IFFCO - PHULPUR UNIT

This is a presentation from IFFCO, one of the finalists at the 5th CII-GBC National
Award for Excellence in Water Management in 2008

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. D

HEICOMES)

Honorable Members of Jun

FCO. FHULPUR UNIT
A Profile

Phupuri Process Licensor Annual Capacity e

Ammonia Plant MWKallg, USA 322400 MT
wa Plant Snamprogot tay 551100 MT FT

Phuipur Process Licensor Annual Caps

Ammonia Plant HTAS, Denmark 01600 MT
“ra Plant Snamproget, tly 864600 MT

-Phutpuet Mar 28, 1981
“Phuipurdt Dec. 22, 1997

\vEXIL]

ANNUAL TURNOVER (07-08)

2. EE 150 90012000 ‘OHSAS 190000

=. -

Certificate

PRODUCTI ON OUTLINE

3. (Major Water Recycle /Reuse Schemes [rc]

during 2004- 2008
Phulpur_ Unit
Sr. [Water “Recycle Rouse investment | Annual [Pay back
scheme (Ps. in ‚| wat
Lakhs) | Saving

m)

increase in Cycle of 609662 [immedi
[Concentration of Cooling ‘ately

[Tower ( trom 6.0 to 9.0)

Direct Recycling & Rouse 33

ot Turbine Condensate in month
amm. - 11 Plant

Recycle of CDR eimuont 386
ior process use as cooling month
Tower make-up through

[Water Softening Plant

Major Water Recycle 7 Reuse Schemes,
2008

Inster Recycle 7 Reuse] Investment [Annual
(scheme (Bs. in. | water

Lakhs) | Saving
(m)

instalation of Rain 3600
[Water Harvesting

(System
(Collection and reuse of 3900
rain water in process.

Ihrougn Mist Cooling
[System

[installation or Water
ISpraying System in
lammonical Guard Pond

4. FAW WATER CONSUMPTION FOR UREA PRODUCTION [IFFCO]

Specific Raw Water Consump! =

aw Wate Saving in Yar 2007.08 104,000 m3
9 (er compares to year 200205)

Raw Water (MS / MT of Urea)

5. SPECIFIC EFFLUENT DISCHARGE [ES2]

323353333858
Sessssszsss

EFFLUENT DI SCHARGE PER MT OF UREA

Per capita Domestic Water consumption

7 om

2 D]

6. TNNOVATIVE PROJECT No. T=]

ETP cum Recycle Plant based on Steam Stripper

‘ear implementation: 200808 Water Sly (ma!)

<50

7. TNNOVATI VE PROJECT Ni
Recycle of CDR Effluent Water in to PL

‘rol implementation: 200697

TNNOVATI VE PROJECT N
Recycle of Turbine Condensate in Ammonia Plart ll

8. [INNOVATIVE PROJECT No-5 [co]
we Pond

ter Spraying System in Gus
Year of Implementation: 2007-08, Cost - Rs. 5.5 Lakh

[an eT Tea Sem |
(Central School & Guest House Ghiyanagat =
Founship

9. Total Raw water Consumption.
Raw Water Consumption per MT. of
Urea

{sent Water Reuse/ Recycle
Eten

Recycle pump Running at Guard
Pond,

RO. Plant

Bottom Ash Deashing to Old Ash
Pond,

Fly Ash Deashing to New Ash Pond,

Où Ash Pond though 6° drect ine
from Guard Pond

Coal Yard Spray
Gordet

continues

10. Water Monitoring Repo}

Treated Sewage Water hom STP | Yes No
water softening Plant Yes No
Lawn krigaton in Township, Yes No
Extra Pump Running No
Hyeroysed Watertrom ea: [cpu

Hydrosed Water rom Woa-l [cpu

In ttuent Holding pitIrom Urea-1/I, | Yes

Am

Leakage / Water Loss UG
Raw Water Leakage
Near Lrea2 silo under maint

aaa C=

Programme
Natural resource conservation & awareness among the
Employee and community are an negra! pal atau,
nvironmental Policy À lot of work regarding these Is being
done in IFFCO Phulpur to Increase awareness among the people

Display of Hoarding and Banners Display of Siogan in

Fegarding water conservation on CCTV in township Lectures on
importance of water conservation regulary, Distribution of
Cireulars & lealets among the community,

In house training programmes on natural resource conservation

Community awareness programmes organised in nearb
Villages, Awareness lectures organised at nearby schools &

Colleges to motivate students

\ Employees are involved through suggestion scheme. Technically
Sulable suggestions are implemented and employees are rewarded.
‘ater leakage /overiow rom pipe lines tanks observed in
township & plant of Immodlately informed by township resido
employees lo EPC group or corrective action

Y Township residents (employees) optimize w
byreducing the wastage of water in day to day work.

11. A

ENVIRONMENT AND SUSTAINABILITY
Zero!

4 Recycle Of Sewage Water For Process Use

+ Hydrolysed Water Being Used As BFW
‘Through CPUOn Continuous Basis

y Ash for Usar
and ash disp

4 Ground water Recharge by Water Harvesting,

4 Bio-Methanation Plants from waste

12. Recognition on Environmental Pert ormancel229]

‘est over al performance Award or Nirogenous (Ammonia & Urs) plant -
+ National Energy Conservation Award - 2007 (Fest Prize in the
Fortliser Sector) From Ministry of Power

ational Energy Conservation Award 207 (Firs Prize the Fortis
Secon)" From Mani of Power

- Best Production Performance Award in Mirogenous Fertliser Pants
“From Fortliaer Association of India, Now

-Mational Award for Excellence in Energy Management - 2007 from Ct
Hyderabad

Year 2006-07
irom Publ Sector Today. Ayers

Recognition on Environmental Performance [ere]

“Best Chet Executive Gold Award to Unit Head of FFCO-Phulpur trom
Publi Sector Today, Hyderabad

+ Best Technical Paper Award by FAI onthe Paper “Implement
Energy Saving Project at IFFCO Phulpur Unit”

- Innovative Prog implementation Arard 200 In tr aa of Water
‘Management by Conederaon of indian industry (ih, GRE Myderabas.

Sonrabt God) Gran Business nto Gnennal

+ National Avar tor “Efiion Water Management 2005 by CI Soma
God) Green Business Centre Chema

fe Rae ina ld ar ret Paton Cov! ner
Year 2004.05
1 aonal Energy Conservation Award (awarded in De, 200) rom.

13. Thank You