Development of Energy

Consumption Standards/ Norms

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

1st Sept. 2008

Fertilizer Sector Workshop, 1

New Delhi
 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.
Fertilizer Sector Workshop, 2
New Delhi
 Provisions of EA-2001 Act
• Identify Energy intensive sectors of
industries/ establishments and specify as
Designated Consumers of energy.
• Establish and prescribe energy consumption
standards/ norms for Designated
Consumers.
• This study is being conducted for setting up
Energy consumption standards & norms for
Fertilizer Industry specified as one of the
designated consumers.

Fertilizer Sector Workshop, 3

New Delhi
 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.

Fertilizer Sector Workshop, 4

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

Fertilizer Sector Workshop, 5

New Delhi
 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 standards/ norms.
6. Preparing draft report on Sp. Energy consumption
standards/ 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.
Fertilizer Sector Workshop, 6
New Delhi
 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.
Fertilizer Sector Workshop, 7
New Delhi
 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.

Fertilizer Sector Workshop, 8

New Delhi
 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.
• Committee View: Major decisions on efficient
energy levels to be taken by BEE to implement
EC Act-2001
Fertilizer Sector Workshop, 9
New Delhi
 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 more than 5 years old; need a fresh
look.

Fertilizer Sector Workshop, 10

New Delhi
 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 including fertilizer
policy faced by units as well as uncertainty of
LNG supply.

Fertilizer Sector Workshop, 11

New Delhi
 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

Fertilizer Sector Workshop, 12
7 RCF-Thal 6.938 6.477
New Delhi 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

Fertilizer Sector Workshop, 13
14 GNFC 7.989 7.56
New Delhi 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.
Fertilizer Sector Workshop, 14
New Delhi
Questionnaire for Data collection
• A first step towards developing energy
norms
• A draft questionnaire developed for the
data collection was presented in Mumbai
Workshop in May 2008.
• Feedback of the questionnaire contents.
• Modifications required have been done.
• Units to fill in the questionnaire and send
to me/ BEE.
Fertilizer Sector Workshop, 15
New Delhi
 Contents of Questionnaire

• General:
1. Name of Unit:
2. Name of Organization:
3. Unit’s Postal Address:
4. Name of CEO/ Contact Person, designation,
communication contact details.
5. Name of Energy Manager
6. Energy Management Policy of Unit

Fertilizer Sector Workshop, 16

New Delhi
 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

Fertilizer Sector Workshop, 17

New Delhi
 Ammonia Plant (contd.)

b) Synthesis:
 Loop pressure:
 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.

Fertilizer Sector Workshop, 18

New Delhi
 Ammonia Plant (contd.)

7. Operating data of Energy consumption for last 3

years (earlier 5 years):
 Production
 Raw materials consumption:
a) Feed
b) Fuel
 Steam consumption (import):
 Steam Export:
 Power Consumption (Captive/ Purchased):

Fertilizer Sector Workshop, 19

New Delhi
 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:

Fertilizer Sector Workshop, 20

New Delhi
 Urea Plant and Utilities

• Questionnaire contents similar to

Ammonia plant
• CDR unit data (added)
• Utilities:
1. Steam
2. Power
• Details of utilities supplied to other plants
not included in Ammonia and urea plant
operation.
Fertilizer Sector Workshop, 21
New Delhi
 Energy Conservation Activities

• Energy Management Policy of Company/

Unit
• Appointment of Energy Manager
• Formation and Functioning of EC Cell
• Encouragement to employees to pass
Energy Auditor/ Energy Manager
Examination; List of EAs/ EMs
• Any other scheme like Suggestion scheme
Fertilizer Sector Workshop, 22
New Delhi
 Questionnaire Feedback

• Group Norms instead of Single norm: Yes

• Factors related to Equipment/ machinery and
their operating parameters in Energy
Consumption
• Capacity related: Original or revamped- data for
the plant being operated now.
• Fuel for Boilers- coal/fuel oil/ naphtha etc.
• Use of RLNG or any other gas/ feedstock-
Questionnaire may be modified by EM of Unit
suitably.

Fertilizer Sector Workshop, 23

New Delhi
 Questionnaire Feedback

• NCV and GCV values: per NM3 or per SM3

• Energy Consumption for Gas turbines and
WHRB
• Energy factors for utilities like steam,
purchased power
• PFD of Ammonia/ Urea plants with key
parameters- to identify difference in design
and operating parameters which affects
specific energy consumption.
Fertilizer Sector Workshop, 24
New Delhi
 Conclusions
• Development of Energy Consumption standards/ norms
for Fertilizer Sector essential to implement Energy
Conservation Act-2001, in spite of various factors and
difficulties.
• Norms considering all factors- group based
• Development through consensus and not by force and
without clashing with existing Govt. policies.
• Cooperation of all Ammonia and Urea Manufacturing
units prerequisite for the success of this execise.
• Units to fill up the questionnaire and send to R V Nesari,
Coordinator for the Study.
• Self Evaluation through BEE software to be developed.
• Encouraging energy conservation and energy efficiency
improvement efforts.
• Benefits to stakeholders and Workshop,
Fertilizer Sector the country. 25
New Delhi
Fertilizer Sector Workshop, 26
New Delhi