Reduction in Steam Consumption Through Revamping of Ammonia Plant-Iffco Plants

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM Executive Board
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CLEAN DEVELOPMENT MECHANISM

PROJECT DESIGN DOCUMENT FORM (CDM-PDD)
Version 02 - in effect as of: 1 July 2004)
CONTENTS
A.
General description of project activity
B.
Application of a baseline methodology
C.
Duration of the project activity / Crediting period
D.
Application of a monitoring methodology and plan
E.
Estimation of GHG emissions by sources
F.
Environmental impacts
G.
Stakeholders comments
Annex
Annex 1: Contact information on participants in the project activity

Annex 2: Information regarding public funding
Annex 3: Baseline information
Annex 4: Monitoring plan
Appendix
Appendix 1: Other Parameters to be measured under monitoring plan
Appendix 2: Abbreviations
Appendix 3: References

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SECTION A. General description of project activity

A.1
Title of the project activity:
Reduction in Steam Consumption through Revamping of Ammonia Plant of Indian Farmers

Fertiliser Cooperative Ltd (IFFCO) plants
Version 01
Date: 17/ 01/2006
A.2.
Description of the project activity:
Purpose:
The purpose of project is to upgrade the existing plant technology with energy efficient technology
and to reduce the Specific Steam Consumption Ratio (SSCR) of Ammonia plant of Urea fertilizer
units. The project activity is implemented in 3 Urea fertilizer units of IFFCO at locations -Kalol,
Phulpur, Aonla (hereafter referred to as IFFCO plants). There are various projects in the plants fall in
the category of new technology alternatives, retrofits, new design and waste heat recovery. Since the
energy efficiency projects are being implemented in various sections of Ammonia plants, the
performance of one project is linked to other project. Therefore the technology supplier and
consultant recommend that these projects should be implemented in all plants of IFFCO in an
integrated manner to achieve maximum energy savings. These projects essentially target the reduction
of steam consumption in plant, which would in turn lead to lower specific steam consumption of plant
and hence would result in reduction in fuel fired (coal, natural gas , naphtha , Low Sulphur Heavy
Stock (LSHS)) in the boilers. This will reduce CO2 emissions in each plant. The project has large
replication potential and can be followed by other fertilizer plants for further substantial reduction in
CO2.
Projects Contribution to Sustainable Development
The project activity to be implemented in IFFCO plants, contributes positively to the sustainable
development of India in following ways:
The project activity uses energy efficient technology in ammonia plant and reduces fossil fuel
consumption resulting in benign environment (CO2 emission reduction) & conserving nonrenewable resources. Thus the project aids in environmental well being.
Project activity would marginally increase employment opportunity for semi-skilled, skilled labour
and professionals in the region during construction phase. Therefore contributing social well being
aspects. The project will create a business opportunity for local stakeholders such as suppliers,
contractors, bankers etc. contributing to economic well-being aspects.
The project positively contributes towards the reduction in demand for Indias carbon intensive
energy resources as well as adoption of energy efficient technology and resource conservation.
Indian economy is highly dependent on coal / natural gas as fuel to generate energy and for
production processes. The project activity reduces fossil fuel consumption for boilers and saving on
non-renewable coal / natural gas / naptha/ LSHS, positively contributes towards the reduction in
use of these finite resources and therefore making it available for important processes.
The project will help the company to maintain its status of being one of the most progressive

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companies of India due to adoption of latest technology and its efforts for sustainability. Adoption of
higher technology helps in capacity building of employees by better exposures.
This project activity is located in a rural setting and contributes to the environmental and social issues
locally and globally through:
Reduces consumption of fossil fuels by adopting energy efficient technologies
Conserving Coal and LSHS in Phulpur, Natural gas in Aonla and Naphtha and Natural Gas in
Kalol plants, thereby reducing the pace of depletion of natural resources.
Making coal / natural gas / naptha/ LSHS available for other important economic applications
Reducing Green House Gases (Carbon Dioxide)
Contributing to marginal increase in the local employment in the area of skilled / unskilled jobs
during construction phase of the project activity & ameliorating economic status of the rural
community
Aids in capacity building of higher technology for employees
Providing a highly replicable, efficient model to other fertilizer plants in the country
A.3.
Project participants:
Name of Party involved Private and/or public entity Kindly indicate if the Party
((host) indicates a host Party) (ies) project participants(as involved wishes to be
applicable)
considered as
project
participant (Yes/No)
India (Host)
IFFCO ( Private entity )
No
Japan
Japan Carbon Finance, Ltd. No
(Private entity )
A.4.
Technical description of the project activity:

A.4.1. Location of the project activity:
>>
A.4.1.1.
Host Party(ies):
India
A.4.1.2.
i) Site 1- Gujarat
ii) Site 2-Uttar Pradesh
iii) Site 3-Uttar Pradesh
Region/State/Province etc.:
A.4.1.3.
i) Site 1- Kalol, City-Gandhinagar
ii) Site 2- Phulpur City-Allahabad
iii) Site 3- Aonla City-Bareilly
City/Town/Community etc:

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A.4.1.4.Detail of physical location, including information allowing the unique identification of

this project activity (maximum one page):
IFFCO proposes to implement energy efficiency measures (Project activity) in Kalol, Phulpur &
Aonla plants.
Kalol Plant (Site 1)
The Kalol Plant started its operation in the year 1974 and has a total installed capacity of 0.363
MTPA of ammonia production and 0.545 MTPA of urea production. The Plant is located on
Ahmedabad-Mehsana state highway and is 25 km away from Ahmedabad.
Phulpur Plant (Site 2)
The Phulpur Plant is also divided into two units viz. Unit I and Unit II. The Plant started its urea
production from the year 1981 onwards and has an installed capacity of 0.824 MTPA of ammonia
production and 1.416 MTPA of urea production. The Plant is located on Allahabad-Gorakhpur road
and is 30 km away from Allahabad. The Plant is spread in an area of 321 acres.
Aonla Plant (Site 3)
The Aonla Plant is divided into two units viz. Unit I and Unit II. The Plant has total installed capacity
of 1.003 Million Tonnes Per Annum (MTPA) of ammonia production and 1.730 MTPA of urea
production. The Plant is located on Bareilly-Aonla highway and is 25 km from Bareilly. The Plant is
spread over an area of 260 hectares and nearest railway station is 10 km from the site.
A.4.2. Category(ies) of project activity:
As per the scope of the project activity enlisted in the list of sectoral scopes and approved baseline
and monitoring methodologies (version 02/28.11.03), project activity can principally be categorized
in Scope Number 3, Sectoral Scope Energy Demand.
A.4.3. Technology to be employed by the project activity:
The technology employed for revamping ammonia plant with energy efficient system is developed by
IFFCO together with M/s Haldor Topsoe (HTAS) Denmark , who is the leader in technology for
ammonia plant. M/s HTAS is the leading process licensor having designed more than fifty percent of
the new ammonia capacity built since 1990 and also M/s HTAS is well conversant with IFFCO
ammonia plants and have been associated with various revamps/retrofits carried out in the past.
M/s HTAS is primarily responsible for basic engineering and procurement assistance, inspection,
expediting services, supervision and assistance during erection and commissioning of critical items.
M/s Projects & Development India Ltd. (PDIL)-is the Indian Engineering Consultant for the project
activity. M/s PDIL has been involved in the design, engineering and construction of almost all the
major grass-root fertilizer projects in India. Also M/s PDIL has successful proven record with the
technology supplied by M/s HTAS.
The project concept for energy efficiency is developed by IFFCO is very innovative and crystallized
after technical analysis of process profile by spending good man-hours, frequent trials, capacity
building & meticulous Research & Development (R&D). The technology is pioneering and one of its
kind for which IFFCO personnel have made many visits to European countries to gain experience in
the technology.

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For the ease of understanding the following Table 1 is prepared to depict the name of each project and
corresponding locations, where these are implemented.

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Table 1 - Details of energy efficiency schemes

Energy efficiency schemes1
Sr.
No
Aonla I
Aonla
II
PhulpurI
PhulpurII
Kalol
New Low Temperature (LT) shift guard, Boiler Feed Water (BFW) preheater
Installation of S-50 radial flow Synthesis Converter and High Pressure (HP) / Medium Pressure (MP) Boiler
Installation of Make-up Gas Chiller
Synthesis Gas Compressor LP (Low Pressure) & HP case Internal Replacement
Drying of Make-up Gas and Synthesis Loop Re-piping
Improvement in outlet systems for High Temperature (HT) / Low Temperature (LT )Shift Converters
Complete revamping of CO2 removal system to a modern two-stage GV process
Installation of additional Process Condensate (PC) / PC Exchanger at Aonla-II
Modification of HT Steam Super Heat Coil in Waste Heat Section of Primary Reformer at Aonla-II
10
New Combustion Air Module in Waste Heat Section of Primary Reformer
11
Closing steam balance for Aonla unit I
12
Closing steam balance for Aonla unit II
13
Complete revamping of CO2 removal system to a modern 2-stage GV process at Phulpur - I
14
Revamping of CO2 removal system to 2-stage a-MDEA process at Kalol
15
Revamp of Induced Draft (ID) Fan Drive Turbine at Kalol
16
Closing steam balance for Kalol Plant
in Ammonia-II of Aonla
4
The location of the projects (in each section of Ammonia plant) is depicted separately in project boundary (Refer section B.4 in this PDD).

