Escolar Documentos
Profissional Documentos
Cultura Documentos
Milestone:
Highest daily dispatch of NPK/DAP/WSF fertiliser of 15927.600 MT on 12.10.2014
surpassing the previous best of 15391.800 MT on 28.10.2007.
IFFCO Kandla has achieved highest daily production of zinc sulphate monohydrate of
82.00 MT on 27.02.215, surpassing the previous best of 78.00 MT on 22.02.215.
v IFFCO Kandla has been awarded for Best Unit for excellence in suggestion scheme for the
year 2013-2014 at the inter-unit creativity meet held at FMDI in May-2014.
v IFFCO Kandla has received Best Suggestion Scheme Implementation Award from
INSSAN, New Delhi.
v IFFCO Kandla has received Gujarat Govt. Award of Shram Ratna and Shram Veer for
the year 2013-2014 for innovative implementation of Energy saving and productivity
improvement schemes.
v Shri Sukesh Nangal has won best suggestor award in INSSAN National seminar held at
Mumbai in Jan-15.
v IFFCO Kandla unit received the "Certificate of Honour" for Accident Free Working "More
than Three Million Manhours" and "Certificate of Appreciation" for Accident Free Working
"More than One Million Manhours" from Gujarat Safety Council in the year 2015.
v OHSAS 18001:2007 certification
IFFCO Kandla has received OHSAS 18001:2007 certification from M/s Bureau Veritas in
Nov-14. The development of system and documentation was done in-house for obtaining
the certification. The whole documentation/audit process has been done on paperless basis
and complete system has been uploaded on the server for reference of all employees.
IFFCO Kandla Township has received ISO 14001:2004 certification from M/s Bureau
Veritas. The development of system was done in-house and paperless documentation and
auditing was done for the certification.
Title
No.
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Separtion of scrubber liquor feed to GPR and inclined Better scrubbing operation.
venture in K-II plant.
12.
Installation of Vibration Monitoring system for fumes and Safety of fan and motor has
increased.
Fast and safe supply of zinc
ash to reactor. Environment
friendly.
For enhancing reliability by
Increase in Height of Zinc Sulphate Reactors by 1.5 m.
increasing capacity of reactor.
Installation of two additional filters with Mud washer tank To increase capacity and
improve production reliability
(MWT) in zinc sulphate plant
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16.
Installation of steep conveyors and FFS in water soluble Automation in water soluble
packaging and saving labour
NPK 18:18:18 plant.
cost.
17.
Effective Utilization of Heat energy gained from AHU of Rs. 9 crore (electrical energy
central AC to heat ammonia for process and return saving of Rs. 2.73 crore and
steam saving of Rs. 6.27
chilled water for AC.
crore)
Use of STP treated water and DM regeneration water for Saving of water consumption
of 200 MTPD equivalent to
Horticulture.
monetary saving Rs. 80
lakhs.
Renovation of old potash storage by enhancing the Simplification in reclaiming
system for material transfer to
capacity storage shed from 20000 MT to 30000 MT.
plant
and
also
saving
electrical and maint. Cost.
UV testing of PP bags through 8 nos. of QUV Bags Quality checking is
Accelerated Weathering tester of M/s Q-Lab Corporation ensured.
(U.S.A.).
Introduction of D Cut provision in water soluble pouches. Easy and safe handling of
pouches.
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Polishing screens have been successfully installed in all four steams of K-I plant. 95% of
the final product is between -4 mm to +2 mm range.
Kandla Unit has started producing 12:32:16:0.5 (Zn) from Nov-14. Zinc sulphate liquor
produced in zinc sulphate plant is transferred to zinc sulphate liquor storage tanks of
K-I and K-II plants. The zinc sulphate liquor is fed to PN/Scrubber Effluent tank of NPK
plants through automated feeding system. 51021 MT of zincated Gr-II has been
produced till Jan-15.
In house modification in Granulator Pipe Reactor (GPR) of E & F Trains has been
carried out by increasing the diameter from 3" to 6". Also, length of GPR is increased by
1 meter, resulting in improved mole ratio from 1.30 to 1.36. This has resulted in
improvement in reaction efficiency due to higher reaction time and product quality has
improved.
