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Modernization & Expansion


Capacity Augmentation & Energy Saving Project (ESP) at Vijaipur

In the FY 2012-13, Company has successfully commissioned Capacity Enhancement & Energy Savings projects along with installation of Carbon Dioxide Recovery plant at its Vijaipur – I & Vijaipur – II units. These projects involved investment of about ₹650 crore.

 

Pre-revamp capacity

Post-revamp capacity

Incremental production

Urea – I

2620 MTPD

3030 MTPD

410 MTPD

Urea – II

2620 MTPD

3231 MTPD

611 MTPD

Annual basis (Urea – I&Urea– II)

17.29 LMT

20.66 LMT

3.37 LMT

The total annual Urea capacity of the company after completion of these revamps of Vijaipur-I & II has been increased by 3.37 LMT to overall 35.68 LMT. 

In addition to the augmentation of installed Urea capacity, Company has also achieved reduction in specific energy consumption per MT of Urea produced

Conversion of Fuel Oil based plants at Panipat, Bathinda & Nangal to Natural gas feedstock

Company has implemented the following capital schemes for feedstock conversion from Fuel Oil to Natural gas at Panipat, Bathinda & Nangal involving a total investment of ₹ 4066 Crore.

 

Ammonia Plant Feedstock conversion project

Panipat & Bathinda

Nangal

LSTK Contractor

M/s Larsen & Toubro Mumbai

Consortium of M/s Tecnimont SpA, Italy & M/s Tecnimont ICB, Mumbai

Process Licensor

M/s Haldor Topsoe, Denmark

M/s Kellog Brown & Root, USA

Post revamp Ammonia capacity, MTPD

900 for each Panipat & Bathinda

950

Zero Date

29th January 2010

29th January 2010

Estimated Project Cost, Rs. Crore

2587 (Panipat & Bathinda combined)

1479

Commissioning

January 2013

April 2013

These feedstock conversion projects involved changeover of feedstock from FO/LSHS to environment friendly energy resource i.e. NG/RLNG. These projects not only resulted in better environment but also resulted in savings on account of subsidy payoffs by GOI.

Long Term RLNG (LTRLNG) agreements are in place to meet the gas requirements at Panipat, Bathinda & Nangal plants.  

Post Feedstock Changeover, all the three plants at Panipat, Bathinda & Nangal are operating at more than 100% daily rated capacity within the design daily energy

 

 

Implementation of Energy Reduction Schemes at NFL Panipat, Bathinda & Nangal Units

As per New Urea Policy-2015, NFL Panipat, Bathinda & Nangal Units have been placed under Group –III for which the target energy norms for the year 2018-19 would be 6.5 Gcal/MT of Urea. However vide letter no: 12012/1/2015-FPP dated 28th Mar' 2018, GoI has extended the energy norms for the units for a further period of two years i.e., till 31st Mar’ 2020 & then further to 30.09.2020 with a penalty of 2% for Yr: 2018-19, 5% for Yr: 2019-20 and 10% thereafter. Revised norms are now effective from 01.10.2020.

In view of the above, NFL is installing 1 (one) unit of Gas Turbo Generator (GTG) of 20 MW capacity  along-with 1 (one) unit of Heat Recovery Steam Generator (HRSG) at Panipat, Bathinda & Nangal Units.


The estimated capex of these projects is around INR 675 crores. The subject works has been awarded to M/s Thermax Limited, Pune on 01.02.2018. GTG-HRSG has been commissioned at Bathinda & Nangal in May’21 whereas at Panipat same is expected by Oct’21 subject to mobilization of foreign experts from M/s Siemens Sweden for commissioning.


Implementation of Energy Reduction Schemes at NFL Vijaipur-I & II

Under New Urea Policy (NUP)-2015, Vijaipur-I & Vijaipur-II units have been placed under Group-I with energy norm of 5.50 Gcal/MT. For reduction of energy at Vijaipur-I and Vijaipur-II, the estimated capital expenditure shall be around INR 234 crore.



Following four schemes are being implemented:

1.  Switch over of Process condensate stripping process from low pressure to MP Stripping Section in Ammonia Plant of Vijaipur-I.

2.  Revamp/retrofit of Synthesis Gas Compressor and Turbine in Ammonia Plant of Vijaipur-I.

3.  Switch over of Condensing steam turbine drives to motor drives of GV solution and Cooling Tower pumps in Ammonia Plant of Vijaipur-II.

4.  Installation of VAM for Gas Turbine in Captive Power Plant, to chill process air compressor suction air and 3rd stage suction of synthesis gas compressor to 15 deg C in Viajipur-II.



The executions of above schemes are in progress. Major energy saving scheme i (Revamp/retrofit of Synthesis Gas Compressor and Turbine in Ammonia Plant of Vijaipur-I) has been implemented in September/October 2020. With the the subject revamp NFL, Vijaipur-I has achieved energy saving of 0.15 Gcal/MT of urea. Rest of the schemes will also be implemented in 2021-22.

 

PURGE GAS RECOVERY PLANT AT VIJAIPUR – II

NFL has installed latest state of the art technology Purge Gas Recovery (PGR) unit at its Vijaipur-II plant. The membrane based PGR unit helps in recovery of Hydrogen from purge gases which in turns increase Ammonia production by 80 MTPD besides reducing energy consumption of Ammonia Plant. The PGR unit has been commissioned in 2016.

BENTONITE SULPHUR PLANT AT PANIPAT


Bentonite Sulphur is a sulphur fertilizer that can be used as a source of plant nutrient and / or as a soil amendment for correction of problem of alkali soils.  In order to meet the demand of Bentonite Sulphur to address the issue of Sulphur deficiency in soil and to improve the top & bottom line, NFL has set up Bentonite Sulphur plant at Panipat Unit with capacity of 25,000 MT per annum. Foundation stone of the project was unveiled by Hon’ble Cabinet Minister (C&F) on 8th September 2016. Bentonite Sulphur Plant at Panipat Unit has been commissioned on 20th December 2017.

JOINT VENTURES


Revival of Ramagundam unit of FCIL 


The Company through a Joint Venture Company namely Ramagundam Fertilizers & Chemicals Limited (RFCL) along with EIL, FCIL and other partners for revival of closed Urea plant with annual installed capacity of 12.71 LMT.  The cost of project was ` 6338.16 crore with equity participation of 26% each of NFL and EIL, 11% each of FCIL and State of Telangana, 14.3% of GAIL  and 11.7% of a Consortium led by M/s HTAS, Denmark. The project was commissioned on 22-03-2021. 

NFL has also been mandated to market 100% of Urea to be produced by RFCL.


 


NFL in joint venture with M/s Engineers India Limited (EIL) & Fertilizers Corporation of India Limited (FCIL) is undertaking the revival of Ramagundam unit of FCIL. The revival project is conceived with setting up of 2200 MTPD Ammonia plant and 3850 MTPD Urea plant at the existing Fertilizer complex of Ramagundam unit of FCIL.

The equity participation in the joint venture is 26% each by NFL & EIL, 11% by FCIL and 11% by State Government of Telangana.

Project is being implemented through EPCM mode and M/s EIL is the EPCM Contractor for the project. Zero date of the revival project was declared as 25th Sept 2015 and is targeted to be completed by end of December 2018. The project is in progress.

NFL is also providing Manpower Management Consultancy (MMC) services to RFCL. As per agreement, NFL is undertaking recruitment and training of all such personnel mutually agreed by RFCL and NFL. In addition to fresh recruitment NFL is also providing experienced manpower on secondment basis to RFCL