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The technical description of energy efficiency schemes implemented in different units of IFFCO
is given below. The projects are descried below in brief, due to their complex nature and
detailed flow charts of schemes are not given as annexure to this PDD for the confidentiality
reasons. However, the flowcharts along with all technical details of schemes would be made
available to Designated Operation Entity during Validation and Verification phases of CDM
project activity.
1. New Low Temperature (LT) shift guard, Boiler Feed Water (BFW) preheater
A new LT shift guard would be installed before LT shift converter in order to reduce the
Carbon mono-Oxide (CO) slippage from the section without increasing the pressure drop
across the section. On an average, the CO slip after LT shift converter, once the LT shift guard
is installed would be lower i.e. 0.10-0.15% as against 0.25-0.30% (the present scenario)
without LT shift guard. Lower CO slip would in turn result in additional ammonia production
due to reduction in the consumption of Hydrogen in Methanator for converting all carbon
oxides into inert Methane before entering Ammonia Synthesis loop. The Ammonia production
would be kept constant; in turn the feed (Naphtha, Natural Gas) would be reduced. The
reduction in feed results in subsequent reduction in steam consumption.
Also a new BFW preheater would be installed at down stream of the new LT shift guard in
order to control the inlet temperature to the LT shift converter. The new BFW preheater would
improve the heat gain in BFW for the production of High Pressure (HP) steam and temperature
control in the LT shift section. With the installation of LT shift guard, it would be possible to
short load the existing LT shift converter and reduce the pressure drop across the converter.
This scheme is to be implemented in Aonla unit I & II , Phulpur unit I & II, Kalol Plant.
2. Installation of S-50 radial flow Synthesis Converter and High Pressure (HP) / Medium
Pressure (MP) Boiler
A new S-50 converter would be installed at the down stream of existing Ammonia Synthesis
Converter. The new converter would increase the ammonia conversion per pass thereby
reducing the amount of recycled gas entering the synthesis compressor and reducing the load on
compressor. The reduced load on the synthesis compressor leads to lesser steam consumption
for compressor operations.
In Aonla-I, Aonla-II and Phulpur-II, a new HP waste heat boiler would be installed at the
downstream of existing converter for utilisation of reaction heat generated in the existing
converter. The existing HP waste heat boiler would utilize the heat of reaction from the new S50 converter.
In Phulpur-I and Kalol , a new MP waste heat boiler would be installed at the downstream of
S-50 converter for utilization of the reaction heat generated in the S-50 converter.
3. Installation of Make-up Gas Chiller
In the existing system make up gas is cooled to 35 0C before being compressed in the synthesis
gas compressor. It is proposed to install a make up gas chiller at the down stream of final gas
cooler to cool the make up gas to 6-8 0C. This would increase the volumetric efficiency due to
lower inlet temperature of make-up gas leading to reduction in steam consumption in the
synthesis gas compressor for the same work output.
This scheme is to be implemented in Aonla unit I & II , Phulpur unit I & II .
4. Synthesis Gas Compressor LP (Low Pressure) & HP case Internal Replacement

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The present Compressor is of mid 1970 design and the operating conditions has changed since
then. The new internals of LP & HP case shall be designed to meet the new operating
conditions with better compression efficiency based on modern 3-D design. Hence the
combined efforts of matching of the system & operating conditions, improvement in efficiency
leads to lesser steam consumption in the synthesis compressor. This scheme is to be
implemented in Kalol Plant and Phulpur Unit - I
5. Drying of Make-up Gas and Synthesis Loop Re-piping
The Ammonia synthesis catalyst gets poisoned if oxides of carbon or water vapour are present
in the converter inlet gas. Currently, to remove these oxides, the fresh makeup gas is mixed
with recycle gas containing ammonia. The recycle and makeup gas mixture is then cooled and
chilled. By means of this, process oxides present in the makeup gas get dissolved in the
ammonia and separated out. Thus making the converter inlet gas free from oxides and is fed to
the synthesis converter. The present system has a disadvantage because the ammonia formed in
converter is compressed in synthesis compressor and chilling of complete make up gas is done
for which relatively higher power is consumed.
Installation of ammonia wash unit between LP & HP case of Synthesis Compressor and
synthesis loop repiping would reduce the power consumption in synthesis and refrigeration
compressor as the ammonia would be condensed at the Synthesis Converter outlet and make up
gas would be fed directly to the Synthesis Converter. The reduction in power consumption of
synthesis compressor leads to steam consumption reduction.
This scheme is to be implemented in Phulpur unit I & Kalol Plant.
6. Improvement in outlet systems for High Temperature (HT) / Low Temperature
(LT )Shift Converters
The present outlet system of HT / LT shift Converters are having Elephant Stool, which would
be modified with the improved design of HTAS. With this modification, it is expected that the
pressure drop in the reactor would reduce. The lower pressure drop would result in higher
suction pressure for the synthesis gas compressor and there would be reduction in power
consumption in the compressor leading to steam consumption reduction.
This scheme is to be implemented in LT shift converters and Methanator of Phulpur unit I and
for Kalol plant the scheme is to be implemented both in LT & HT shift converters at next
opportunity of catalyst replacement.
7. Complete revamping of CO2 removal system to a modern two-stage GV process at
Aonla-I
The present CO2 removal system is designed for one stage absorption process. It is proposed to
modify the single stage GV process to two-stage GV process for reduction of energy
consumption. The main features of two-stage GV process are the lean and semi lean
absorption, high pressure and low-pressure stripping. A new LP stripper would be installed
where the solution would be regenerated by flashing instead of reboiling/steam heating , thus
reducing the steam consumption for regeneration of the solution in the stripper. Also with the
above modification a better absorption is obtained and more pure CO2 product would be
available with lower regeneration energy.
8. Installation of additional Process Condensate (PC) / PC Exchanger at Aonla-II
During the cooling of process gas, condensate is separated. This process condensate contains
dissolved gases like ammonia and carbon dioxide. These gases are removed from the process
condensate by stripping the condensate in the MP Process Condensate Stripping unit by MP

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steam. The hot condensate after stripping is cooled in two exchangers and sent to
Demineralized water plant.
Presently the outlet temperature of process condensate from condensate feed/effluent exchanger
going to Stripping remains around 2050C as against the design temperature of 2280C.In view of
above, it is proposed to provide an additional exchanger to heat the process condensate to
2280C thus extracting the maximum heat from the stripped process condensate coming from
stripper.
9. Modification of HT Steam Super Heat Coil in Waste Heat Section of Primary Reformer
at Aonla-II
The HP steam super heat coils are designed to give HP steam at temperature of 525 0C.
However presently the temperature of HP steam at the exit of super heater coils remains around
491 0C. In view of the above, it is proposed to modify the HP Steam Super Heat Coil to raise
the temperature of the HP steam close to design value and thereby have more efficient
operation with less steam consumption.
10. New Combustion Air Module in Waste Heat Section of Primary Reformer
Ammonia-II of Aonla
in
It is proposed to provide additional air preheating modules in the waste heat section to recover
more heat duty from the flue gases. The existing Combustion Air Pre-heater is having a dummy
section and therefore can accommodate additional modules. Thus by providing additional
modules in dummy section of existing Combustion Air Pre-heater the heat transfer surface area
will increase and there will be reduction in flue gas temperature from 1530 C to around 1380 C.
The additional heat transfer in combustion air pre-heater will result in lower specific energy
consumption owing to less fuel gas consumption.
11. Closing steam balance for Aonla unit I
With the implementation of energy saving schemes, there would be reduction in LP steam
consumption and LP steam will be surplus. Presently most of the LP steam is available through
back pressure turbines.
It is proposed to change the back pressure turbines (GV Booster pump turbine and Ammonia-I
Cooling water pump turbine) to motors in order to reduce the LP steam availability from back
pressure turbines. This will help in utilizing the LP Steam available from implementation of
energy saving schemes like complete revamping of CO2 system to 2-stage GV system.
12. Closing steam balance for Aonla unit II
With the implementation of energy saving schemes, the following turbines will be changed to
motor to close the steam balance
One Turbine for Ammonia-II Cooling water pump
One Turbine for Urea-II cooling water pump
13. Complete revamping of CO2 removal system to a modern 2-stage GV process at
Phulpur - I
The present CO2 removal system is based on Low Heat Benfield system. It is proposed to
modify the same to a 2-stage GV process for reduction of energy consumption.
The main features of 2-stage GV process are the lean and semilean absorption, high pressure
and low-pressure stripping in two stripping towers, which are presently operating in parallel at

