energy
Consumption
• Diversified technologies,
• Variety of raw materials/ feedstock,
• Fuel characteristics,
• Age factor of plants,
• Location,
• Plant capacity & capacity utilization,
• Performance of critical equipment.

5/14/2008 Fertilizer Sector Workshop, 5

Mumbai
 Broad Activities of Study
1.Categorization/ Groups.
2.Design of the data collection format.
3.Design of the Annual reporting format.
4.Collection and compilation of data.
5.Data analysis for setting up specific energy
consumption norms.
6. Preparing draft report on Sp. Energy consumption
norms and discuss with all participating units and
FAI and Govt. representatives through meetings/
workshops to finalise the norms.
7. Report presentation to High Power Technical
Committee.
5/14/2008 Fertilizer Sector Workshop, 6
Mumbai
 Fertilizer Industry in India
• Ammonia Plants: 32 No.
• Urea Plants: 31 No.
• DAP based NPK Plants: 12 No.
• ANP Plants: 3 No.
• Sulphuric Acid/ Phosphoric Acid
Plants: 10 No.
• SSP Plants: small scale not likely to fall
under Designated Consumer Category.
5/14/2008 Fertilizer Sector Workshop, 7
Mumbai
 Ammonia/ Urea Plants
• Controlled price of sale of urea to farmers.
• Fixation of preset energy consumption
norms of individual units for calculating NPS.
• 6 groups of plants based on feed-stock use
and starting year of commercial production
viz. Pre-1992 gas, Post-1992 gas, Pre-1992
Naphtha, Post-1992 Naphtha, FO/ LSHS and
Mixed Feedstock.

5/14/2008 Fertilizer Sector Workshop, 8

Mumbai
 Gokak Committee Report on Efficient
Energy Levels for Urea Plants
• Committee constituted by GoI in June 2001 to
suggest efficient energy levels based on
prevailing energy norms and norms expected
from modern plants.
• Committee recommended target energy levels
for six groups.
• Committee felt that targets suggested were
relevant as milestones to achieve national goal
of energy conservation.
• Major decisions on efficient energy levels to be
taken by BEE to implement EC Act-2001

5/14/2008 Fertilizer Sector Workshop, 9

Mumbai
 Energy Norms for NPS-III
• Actual norms fixed for NPS-III are different than
those suggested by Gokak Committee.
• Norms fixed based on historic data of operation
i.e. energy norm for NPS-II or actual specific
energy consumption of 2002-03, whichever is
lower.
• Norms does not take into account energy
conservation potential.
• Norms are 5 years old; needs a fresh look.

5/14/2008 Fertilizer Sector Workshop, 10

Mumbai
 NPS-III Policy Objectives
• Promote usage of most efficient and
cheaper feedstock NG/LNG for urea
production.
• Conversion of all non-gas based units to
gas (9 units running presently on naphtha/
LSHS) within 3 years from 1.10.2006.
• Progress on conversion to NG/LNG still
slow due to various constraints faced by
units.
5/14/2008 Fertilizer Sector Workshop, 11
Mumbai
 Comparison of NPS-III Energy Norms
with Actual Sp. Energy Consumption
S. Name of Unit NPS-III 2004-05 2005-06 2006-07
No. Norm,
Gcal/ MT
of urea
1 CFCL-I 5.621 5.709 5.611 5.613

2 CFCL-II 5.678 5.608 5.556 5.603

3 IFFCO-Aonla-I 5.69 5.738 5.618 5.673

4 IFFCO-Aonla-II 5.522 5.544 5.494 5.510

5 IFFCO-Kalol 6.607 6.347 6.179 5.981

6 IFFCO-Ph-I 7.584 7.630 7.433 7.091

5/14/2008 Fertilizer Sector Workshop, 12
7 RCF-Thal 6.938 6.477
Mumbai 6.505 6.506
 Comparison of NPS-III Energy Norms
with Actual Sp. Energy Consumption
(Contd.)
S. No. Name of Unit NPS-III 2004-05 2005-06 2006-07
Norm,
Gcal/MT
of urea
8 NFL- Vijaipur-I 5.952 5.807 5.795 5.756