The slurry header has been elevated with the beam resulting in increased slurry
distribution area over the bed. This has resulted in better granulation.
Process stack of A and B trains has been replaced with new stack. The discharge of
fumes fan will go through cooler scrubber which will act as second stage scrubber and
improve ammonia efficiency (reduce ammonia by 10-20 ppm after second stage
scrubbing). Annual Saving is about Rs. 48 lakh.
IFFCO Kandla unit has procured 8 nos. of QUV Accelerated Weathering tester
from M/s Q-Lab Corporation (U.S.A) in which bags are exposed to UV rays for 144hours
and its tensile strength before testing and after testing is measured. This has helped in
ensuring bag quality.
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IFFCO Kandla Unit has entered into power purchase agreement through Indian
Energy
Exchange (IEX) and Power Exchange India Ltd. (PXIL) under provisions of short term open
access.
During 2014-15, Rs. 6.78 crore has been saved by Power trading.
Cumulative saving since inception i.e. Dec-13 is Rs. 9.92 crore.
3. Total 175 nos. of energy efficient HT and LT motors of IE3 class have been installed. Total
saving is approx. Rs. 1 crore. Payback period is 1.5 years.
4. One 60 HP & 100 HP VFD were installed at Primary air Blower & Quench air fan D train in
order to conserve energy by operating the fans at desired speed.
5. Installation of 600 nos. of 18 watt/15 watt LED fixtures in place of 36 watt
fixtures at IFFCO Kandla plant office buildings.
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conventional
3. All sulphuric Acid handling lines has been replaced with SS 316L from Mild steel for
enhancing safety in the Plant.
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4. Preneutraliser (PN) tank level indicator has been relocated outside of PN and proper
jacketing is also ensured for continuous & reliable readings of PN level.
5. In NPK-I, all trains have been retrofitted by replacing solid shaft PN agitator with hollow
shaft agitator for better gearbox life and cost reduction of maintenance and power.
6. The Reco make slurry pump has been put to use against the traditional wilfley slurry
pump. As the Reco pump has carbon-steel material with gland packing (which provides
more secure sealing), seal failure has been reduced significantly. Also the
maintenance cost of seals has reduced. Reco pumps cost less than wilfley pumps.
7. Ramp of ammonia sparger in K-II has been modified by suitable positioning of
proximity sensors.
8. CDR 480 fluid coupling has been replaced with FCU type fluid coupling in RMTE A &
B. This will reduce breakdown of elevator chains in case of excess load.
9. Raw material feed conveyor (Potash feeder) speed measurement instrument has been
replaced from Tachometer to Decoder(Electronic sensor), which has high pulse rate
(1025 per second). This increases the sensitivity and accuracy of measurement
10. Use of STP treated water and DM regeneration water for Horticulture
A piping network has been provided for usage of STP treated water and DM
regeneration water which are mixed and same is used for horticulture and general
cleaning purpose. It has helped in conserving 200 MTPD water.
Annual saving is Rs. 80 lakh.
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The capacity of Urea & Filler storage shed has been increased from 20000 MT to 30000
MT. Reclaiming system for material transfer to plant has been simplified with few
conveyors for material feeding.
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18. In bagging plant, Scrapper loader of two trains has been installed with torque regulated
mono spiral CRD. This has given advantage of continuous operation without need to
change over for plug in cable at various location, which was tedious operation with old
CRD. This will ensure safety and continuity of operation and also manual intervention
is avoided.
19. MOC for Scrapper Loader chain bush and bush link has been changed to EN 19 &
SAE 8620 which has more Mn content and has 0.2-0.4% Mo(earlier material was
20MnCr5 & 16MnCr5).
20. Sack grip of bagging machine of product handling plant has been modified with curve
shape in place of existing flat sack grip. This has increased sealing area between the
machine discharge chute and bag resulting in better gripping of bag.
21. Colour printing of strips on NPK/DAP bags has been implemented in place of weaving
colour strips for identification of bags.This has reduced lead time of bags procurement
and it will reduce the inventory of bags.