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same operating pressure. The LP stripper would be installed where the solution would be
regenerated by flashing instead of reboiling/steam heating, thus reducing the steam
consumption for regeneration of the solution in the stripper. This would lower the energy
consumption for regeneration of the solution in the strippers considerably.
A new CO2 blower shall be installed at LP stripper outlet to match the HP stripper outlet CO2
pressure for CO2supply to urea plant.
With the above modification, a better absorption would be obtained and more pure CO2
product would be available with lower regeneration energy.
14. Revamping of CO2 removal system to 2-stage a-MDEA process at Kalol
A large energy saving can be obtained by changing the present a-MDEA based system from
one stage CO2 removal system to the a-MDEA two stage system. The system includes a twostage absorption, low pressure and high pressure flash and stripping. The introduction of LP
and HP flash vessels reduces the energy for regeneration of the solution and improves the
quality of the CO2 product. In flash vessels where the solution would be regenerated by flashing
instead of reboiling / steam heating, thus reducing the steam consumption for regeneration of
the solution in the stripper.
It is foreseen to install a complete new absorber having both lean and semilean absorption.
15. Revamp of Induced Draft (ID) Fan Drive Turbine at Kalol
For closing and optimizing the steam balance, existing back pressure ID fan turbine is
proposed to be modified to condensing one with a provision of atmospheric venting during
plant startup. The conversion of backpressure turbine to condensing type would result in lesser
steam consumption for the same work output.
16. Closing steam balance for Kalol Plant
With the implementation of energy saving schemes, there would be reduction in HP steam
consumption and LP steam consumption and LP steam would become surplus. HP steam
generation can be reduced at the source of generation i.e. in Ammonia Plant itself or from Offsite Boilers. However, LP steam generation available through back pressure turbines which are
used for driving pumps etc. shall remain.
Any modification required to utilize the LP steam available from implementation of energy
saving schemes like complete revamping of CO2 system would be carried out. Improved BFW
heating shall also be done so as to optimise the complete steam system.
A.4.4. Brief explanation of how the anthropogenic emissions of anthropogenic greenhouse
gas (GHGs) by sources are to be reduced by the proposed CDM project activity,
including why the emission reductions would not occur in the absence of the proposed
project activity, taking into account national and/or sectoral policies and circumstances:
The project adopts energy efficient technology measures in ammonia plant and reduces SSCR
(Specific Steam Consumption Ratio) of ammonia plant. The reduction of SSCR would lead to
reduction in fossil fuels consumption in the boilers, which would in turn reduce CO2 emissions
of IFFCO plants. In absence of the project activity, IFFCO plants would continue to have high
SSCR leading to higher GHG emissions. By implementing the project activity, IFFCO
proposes to reduce the SSCRs levels by following manner:
Sl No
IFFCO plant
SSCR
Ton of steam consumed /
Ton of ammonia produced
Annual
CO2
Emission reductions
(tons/ annum)

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Baseline
Project
Aonla- I
4.29
3.44
Aonla-II
4.29
3.86
Phulpur-I
6.32
5.54
Phulpur-II
4.57
4.54
Kalol
5.64
4.33
75,138
76, 801
110,772
Perceived technical and financial risks to fertiliser industry in adopting innovative energy
saving technologies are very high in India because of complex fertilizer technology and huge
investment required in modifications. Moreover, fear that a new technology may not work
inhibits industry from adopting new energy saving technologies. Despite these inhibiting
factors, IFFCO took the initiative in adopting this energy efficient technology.
The Ministry of Fertilizers, Ministry of Power (MoP) and Ministry of Non-conventional
Energy Sources (MNES) in India encourage energy conservation; they do not require Fertilizer
industries to reduce their specific energy consumption to a prescribed standard. Nor do the
Fertilizer association of India have imposed any directives for improving energy efficiency. The
project proponent has implemented the project activity over and above the national or sectoral
requirement and the GHG reductions achieved by the project activity are additional to those
directed by the governmental policies and regulations.
The project proponent is implementing the project, as there is an opportunity to sell the CO2
emission reductions and gets carbon revenue through Clean Development Mechanism (CDM)
stream for the project activity, which would ameliorate the financial attractiveness of the
project. The additionality criteria of the project activity are dealt with in details in section B.
A.4.4.1.
period:
Estimated amount of emission reductions over the chosen crediting
Years
Annual estimation of emission

reductions in tonnes of
CO2 e
2006-2007
2007-2008
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
2014-2015
2015-2016
Total estimated reductions
(tonnes of CO2 e)
262,711
262,711
262,711
262,711
262,711
262,711
262,711
262,711
262,711
262,711
2,627,110

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Total number of crediting years

Annual average over the
crediting period of estimated
reductions (tonnes of CO2 e)
Page 12
10
262,711
A.4.5. Public funding of the project activity:

No public funding from parties included in Annex I is available to the project

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SECTION B. Application of a baseline methodology

B.1.
Title and reference of the approved baseline methodology applied to the project
activity:
>>
Title: Baseline methodology for steam optimization systems
Reference: AM0018, UNFCCC website
B.1.1. Justification of the choice of the methodology and why it is applicable to the
project activity:
>>
As per the Kyoto Protocol (KP) baseline should be in accordance with the additionality criteria
of article 12, paragraph 5(c), which states that the project activity must reduce emissions that
are additional to any that, would occur in the absence of the certified project activity.
As per the paragraph 48 of decision-17/CP 7 of Modalities and Procedures for CDM as
defined in article 12 of KP, project participants shall select baseline methodology for a project
activity from the following three alternative approaches mentioned, the one deemed most
appropriate for the project activity, taking into account any guidance by executive board and
justify the appropriateness of their choice.
a)
Existing actual or historical emissions, as applicable; or
b)
Emissions from a technology that represents an economically attractive course of
action, taking into barriers to investment; or
c)
The average emissions of similar project activities undertaken in the previous five
years, in similar social, economic, environmental and technological circumstances, and
whose performance is among the top 20 percent of their category.
Out of above options, Option-(a) is most suitable choice for selection of baseline methodology.
This is because the new CDM project scenario can be directly compared with emission
scenario of the old processes (Please refer approved methodology AM0018 for approach 48-a)
in similar case).
Justification for why is the approach 48-a applicable to project activity.
Both the scenarios before and after the implementation of the project activity are as follows:
Scenario 1
Non-project option: In the business-as-usual scenario, IFFCO continues to emit carbon dioxide
by maintaining the earlier technology status and not carrying out energy efficiency measures.
This will lead to additional steam generation at boilers in three plants of IFFCO i.e., Kalol,
Phulpur and Aonla
Scenario 2
CDM Project option: In the project activity scenario, the energy efficiency projects (described
in section A.2 of this PDD) are implemented in IFFCO plants at Kalol, Phulpur and Aonla.
This will result the reduction of steam consumption and thereby reduction in consumption of
Natural Gas/ LNG/Naphtha / Fuel Oil / LSHS / Coal in boilers of these plants.

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There is direct comparison of emissions that can be made available with IFFCO plants after
commissioning of projects. This will be based on recorded data.
As per the Kyoto Protocol (KP) baseline should be in accordance with the additionality criteria
of article 12, paragraph 5(c), which states that the project activity must reduce emissions that
are additional to any that would occur in the absence of the certified project activity.
Moreover, the project activity is of the first type in India, therefore any other project activity is
not available for comparison. On the basis of this, it can be justified that most suitable baseline
methodology for this application would be based on Existing actual or historical emissions.
Justification for why is the approved baseline methodology AM-0018 is applicable to
project activity.
Following are the various points, which justify the application of AM-0018 for project activity.
1. The methodology is applicable for 48-(a) approach only.
2. The applicability conditions of methodology for production processes with homogeneous
and relatively constant output and continuous monitoring of steam outputs. These
conditions are perfectly applicable to proposed CDM project activity of IFFCO.
IFFCO plants (Aonla-I, Aonla-II, Phulpur-I, Phulpur-II and Kalol) are constant output Urea
production plants. The Ammonia production is these plants is relatively constant. In fact,
Fertilizer Industry in India can produce the quantity of Fertilizers that is allotted by
Government of India, based on capacity. This ensures the constant nature of output.
B.2.
Description of how the methodology is applied in the context of the project
activity:
>>
The methodology uses four-point approach. In this approach, actual data shall be collected for
direct comparison of baseline and project specific steam consumption and thus estimating
reduction in CO2 emissions.
1. Baseline Fixation: Baseline will be fixed by calculating specific steam consumption (Tonne
of steam/ Tonne of Ammonia Produced) in Ammonia plant from the data documented in the
record sheets. The value of Ammonia Produced used is the average representative value
of normal range2 of output3 (Ammonia Production) measured in a day. The steam
consumption values corresponding to Ammonia production values selected above needs to
be identified and the average representative value required to be calculated (refer section-D
for details).
2. Estimation of Specific Steam Consumption After Project Implementation: In the project
scenario, specific steam consumption (Tonne of steam/ Tonne of Ammonia Produced) in
Ammonia plant shall be calculated based on the ratio of average
representative values of
steam consumed and Ammonia Produced. The method for estimating representative data of
2
Normal range is the range in which the plant output takes place most of the time. This is based on
the rated plant capacity and internally acceptable deviations ( 5% of rated plant capacity).
3
Output here is defined as the main outcome of process/system for which process/system is designed
and where the steam generated by using fossil fuel is utilized. Therefore, in case of IFFCO, output of
the process is the quantity Ammonia Produced per hour (in kg or Tons) and accounted through the
monitoring system.