9 NFL- Vijaipur-II 5.712 5.464 5.488 5.415

10 KRIBHCO 5.952 5.872 5.902 NA

11 IGFL 5.534 5.43 5.38 5.31

12 NFCL-I 5.712 5.711 5.62 NA

13 TCL 5.417 5.23 5.13 5.18

5/14/2008 Fertilizer Sector Workshop, 13
14 GNFC 7.989 7.56
Mumbai 7.45 7.65
 Benefits of Developing Energy Norms

• Encouraging efficiency improvement

through benchmarking.
• Adopting newer technologies to reduce
energy losses
• Improving bottom line of Balance Sheet
• Reduction in environmental emissions
(GHGs).
• Key to continual improvements.
5/14/2008 Fertilizer Sector Workshop, 14
Mumbai
Questionnaire for Data collection
• A first step towards developing energy
norms
• A draft questionnaire developed for the
data collection.
• Discussion of the questionnaire contents.
• Modifications required.
• Units to fill in the questionnaire and send
to BEE.
5/14/2008 Fertilizer Sector Workshop, 15
Mumbai
 Contents of Questionnaire

• General:
1. Name of Unit:
2. Name of Organization:
3. Unit’s Postal Address:
4. Name of Contact Person, designation,
communication contact details.
5. Name of Energy Manager
6. Energy Management Policy of Unit
5/14/2008 Fertilizer Sector Workshop, 16
Mumbai
 Ammonia Plant

1. Daily rated capacity, MTPD:

2. Month and year of commissioning:
3. Month and year of starting commercial production:
4. Feedstock used:
5. Process technology:
a) Front End:
» Desulphurisation:
» Gasification Process
» Gas Purification Process
» CO2 Removal Process

5/14/2008 Fertilizer Sector Workshop, 17

Mumbai
 Ammonia Plant (contd.)

b) Synthesis:
¾ Loop pressure:
¾ Synthesis Convertor flow: Axial/ Radial/ Axial
radial
c) Purge Gas Hydrogen recovery:
Membrane/ Cryogenic
d) Other related facilities in Ammonia plant: Naphtha
handling/ Cooling Tower/ IA/ IG/ Ammonia storage
and handling
6. PFD with design/ actual material balance at key
points.

5/14/2008 Fertilizer Sector Workshop, 18

Mumbai
 Ammonia Plant (contd.)

7. Operating data of Energy consumption for last 5

years:
¾ Production
¾ Raw material consumption:
a) Feed
b) Fuel
¾ Steam consumption (import):
¾ Steam Export:
¾ Power Consumption:

5/14/2008 Fertilizer Sector Workshop, 19

Mumbai
 Ammonia Plant (contd.)

8. GCV and NCV of feedstock and fuel used.

9. Specific Energy Consumption data:
10. Stream days achieved:
11. Data on Best performance achieved so far:
12. Whether external energy audit carried out?
13. If yes, name of EA organization:
14. Main recommendations made and implemented:
15. Improvements through internal energy audit and suggestions:
16. Major revamps/ retrofitting carried out:
17. Energy saving schemes studied but not implemented with reasons:
18. Next three years’ planning of energy conservation:

5/14/2008 Fertilizer Sector Workshop, 20

Mumbai
 Urea Plant and Utilities

• Questionnaire contents similar to

Ammonia plant
• Utilities:
1. Steam
2. Power
• Details of utilities supplied to other plants
not included in Ammonia and urea plant
operation.

5/14/2008 Fertilizer Sector Workshop, 21

Mumbai
 Conclusions
• Development of Energy Consumption
norms essential to implement Energy
Conservation Act-2001.
• Development through consensus and not
by force and without clashing with existing
Govt. policies.
• Encouraging energy conservation and
energy efficiency improvement efforts.
• Benefits to stakeholders and the country.
5/14/2008 Fertilizer Sector Workshop, 22
Mumbai
5/14/2008 Fertilizer Sector Workshop, 23
Mumbai