22. MS hand-railing in plant has been replaced with SS 304. This has increased reliability.
23. Mechanized Zinc ash feeding to all four reactors of Zinc Sulphate plant has been
implemented. This has resulted in uninterrupted feeding of Zinc ash, resulting in better
control, manual handling of zinc ash and avoiding spillages.
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25. Filter press outlet mother liquor line MOC (Material of Construction) has been changed
from MSRL(Mild Steel Rubber Lining) to SS . This has increased reliability of the pipe
line.
26. Agitator has been provided in Reaction Holding Tanks (RHT) of zinc sulphate plant.
This has improved thorough mixing of the slurry and prevention of settling of mud in
RHTs.
27. Two additional filters with Mud washer tank (MWT) are being installed to increase
capacity and improve production reliability.
28. Primary Mud washer tank agitator MOC has been changed from MSRL to SS 904L in
Zinc Sulphate Plant. This has increased reliability of the agitator as earlier agitator got
frequently damaged due to low pH condition.
29. Reaction Holding Tank (RHT) pump of Zinc sulphate plant has been replaced with
Warman make. This has reduced seal leakage of the pump and increased reliability of
operation.
30. Control logic has been developed for using FFS machine for product from either of
the two dryers of Zinc Sulphate plant. This has improved the operational flexibility for
packaging of product.
31. Slope of Urea Phosphate dryer has been reduced by lifting the trunion. This has
increased retention time and improved moisture content to 0.5% or less in urea
phosphate product resulting in free flowing of product.
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32. Agitator has been provided in Urea Phosphate Mother Liquor Tank which has ensured
continuous transfer of mother liquor recycled to K-II plant and reactor and prevents
settling of impurities at tank bottom and also reduced downtime while cleaning of tank.
The recovery of nutrient has also increased in urea phosphate plant.
33. Installation of steep conveyors and FFS in NPK 18:18:18 plant
Steep conveyor has been installed in NPK-18:18:18 (R & D plant) along with FFS(form,
fill and seal) machine. This has resulted in automation of water soluble product
packaging, reducing manual handling process, labour and handling losses and overall
housekeeping has improved.
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35. Minimum oil circuit breaker of 66 kV switchyard, installed since inception, was replaced
with Sulphur Hexa fluoride (SF6) circuit breaker which has high dielectric strength and
capacity.
36. 2000 kVA transformer has been installed by replacing old 1500 kVA transformer in
order to improve the operation reliability in A train.
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i) Civil Work: Foundation work for equipments is in progress for HAG A & B.
Dismantling of boiler roof is in progress. Piling and foundation work for CD duct is in
progress. Civil site shall be handed over for execution by 10th April-2015.
ii) Overall Project Schedule: Erection of equipments for HAGs in K-I shall be started
by second week of April-15. Commissioning of four direct HAG in K-I and coal fired
boiler is expected to be done by Aug. 15.
The annual savings on replacement of fuel oil with coal will be about Rs. 40 crore @ FO cost
of Rs. 39400/MT and coal cost of Rs. 4500/MT. Based on current market scenario, at FO
price of Rs. 27267/MT and coal price of Rs. 3800/MT, current annual saving on replacement
of fuel oil with coal of HAGs will be about Rs. 30 crore.
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Installation of approximately 400 nos. of 20 watt/18 watt/15 watt LED fixtures in place of 36
watt conventional fixtures at IFFCO Kandla plant office buildings. This has saved electrical
energy consumption equivalent to monetary saving of Rs. 9 lakh per annum
approximately.
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During 2014-15, total cargo of 9.66 lakh MT solid cargo has been handled at barge jetty.
The total cargo handled at Barge Jetty since inception i.e. Nov.-13 is 12.35 lakh MT.
A storage shed of 35000 MT capacity is under construction at Barge Jetty and will be ready
by August-2015. The storage will be used for storing the solid cargo received at jetty as per
requirement of IFFCO and third party.
c) Mangrove Plantation
IFFCO Kandla has carried out mangrove plantation in an area of 200 hectares at Sat Saida
Bet, Kandla. IFFCO has constructed a Captive barge jetty and committed to maintain the
balance eco system by plantation of Mangroves. Gujarat Institute of Desert Ecology
(GUIDE) was the consultant and has executed the plantation work.
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