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output and steam consumption is same as in case of baseline scenario (refer section D for
details).
3. Estimation of Emission Reduction: Total reduction in steam consumption in project
scenario shall be calculated by multiplying the reduction in specific steam consumption by
total Ammonia Produced in project scenario. The reduction in emission shall be calculated
by estimating the fuel required for the generation of additional steam in the boiler (or Heat
Recovery Steam Generator (HRSG) or Heat Recovery Unit (HRU) or Auxiliary Boiler
depending on plant). The efficiency of boiler (in case of Phulpur-I and Phulpur-II plant) and
net enthalpy of steam is monitored to estimate the saving in fuel. In case of Aonla-I and
Aonla- II plant, the fuel is saved in HRSG and HRUs of Gas turbine, where the fuel is used
to add superheat to the gases going to steam generators. The manufacturers table is used to
derive the relationship between power generation in generator, steam generated and fuel
consumed. In case of Kalol plant the fuel is saved in Auxiliary boiler, which is producing
the steam by the combination of process waste heat streams and fuel. Therefore efficiency
of auxiliary boiler of Kalol and HRSG, HRU of Aonla I & II would is estimated by
simple heat balance method.
B.3.
Description of how the anthropogenic emissions of GHG by sources are reduced
below those that would have occurred in the absence of the registered CDM project
activity:
>>
As per the decision 17/cp.7 Para 43, a CDM project activity is additional if anthropogenic
emissions of greenhouse gases by sources are reduced below those that would have occurred in
the absence of the registered CDM project activity. The proposed project activity is energy
efficiency improvement activity and results into net reduction in CO2 emissions of facility.
Following steps of additionality test are followed with respect to IFFCO steam optimisation
projects for demonstration of additionality
Step 0. Preliminary Screening based on the starting date of the project activity
IFFCO wishes to have the crediting period starting prior to the registration of their project
activity. IFFCO is therefore required to
(a) Provide evidence that the starting date of the CDM project activity falls between 1 January
2000 and the date of the registration of a first CDM project activity, bearing in mind that only
CDM project activities submitted for registration before 31 December 2005 may claim for a
crediting period starting before the date of registration; and
(b) Provide evidence that the incentive from the CDM was seriously considered in the decision
to proceed with the project activity.
IFFCOs management took the decision of taking up the project activity, considering the
incentive from the CDM. The incentive provided by CDM was critically considered before
decision making by the project Proponent. Following are the documents available that can be
shown as evidence to support that CDM was seriously considered in the decision to proceed
with the project activity:
The officially approved internal notes of IFFCO on Revamping of ammonia plant
project and considering CDM revenues generated by the revamping project.
Communication of IFFCO with CDM consultants and various other parties for
availing funds for these schemes.

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Step 1. Identification of alternatives to the project activity consistent with current laws
and regulations
Define realistic and credible alternative scenarios to the CDM project activity that can be (part
of) the baseline scenario through the following sub-steps:
Sub-step 1a. Define alternatives to the project activity
Sub-step 1b. Enforcement with applicable laws and regulations:
Alternative 1
Continuation of current practice: In the business-as-usual scenario, IFFCO continues to emit
higher quantity of carbon dioxide by maintaining the earlier technology status and not carrying
out energy efficiency measures.
Alternative 2
Implementation of the CDM project activity Reduction in steam consumption through
revamping of ammonia plant. In the project activity scenario, the energy efficiency projects
(described in section A.2 of this PDD) are implemented in IFFCO plants at Kalol, Phulpur and
Aonla. This will result the reduction of steam consumption and thereby reduction in
consumption of Natural Gas/ LNG/Naphtha / Fuel Oil / LSHS / Coal in boilers of these plants.
All these Alternatives are in compliance with all applicable legal and regulatory requirements.
There is no legal binding on IFFCO to implement the CDM project activity. In India it is not
mandatory to implement energy efficiency projects in fertilizer sector. There is no policy, which
promotes implementation of energy efficiency projects in fertilizer sector and would be
adequate to stimulate implementation of the project activity in absence of CDM
IFFCOs Alternative 1 to project activity (continuing the current practice) does not face any
Investment and Technological barriers. Therefore the barriers to IFFCOs project activity
detailed below do not exist for Alternative 1 so as to prevent its wide spread implementation.
Therefore Alternative:1 Continuation of the current practice is found to be the most appropriate
and conservative baseline scenario.
Step 2. Investment Analysis
If this step is used, determine whether the proposed project activity is the economically or
financially less attractive than other alternatives without the revenue from sale of CERs. To
conduct the investment analysis, use the following sub-steps:
Sub-step 2a. Determine appropriate analysis method
Option-III of Benchmark Analysis is chosen for demonstration of additionality.
Sub-step 2b Option III. Apply benchmark analysis
The Opportunity Cost of Capital (Based on expected rate of returns on equity and cost of debt
and the debt to equity ratio) for IFFCO is 14.50%. If the project is below this rate of return, the
project can not be taken up for implementation by IFFCO.
Sub-step 2c- Calculation of suitable financial indicator

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The Internal Rate of Return (IRR) is calculated for entire investment in projects (in five
plants). This is given below.
Overall IRR of all plants
IRR (%) without CDM fund

13.25
IRR (%) with CDM funds

14.69
Note: As IFFCO is implementing steam saving projects simultaneously for all five plants, the
consultants and technology suppliers will get order for bulk volume of supply. This will help in
achieving high price discounts in the supplies being made to these plants. This leads to constraints in
terms of IRR analysis of each plant separately. The analysis of IRR can only be done collectively for
all plants.
Following are the assumptions while conducting IRR analysis of the project.
1. Escalation in fuel price (Natural Gas 5%, Naphtha 17%, LSHS 10%, LNG 10%, Coal
6% and GEB electricity 5%) every year.
2. Maintenance cost is 3% of project cost with escalation of 5% every year.
3. CER Price of 5 Euro.
The Opportunity Cost of Capital for IFFCO is 14.50%, which is calculated based on Return
on Debt and Return on Equity in the projects taken by IFFCO.
Opportunity Cost of Capital (%)
= {Expected Return of debt (%) x debt / (debt+equity)} + {Expected Return on equity x equity
/(debt +equity)}
Expected return on equity IFFCO is estimated from last three years data of return achieved by
IFFCO on various projects, which is 17%. The expected return of bank on debt given to
IFFCO is 7.0%. The debt for project is expected to be 25% and equity is planned to be 75%.
The IRR Calculations can be referred from Enclosure-1. The overall IRR calculations of all
plants show that the IRR of the project (13.25%) is below the Opportunity Cost of Capital
(Financial benchmark) that can be achieved without CDM funds. It improves to 14.69% with
CDM funds availed against CERs, which is more than financial benchmark.
According to Consolidated additionality tool (point no. 8 of step 2c), if the CDM project
activity has a less favorable indicator (e.g. lower IRR) than the benchmark, then the CDM
project activity cannot be considered as financially attractive. In the project case, the IRR is
better than the minimum returns achievable through financial benchmark (14.5%) discussed
above. This shows that viability of project can be improved substantially i.e, beyond financial
benchmark, with CDM funds. Thus, IFFCOs project activity is financially additional.
Sub-step 2d- Sensitivity Analysis
Sensitivity analysis is conducted considering following deviations in assumptions to find out
worst case IRR of CDM project, to analyze whether the project remains financially additional
inspite of expected deviations in assumptions.
Sr. No.
Assumptions
NG escalates by 6 % , LNG
IRR (%) without IRR

