Aonla

Located near the city of Bareilly, the IFFCO Aonla facility has always been a front runner when it comes to environmental concerns. It is known for adopting the most stringent measures to maintain ecological balance

PROGRESS OF THE PROJECTS UNDER IMPLEMENTATION

Energy Saving Project

Energy saving project has been successfully implemented in IFFCO Aonla Unit in addition to debottlenecking schemes during the annual turnarounds. In order to sustain the plant operations and to increase profitability, various schemes/ modifications have been incorporated in Aonla Complex. For Energy Saving Project, Basic engineering has been carried out by M/s Casale and Detailed engineering has been carried out by M/s PDIL. Following schemes have been implemented during turnaround of IFFCO Aonla-I Unit and Aonla-II Unit:

Ammonia-I

1.   Replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section.

2.   Replacement of HP boiler at downstream of High Temperature Shift Converter with new Steam Superheater.

3.   New Ammonia wash system in Synthesis Gas Compressor 2nd stage discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to re-circulator stage discharge.

4.   Replacement of existing Water Cooler using indirectly cooled DM water as cooling medium for cooling of synthesis gas with new heat exchanger using cooling water as cooling medium.

5.   Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency.

6.   Replacement of existing finned type combustion Air pre-heater with new plate type combustion Air pre-heater of higher surface area.

7.   Replacement of Existing BFW Pre-heater in synthesis loop with a new BFW Pre-heater with higher surface area.

Urea-I

1.   Replacement of existing CO2 Compressors by new higher efficiency compressors

2.   Installation of Ammonia Preheaters.

3.   Installation of Vapour Absorption Machine (VAM).

Ammonia-II

1.   Replacement of existing GV solution based CO2 removal section by aMDEA solution based CO2 removal section.

Urea-II

1.   Provision of Vapour Absorption Macine (VAM) and CO2 Cooler at the suction of CO2 Compressor for chilling of inlet CO2.

2.   Installation of Ammonia Preheaters.

Debottlenecking Schemes

SGPG

1.   Modification in Exhaust Duct Silencer in GTG-I and GTG-II.

2.   Advance seal uprate for GTG-I.

On Going Projects:

I)   Replacement of Vertical Synthesis Loop Boiler (E-1501) of Ammonia-I plant

The existing Vertical Synthesis Loop Boiler (E-1501) of Ammonia-I plant has been in service for last 20 years. The existing Boiler will be replaced with new Horizontal Synthesis Loop Boiler alongwith Steam drum in forthcoming turnaround as frequent problems of tube leakages are being faced in the Boiler due to aging. Erection and commissioning of new Horizontal Synthesis Loop Boiler is under progress.

II)   Replacement of HP Carbamate Condenser (11-E-5) of Urea-I Plant:

The Existing HP Carbamate Condenser (11-E-5) is in line since inception of Urea-I plant and has been in service for last 28 years. The existing Condenser is being replaced with new Condenser in forthcoming turnaround as frequent problems of tube leakages are being faced in the Condenser.

III)   Installation of Vibro Priller in Urea-I Plant:

At Aonla Unit, the Prilled Urea is being produced using conventional Prilling Bucket supplied by M/s Simco Prilling Equipments, Mumbai in Urea-I Plant. The temperature of Prills remains higher during summer season. To improve the product quality existing Rotating Bucket, used for urea prilling shall be replaced with new Vibro-prilling System. Order placed on M/s Chem Seals Engineering Pvt. Ltd.