(%)
CDM fund
CDM funds
13.33
14.74
with

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escalates by 10 % , Naphtha
escalates by 17 % , LSHS escalates
by 10 % ,Coal escalates by 7.5%
and GEB escalates by 5% every
year
Therefore in spite of sensitivity analysis on the basis of realistic deviations in assumptions, the
IRR of project activity remains less attractive than the financial benchmark. Please see
Enclosure-2 to refer sensitivity analysis.
Step 4. Common Practice Analysis
Sub-step 4a. Analyse other activities similar to the proposed project:
This is the first kind of retrofit taken up by IFFCO based on M/s Haldor Topsoe study in India.
Probably scale of implementation of energy saving retrofits in financial terms is one of the
highest in India.
Projects with Latest Technologies
Some of the projects are based on latest technologies of Haldor Topsoe, which have only one or
two credentials in India. These are as following.
1. Low Temperature Shift (LTS) Guard
2. S-50 Radial flow converter
Both the above technologies are being implemented in all five plants i.e. Aonla unit I & II,
Phulpur unit I & II and Kalol unit.
Retrofits with unusual practice
The project of complete revamping of CO2 removal system, being implemented in Aonla-I for
converting single-stage GV system into 2-stage GV system is quite unusual retrofit project and
is one of the first kinds in India.
The projects with in-depth engineering analysis of technology, design and operational
practices
The energy saving projects are planned with an independent analysis of operational practices,
design and technology status of plant and the best operational practices, technology and design
changes are recommended by M/s Haldor Topsoe. These projects have not come up out of
common practice in the fertilizer industry but are tailor-made for the IFFCO plants. These
might be some similarity exists in other Fertilizer plants in India, which IFFCO is not aware of.
Sub-step 4b. Discuss any similar options that are occurring:
The new Ammonia plants in the world scenario, for which technology is supplied by Haldor
Topsoe have the technologies such as S-50 radial converters and LTS guard is supplied.
Similarly 2-stage GV based CO2 removal plants are supplied in new plants of M/s GV.
But in India, the latest technology plants are the ones, which were implemented in the year
1998 by M/s Haldor Topsoe.
Step 5. Impact of CDM Registration
As stated earlier, during the planning stage of proposed CDM project activity the CDM fund
was under consideration. Following impacts of CDM fund are identified from the point of view
of removal of barriers discussed above. Please refer the approved internal notes of IFFCO on

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Revamping of ammonia plant project and considering CDM revenues generated by the
revamping project.
Improve IRR of project from 13.25 % to 14.69% (Higher than financial benchmark of
14.5%).
Since the retrofits are not based on common practice and the CDM fund will provide
additional coverage to the risk due to failure of projects, shut down of plant and loss of
production. The support will be available to the losses already incurred after
commissioning of project
CDM funds will encourage IFFCO to come up with more GHG abatement projects for its
plants.
B.4.
Description of how the definition of the project boundary related to the baseline
methodology selected is applied to the project activity:
>>
Project Boundary
As per definition of project boundary as given in glossary of terms, it will encompass all
anthropogenic emissions by sources of Green House Gases (GHGs) under the control of project
participants that are significant and reasonably attributable to the CDM project activity.
Based on the definition as per the proposed methodology, the project boundary covers the
following.
Ammonia Plant
All the retrofit projects discussed in section A.2 will be implemented in following sections of
ammonia plant; these sections become part of the project boundary
1.
Primary and Secondary Reformers section
2.
LT and HT Shift Converter section
3.
CO2 removal Section
4.
Synthesis Loop Converter section
The steam consumed in primary reformer, process heating and back pressure turbines in this
section will be saved as a result of retrofit measures. The flow of steam will be monitored
centrally.
Boilers (HRSG-1, HRSG-2 and HRU in Aonla plant, LSHS and Coal Fired boilers in
Phulpur plant and Auxiliary boiler in Kalol plant)
The actual baseline CO2 emissions take place in these boilers

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Flow chart and project boundary is illustrated in the following diagram. The projects are depicted in diagram by code nos. (e.g. 9.A.2, 14.K etc.). The coding is
summarised below.
Illustration of code: 1.A.1 : Initial 1means Energy saving scheme no 1( according to Sr. No. of Table 1 of section A .4.3) , A..1 - Aonla unit I
Similarly, P.1- Phulpur unit I , K -Kalol
CO2 emissions due
to steam generation
HRSG-1,
HRSG-2 and HRU
(Aonla Plant)
Primary Reformer
Section
9. A.2
10. A.2
LSHS Fired Boiler and

Coal Fired Boiler
(Phulpur Plant)
Gas/Naptha fired
Auxiliary Boiler (Kalol
plant)
11.A.1, 11.A.2,
15.K, 16.K
HT Converter
Section
6.K
Secondary
Reformer
Section
LT Converter
Section
1. A.1
1. A.2
1. P.1
1. P.2
1. K
6. P.1
6. K
Steam pipe
lines
Process Gas
CO2 Removal Section

7. A.1
8.A.2
13. P.1
14. K
Synthesis Converter Section

2. A.1, 2.A.2, 2. P.1, 2.P.2
2 K, 3.A.1, 3.A.2, 3. P.1, 3.P.2, 4. P.1, 4.
K, 5. P.1
5. K ,
Output Ammonia to
Urea plant
Main Steam
Header
The project is part of Ammonia plant

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B.5.
Details of baseline information, including the date of completion of the baseline
study and the name of person (s)/entity (ies) determining the baseline:
>>
Date of completing the final draft of this baseline section:
01/12/2005
Name of person/entity determining the baseline:
IFFCO has determined the baseline and is also project participant. The contact details are given
in Annex 1.
Page 22
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SECTION C. Duration of the project activity / Crediting period

C.1
Duration of the project activity:
C.1.1. Starting date of the project activity:

>>
01/11/04
C.1.2. Expected operational lifetime of the project activity:
>>
15 years 0 months
C.2
Choice of the crediting period and related information:

C.2.1. Renewable crediting period
C.2.1.1.
Starting date of the first crediting period:
>>
Not opted
C.2.1.2.
Length of the first crediting period:
>>
Not opted
C.2.2. Fixed crediting period:
C.2.2.1.
Starting date:
C.2.2.2.
Length:
>>
01/05/06
>> 10 years

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SECTION D. Application of a monitoring methodology and plan

D.1.
Name and reference of approved monitoring methodology applied to the project
activity:
Title: Baseline methodology for steam optimization systems
Reference: AM0018, UNFCCC website
D.2.
Justification of the choice of the methodology and why it is applicable to the
project activity:
The applicability conditions of methodology for production processes with homogeneous and
relatively constant output and continuous monitoring of steam outputs. These conditions are
perfectly applicable to proposed CDM project activity of IFFCO.
IFFCO plants (Aonla-I, Aonla-II, Phulpur-I, Phulpur-II and Kalol) are constant output Urea
production plants. The Ammonia production is these plants is relatively constant. In fact,
Fertilizer Industry in India can produce the quantity of Fertilizers that is allotted by
Government of India, based on capacity. This ensures the constant nature of output. The
project activity is reduction in steam consumption through revamping (retrofit) in various
sections of ammonia plant. The steam is supplied by boilers (Heat Recovery Steam Generators,
Coal/LSHS fired boilers and Auxiliary boilers) which are operated by combustion of fossil
fuels.
The approved monitoring methodology requires monitoring of the following:
The output rate is to be monitored shift-wise (for continuous processes);
The steam consumption rate for the process, where the optimisation has taken place, needs
to be monitored shift-wise (for continuous processes) or batch-wise (for batch processes);
Boiler efficiency (see below for different monitoring methodologies);
Steam enthalpy (see below for details);
Additional electricity consumption due to the project activity needs to be monitored shiftwise (for continuous processes)
The fuel composition analysis and calorific value.
All these parameters are monitored at IFFCO plants in baseline scenario and same will
continue in project scenario.
Monitoring Plan is given in Annex-4.

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D.2. 1. Option 1: Monitoring of the emissions in the project scenario and the baseline scenario
D.2.1.1. Data to be collected in order to monitor emissions from the project activity, and how this data will be archived:
Considering the above, the details of quantity of steam consumed & NH3 produced and other important project parameters to be monitored and verified in
IFFCO plants are as given below.
ID number
Data
Variable
Source of
data
D.2.1.1.(a)1
Steam
Plant
consumption
in ammonia
section
Data unit
Measured
Recording
Proportion How will the
(m),
Frequency
of data
data be
calculated (c)
to be
archived?
or estimated
monitored
(electronic/
(e)
paper)
Table 2 : Primary Parameters for Estimation of Emission Reduction
Tonne / shift
Measured
Every Shift
Total
Paper
D.2.1.1.(a)2
NH3
Production
Plant
Tonne/shift
Measured
Every Shift
Total
Paper
D.2.1.1.(a)3
Quantity of
Fuel(s) used
in the
boiler(s)
Plant
Tonne/shift
Measured
Every Shift
Total
Paper
D.2.1.1.(a)4
Steam
temperature
Plant
Deg C
Measured
Every Shift
Total
Paper
D.2.1.1.(a)5
Steam
pressure
Plant
Kg/sqcm(g)
Measured
Every Shift
Total
Paper
D.2.1.1.(a)6
Feed
water Plant
temperature
Deg C
Measured
Every Shift
Total
Paper
Comment
Measured in the plant premises to the best accuracy

and will be monitored shift-wise through DCS.
Parameter shall be recorded daily. The data would
be archived until 2 years after end of the crediting
period.
period.
period.
Monitored by temperature indicator at the end of
shift/batch (either using instantaneous instrument or
through DCS). The data would be archived until 2
years after end of the crediting period.
Monitored based on shift logbooks, for change in
fuel and time of change. The data would be archived
until 2 years after end of the crediting period.
shift. The data would be archived until 2 years after
end of the crediting period.

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ID number
Data
Variable
Page 25
Source of
data
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Measured
D.2.1.1.(a)7
Feed
flow
D.2.1.1.(a)8
Calorific
Plant
Value of Fuel
(GCV &
NCV )
Natural Gas: Measured

kcal/SM3
Naphtha, Coal,
LSHS kcal/kg
D.2.1.1.(a)9
Ultimate
Analysis of
fuel
Plant
Kg or kg-mole Measured
D.2.1.1.(a)10
Boiler
efficiency
Plant
Estimated
D.2.1.1.(a)11
Retrofit
Event
Measured
water Plant
Cum/shift
Recording
Frequency
Proportion
of data
to be
monitored
Every Shift
Total
How will the

data be
archived?
(electronic/
paper)
Paper
With
every Total
delivery
of
fuel.
(Refer
guidelines on
boiler
efficiency
monitoring)
With
every Total
delivery
of
fuel.
Paper
Monthly (Refer Total

guidelines on
boiler
efficiency
monitoring)
As and when Total
occurs.
Paper
Paper
Paper
Comment
Monitored by flow recording meter at the end of

shift. Or blow down level indicator in case of one
time blow down at the end of shift (and not
continuous blow down). The data would be archived
Fuel tested for each delivery by supplier or in-house
or external reliable laboratory. (Refer guidelines on
boiler efficiency monitoring). The data would be
archived until 2 years after end of the crediting
period.

or external reliable laboratory. The data would be
period.
Direct efficiency based on heat balance.(Refer
guidelines on boiler efficiency monitoring). The
data would be archived until 2 years after end of the
crediting period.
Follow Retrofit Monitoring Test as given in
monitoring methodology. The data would be
period.
Effect of future retrofitting on baseline and project emissions:

The following test should be applied while monitoring the effect of future retrofitting within the project boundary (change in output level, process change,
equipment change etc. affecting specific steam consumption) on baseline and project emissions. The following question should be asked if retrofit measures
reduce the steam consumption within the project boundary.
Question: Does retrofitting reduce the steam consumption of the CO2 removal system? (I.e. there is a reduction in estimated project emissions, though not
caused by the CDM project activity itself.)

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Action: The enhanced steam saving due to the impact of retrofit on CO2 removal sysem needs to be estimated and deducted from claimed emission
reductions.
D.2.1.2. Description of formulae used to estimate project emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ.)
1. Emissions due to steam Consumption in Ammonia Plant
The source of greenhouse gas emissions in the project activity is due to steam consumption in the Ammonia plant resulting into CO2 emitted from
fossil fuels like Natural gas/Naphtha etc., fired in the boilers for generating steam.
Step-1: Estimate representative value of Ammonia ( NH3 ) production of the unit
Based upon NH3 production of the unit, all values (P1, P2, P3 etc.) under normal range of plant capacity to be selected and averaged out to find
out representative value.
Prep =
(P1 ... + Pn ) x3
n
Where,
P1Pn = value(s) of NH3 produced (Tonne / shift )
No. of shifts per day = 3
Prep = Representative value of NH3 produced in the unit (Tonne /day)
Note: n may not be equal to 3 (no. of shifts), because if some shift-data is filtered out because it is out of normal production range, n will be
less than 3.
Step-2: Estimate steam consumption for representative output values
The steam consumption (consumption per shift) values corresponding to representative NH3 production values are selected and the average of the
same is calculated.
Srep =
S1Sn = Values of steam consumption per shift (Tonne /shift).
(S1 + ....S n ) 3
n

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Srep= Representative steam consumption for the day (corresponding to representative production of the day)
Step-3: Calculate Specific Steam Consumption Ratio-SSCR (Tonne of steam consumed / Tonne of NH3 produced)
The steam consumption values corresponding to NH3 produced values selected above, to be identified and average representative value (Ss ) to be
worked out.
Ss = Srep / Prep
Where,
Ss
= Specific Steam Consumption Ratio (Tonne of steam/ Tonne of NH3 produced from Ammonia plant)
Srep
= Representative Steam Consumption Rate (Tonne/day)
D.2.1.3. Relevant data necessary for determining the baseline of anthropogenic emissions by sources of GHGs within the project boundary and how
such data will be collected and archived :
ID number
Data Variable
Source of
data
D.2.1.3.(a)1
Steam consumption Plant

in ammonia section
Data unit
Proportion
of data
to be
monitored
Tonne / shift
Measured
Recording
(m),
Frequency
calculated (c)
or estimated
(e)
Measured
Every Shift
Total
How will the

data be
archived?
(electronic/
paper)
Paper
D.2.1.3.(a)2
NH3 Production
Plant
Tonne/shift
Measured
Every Shift
Total
Paper
D.2.1.3.(a)3
Quantity of Fuel(s) Plant

used in the boiler(s)
Tonne/shift
Measured
Every Shift
Total
Paper
D.2.1.3.(a)4
Steam temperature
Deg C
Measured
Every Shift
Total
Paper
Plant
Comment

Daily print out for the data will be taken. The data
would be archived until 2 years after end of the
crediting period.
crediting period.
crediting period.

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ID number
Page 28
Data Variable
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated (c)
or estimated
(e)
D.2.1.3.(a)5
Steam pressure
D.2.1.3.(a)6
Feed
temperature
D.2.1.3.(a)7
Feed water flow
D.2.1.3.(a)8
Calorific Value of Plant

Fuel
(GCV & NCV )
Natural Gas: Measured

kcal/SM3
Naphtha , coal
,
LSHS:
kcal/kg
D.2.1.3.(a)9
Ultimate Analysis of Plant

fuel
Kg or kg-mole
Measured
D.2.1.3.(a)10
Boiler efficiency
Plant
Estimated
D.2.1.3.(a)11
Retrofit
Event
Measured
Plant
water Plant
Plant
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
Comment
shift/batch (either using instantaneous instrument or

through DCS). The data would be archived until 2
Monitored based on shift logbooks, for change in
fuel and time of change. The data would be archived
shift/batch. The data would be archived until 2
shift/batch. Or blow down level indicator in case of
one time blow down at the end of shift (and not
continuous blow down). The data would be archived
period.
Kg/sqcm(g)
Measured
Every Shift
Total
Paper
Deg C
Measured
Every Shift
Total
Paper
Cum/shift
Measured
Every Shift
Total
Paper
With
every
delivery
of
fuel.
(Refer
guidelines on
boiler
efficiency
monitoring)
With
every
delivery
of
fuel.
(Refer
guidelines on
boiler
efficiency
monitoring)
Monthly (Refer
guidelines on
boiler
efficiency
monitoring)
As and when
occurs.
Total
Paper
Total
Paper

period.
Total
Paper
Direct efficiency based on heat balance.(Refer

guidelines on boiler efficiency monitoring). The
crediting period.
Total
Paper
Follow Retrofit Monitoring Test as given in

monitoring methodology. The data would be

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ID number
Data Variable
Page 29
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated (c)
or estimated
(e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
Comment

period.
D.2.1.4. Description of formulae used to estimate baseline emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ.)
The specific steam consumption (Tonne) in Ammonia plant per NH3 production is derived for base case scenario. This figure of specific steam
consumption is used for all future project scenarios to compare the emissions of project scenario and likely emissions of baseline scenario.
Emissions due to steam Consumption in Ammonia Plant
The source of greenhouse gas emissions in the project activity is due to steam consumption in the boilers resulting into CO2 emitted from fossil
fuels like Natural gas/Naphtha /Coal /LSHS/fired in the boilers for generating steam.
The historical one-month data on shift-wise output of NH3 produced is analysed and representative output value (Prep) is calculated. While
calculating daily average, the extreme values are segregated from the available values of output rate (shift output). This is because the specific
steam consumption in a plant reduces with increased production rates. Based on our experience, the energy-production relationship is not
significantly sensitive up to +/-5% of normal rated production. Therefore +/- 5% range is taken as normal production range for this purpose. If
production fluctuates (from shift to shift) beyond normal production range, these specific values are segregated to derive average production of
the day. Similarly steam consumption value corresponding to such production is also segregated.
Step-1: Estimate representative value of Ammonia ( NH3 ) production of the unit
Based upon NH3 production of the unit, all values (P1, P2, P3 etc.) under normal range of plant capacity to be selected and averaged out to find
out representative value.
Prep =
(P1 ... + Pn ) x3
Where,
P1Pn = value(s) of NH3 produced (Tonne / shift )
Prep = Representative value of NH3 produced in the unit (Tonne /day)

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Note: n may not be equal to 3 (no. of shifts), because if some shift-data is filtered out because it is out of normal production range, n will be
less than 3.
Step-2: Estimate steam consumption for representative output values
The steam consumption (consumption per shift) values corresponding to representative NH3 production values are selected and the average of the
same is calculated.
Srep =
(S1 + ....S n ) 3
n
S1Sn = Values of steam consumption per shift (Tonne /shift).

Srep= Representative steam consumption for the day (corresponding to representative production of the day)
Step-3: Calculate Specific Steam Consumption Ratio-SSCR (Tonne of steam consumed / Tonne of NH3 produced)
The steam consumption values corresponding to NH3 produced values selected above, to be identified and average representative value (Ss ) to be
worked out.
Ss = Srep / Prep
Where,
Ss
= Specific Steam Consumption Ratio (Tonne of steam/ Tonne of NH3 produced from Ammonia plant)
Srep
= Representative Steam Consumption Rate (Tonne/day)
D. 2.2. Option 2: Direct monitoring of emission reductions from the project activity (values should be consistent with those in section E).
D.2.2.1. Data to be collected in order to monitor emissions from the project activity, and how this data will be archived:

CDM Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to table
D.3)
Data
variable
Source of
data
Page 31
Data
unit
Measured (m),
calculated (c),
estimated (e),
Recording
frequency
Proportion
of data to
be
monitored
How will the data

be archived?
(electronic/
paper)
Comment
D.2.2.2. Description of formulae used to calculate project emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ.):
>>
D.2.3. Treatment of leakage in the monitoring plan
D.2.3.1. If applicable, please describe the data and information that will be collected in order to monitor leakage effects of the project activity
ID number
(Please use
numbers to
ease crossreferencin
g to table
D.3)
Data
variable
Source of
data
Not
applicable
Not
applicabl
e
Not
applicable
Data unit
Not
applicabl
e
Measured (m),
calculated (c)
or estimated
(e)
Recording
frequency
Proportion
of data to
be
monitored
How will the

data be
archived?
(electronic/
paper)
Comment
Not applicable
Not
applicable
Not
applicable
Not applicable
Not applicable
D.2.3.2. Description of formulae used to estimate leakage (for each gas, source, formulae/algorithm, emissions units of CO2 equ.)
Not applicable

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Page 32
D.2.4. Description of formulae used to estimate emission reductions for the project activity (for each gas, source, formulae/algorithm, emissions units of
CO2 equ.)
Step 4: Net Reduction in SSCR (Tonne of steam consumed / Tonne of NH3 produced )
Sr1 = Ss1-Ss
Where:
Sr1 = Net Reduction in SSCR (Tonne of steam consumed / Tonne of NH3 produced )
Ss1 =SSCR of the unit in base case scenario (Tonne of steam consumed / Tonne of NH3 produced )
Ss = SSCR of the unit in project scenario (Tonne of steam consumed / Tonne of NH3 produced )
Step 5: Calculate reduction in daily steam consumption due to project activity (Tonne / day)
Srf = Sr1 x Pgv
Where:
Srf = Net reduction in steam due to project activity (Tonne /day)
Sr1 = Net reduction in specific steam consumption (Tonne of steam consumed / Tonne of NH3 produced )
Pgv= Actual NH3 production in the unit (Tonne /day)
Step-6: Calculate equivalent energy for steam reduction (GJ/day)

Ei = Srf x Es
Where
Ei
= Reduction in equivalent energy due to steam reduction (GJ/day)
Srf
= Net reduction in steam due to project activity (Tonne/ day)
Es
= Net enthalpy of steam = Total enthalpy of steam (GJ/tonne) Feed water enthalpy (GJ/tonne)
Step-7: Calculate CO2 emissions reduction (T /day)
Ce1 = ((Ei x (Fn x Pn)) / (1000 x h b )
Where
Ce1 = CO2 emissions reduction per day due to fuel combustion in boiler to produce steam required in the unit (Te/day)
Ei
= Reduction in equivalent energy for steam reduction (GJ/day)
Fn
= Emission factor of fuel n used ( as per IPCC-guidelines (IPCC) (Te / GJ)
Pn
= Energy contribution share of fuel n in total energy generated by fuel mix (%)

CDM Executive Board
hb
Page 33
= Efficiency of boiler (monitored monthly. See boiler efficiency monitoring guideline)
Note : Since steam saved in Aonla plant is in Heat Recovery Steam Generators (HRSGs) and Heat Recovery Units (HRUs), the efficiency calculation on regular
basis is difficult. Therefore the manufacturers table is followed to get the figure of natural gas consumption based on reduction in steam generation in HRSG and
HRU. This table (chart) is validated by heat balance once in a year.
Net effect on emissions due to electrical energy consumption

The emission is resulted due to operation of some additional new motors installed during implementation of the energy savings schemes. The formulae
used to calculate the emissions are given below:
Step-8: Calculate increase in CO2 emissions due to combustion of fuel in power generation system for net increase in power consumption (T /day)
Ce1 = (Pto x Fn x Hdt) / (1000 x h b )
Where
Ce2
= Increase in CO2 emissions due to increase in power consumption (Te/day)
Fn
= Emission factor of fuel n used (as per IPCC-guidelines (IPCC) (Te / GJ)
Hd
= No of operating hours in a day (24 hrs/day)
Ptot
= Power consumption of additional motors (GJ/day)
hg
= Efficiency of electricity generating system based on historical data (assumed constant)
D.3.
Quality control (QC) and quality assurance (QA) procedures are being undertaken for data monitored
Data
(Indicate table and
ID number e.g. 3.1.; 3.2.)
Uncertainty level of data

(High/Medium/Low)
Explain QA/QC procedures planned for these data, or why such procedures are not necessary.
ISO 9001
ISO 9001
ISO 9001
D.3.(a)4
Low
Low
Low
Low
D.3.(a)5
Low
D.3.(a)1
D.3.(a)2
D.3.(a)3
ISO 9001
ISO 9001

CDM Executive Board
D.3.(a)6
D.3.(a)8
Low
Low
Low
D.3.(a)9
Low
D.3.(a)10
Low
D.3.(a)11
Low
D.3.(a)7
Page 34
ISO 9001
ISO 9001
There is no procedure required for the testing of fuels as the test certificate given by reputed
Naphtha/coal/LSHS supplier for each fuel delivery. In case of Natural Gas, the calorific value is available
for every days supply.
The procedure is required if emission factor is determined by testing of fuel supplier or in-house or
external reliable laboratory . Otherwise IPCC/National emission factor to be used.
ISO 9001
For retrofit monitoring retrofit test should be followed as given in section D.2.1.1.
D.4
Please describe the operational and management structure that the project operator will implement in order to monitor emission
reductions and any leakage effects, generated by the project activity
Joint General Manager (Technical) would be responsible for monitoring and archiving of data required and for estimating the emission reductions. He
would be supported by Plant incharge, who would continuously monitor the data and would generate Daily, Monthly report of the same
D.5
Name of person/entity determining the monitoring methodology:
IFFCO has determined monitoring methodology and is also project participant. The contact details are given in Annex 1.

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Page 35
SECTION E. Estimation of GHG emissions by sources

E.1.
Estimate of GHG emissions by sources:
Following are sample calculations. Please refer Enclosure-3, Enclosure-4 and Enclosure-5 for
Excel sheet calculations for Aonla, Phulpur and Kalol plants respectively.
Sample Calculations Aonla-I plant for representative production of 1520 MTPD +/- 5%.
The SSCR in project case is estimated for 1-months baseline production data.
Ammonia Production
Steam
Cons to
syn gas
turbineBaseline
case
Steam Cons
to syn gas
turbineProject
case
SSCR-Baseline case
SSCRProject
case
T/Day
T/Day
T/Day
T of steam/ T of Amm
1479.700
1497.700
6384
6451
5102.4
5169.4
5322.4
4.31
4.31
4.35
T of steam/
T of Amm
3.45
3.45
3.50
1519.400
1514.100
1513.200
1514.000
1520.400
1520.300
1520.300
1520.500
1486.800
1504.300
1542.400
1521.400
1520.300
1520.400
1520.200
1512.000
1518.200
1537.300
1502.200
1519.200
1497.000
1505.100
1531.500
1528.400
1506.600
1538.700
1530.400
1531.400
1481.700
1479.900
1462.600
6604
6524
6464
6542
6546
6646
6558
6667
6474
6570
6646
6482
6540
6540
6576
6504
6469
6596
6384
6478
6396
6384
6504
6528
6534
6663
6422
6456
6216
6240
6205
5242.4
5182.4
5260.4
5264.4
5364.4
5276.4
5385.4
5192.4
5288.4
5364.4
5200.4
5258.4
5258.4
5294.4
5222.4
5187.4
5314.4
5102.4
5196.4
5114.4
5102.4
5222.4
5246.4
5252.4
5381.4
5140.4
5174.4
4934.4
4958.4
4923.4
4.31
4.27
4.32
4.31
4.37
4.31
4.38
4.35
4.37
4.31
4.26
4.30
4.30
4.33
4.30
4.26
4.29
4.25
4.26
4.27
4.24
4.25
4.27
4.34
4.33
4.20
4.22
4.20
4.22
4.24
3.46
3.42
3.47
3.46
3.53
3.47
3.54
3.49
3.52
3.48
3.42
3.46
3.46
3.48
3.45
3.42
3.46
3.40
3.42
3.42
3.39
3.41
3.43
3.49
3.50
3.36
3.38
3.33
3.35
3.37

CDM Executive Board
1476.700
1476.800
1479.700
1509.744
Page 36
4982.4
4958.4
5006.4
6264
6240
6288
SSCR of the Project case of Aonla-I
4.24
4.23
4.25
4.287
3.37
3.36
3.38
3.437
= 3.437Ton of steam consumed/ Ton of Ammonia produced
Sample Calculations Aonla-II plant for representative production of 1520 MTPD +/- 5%.
The SSCR in project case is estimated for 2-months baseline production data.
Ammonia Prodn.
Steam Cons.
in Syn
gasTurbineBaseline
case
T/Day
T/Day
1481
1522
1517
1510
1483
1520
1525
1525
1525
1525
1512
1520
1520
1515
1520
1520
1520
1497
1520
1567
1521
1540
1496
1502
1510
1507
1540
1532
1482
1540
1468
1458
1520
1486
1479
1486
6601
6667
6660
6590
6428
6514
6392
6439
6293
6464
6379
6503
6508
6480
6532
6536
6503
6476
6549
6671
6552
6680
6530
6529
6577
6554
6684
6611
6442
6623
6386
6321
5896
6330
6256
6260
Steam
Cons to
syn gas
turbineProject
case
T/Day
5955.4
6021.4
6014.4
5944.4
5782.4
5868.4
5746.4
5793.4
5647.4
5818.4
5733.4
5857.4
5862.4
5834.4
5886.4
5890.4
5857.4
5830.4
5903.4
6025.4
5906.4
6034.4
5884.4
5883.4
5931.4
5908.4
6038.4
5965.4
5796.4
5977.4
5740.4
5675.4
5250.4
5684.4
5610.4
5614.4
SSCR
-Baseline case
T of steam /
T of Amm
4.46
4.38
4.39
4.36
4.33
4.29
4.19
4.22
4.13
4.24
4.22
4.28
4.28
4.28
4.30
4.30
4.28
4.33
4.31
4.26
4.31
4.34
4.37
4.35
4.36
4.35
4.34
4.32
4.35
4.30
4.35
4.34
3.88
4.26
4.23
4.21
SSCR
-Project case
T of steam /
T of Amm
4.02
3.96
3.97
3.94
3.90
3.86
3.77
3.80
3.70
3.82
3.79
3.85
3.86
3.85
3.87
3.88
3.85
3.89
3.88
3.84
3.88
3.92
3.93
3.92
3.93
3.92
3.92
3.89
3.91
3.88
3.91
3.89
3.45
3.83
3.79
3.78

CDM Executive Board
1512
Page 37
4.29
3.86
SSCR of the Project case of Aonla-II= 3.86 Ton of steam consumed / Ton of Ammonia produced
E.2.
Estimated leakage:
There are no potential significant sources of leakages
E.3.
The sum of E.1 and E.2 representing the project activity emissions:
Total emissions reduction due to project activity = Ce1 Ce2 Te / day
E.4.
Estimated anthropogenic emissions by sources of greenhouse gases of the baseline:
SSCR of the Baseline case of Aonla-I =4.287 Ton of steam consumed/ Ton of Ammonia produced
SSCR of the Baseline case of Aonla-II = 4.29 Ton of steam consumed/ Ton of Ammonia produced
Reduction in steam consumption due to project activity in Aonla-I
= 1281.83 Ton of steam /day

=
53.41 Ton of steam /hour
Reduction in steam consumption due to project activity in Aonla-II = 645.74 Ton of steam /day
= 26.91 Ton of steam /hour
Total Emission Reduction in Aonla Plant

Total steam saved by the project activity
Reduction in steam produced in GTG-I/HRSG-I of Power plant
Reduction in steam produced in GTG-II/HRSG-II of Power plant
Reduction in steam produced in HRU of Aonla-II
=
=
=
=
80.32 TPH
21.2 TPH
26.8 TPH
32.5 TPH
GT/HRU OF Aonla
NG consumption in GT/HRU (Baseline Scenario)
NG consumption in GT/HRU (Project Scenario)
NG saving in GT/HRU
=
=
=
9025 NM3/Hr
6802 NM3/Hr
2223 NM3/Hr
Natural Gas saving in GTG-I /HRSG-I of power plant due to reduction in steam generation
NG consumption in GTG-I(Baseline Scenario)
NG consumption in HRSG-I (Baseline Scenario)
NG consumption in GTG-I(Project Scenario)
NG consumption in HRSG-I (Project Scenario)
Increase in NG consumption in GTG-I
NG saving in HRSG-I
=
=
=
=
=
=
5553 NM3/Hr
3423 NM3/Hr
5870 NM3/Hr
1986 NM3/Hr
317 NM3/Hr
1437 NM3/Hr
Natural Gas saving in GTG-II /HRSG-II of power plant due to reduction in steam generation
NG consumption in GTG-II(Baseline Scenario)
NG consumption in HRSG-II (Baseline Scenario)
NG consumption in GTG-II(Project Scenario)
NG consumption in HRSG-II (Project Scenario)
Increase in NG consumption in GTG-II
NG saving in HRSG-II
=
=
=
=
=
=
5487 NM3/Hr
3637 NM3/Hr
5870 NM3/Hr
1986 NM3/Hr
383 NM3/Hr
1651 NM3/Hr

CDM Executive Board
Total Natural gas saved
Lower Calorific value of natural gas
Emission factor for natural gas
Page 38
=
=
=
=
=
Total emission reduction
4611 NM3/Hr
8774 kcal/NM3
15.3 tC/TJ
56.1 tCO2/TJ
75,138 tCO2/year
E.5.
Difference between E.4 and E.3 representing the emission reductions of the
project activity:
Net Reduction in SSCR of Aonla-I
= 0.849 Ton of steam consumed/ Ton of

Ammonia produced
Net Reduction in SSCR of Aonla-II
= 0..43 Ton of steam consumed / Ton of

Ammonia produced
E.6.
Table providing values obtained when applying formulae above:
Following table indicates the emission reductions in each year of credit period for all plants
(Aonla-I, Aonla-II, Phulpur - I, Phulpur-II, Kalol).
Year
Estimation of
Estimation
Estimation Estimation
Project activity of baseline
of
of
Emission
Emission
leakage
emission
reductions
reductions
(tonnes
reductions
(tonnes of CO2 (tonnes
of CO2 e)
(tonnes of
e)
of CO2 e)
CO2 e)
2006-2007
1805269
2067980
262711
2007-2008
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
2014-2015
2015-2016
Total
(tonnes of
CO2 e)
1805269
1805269
1805269
1805269
1805269
1805269
1805269
1805269
1805269
2067980
2067980
2067980
2067980
2067980
2067980
2067980
2067980
2067980
18052690
20679800
0
0
0
0
0
0
0
0
0
0
262711
262711
262711
262711
262711
262711
262711
262711
262711
2627110

CDM Executive Board
Page 39
SECTION F. Environmental impacts

F.1.
Documentation on the analysis of the environmental impacts, including
transboundary impacts:
The Ministry of Environment and Forests (MoEF), Government of India, under the
Environment Impact Assessment Notification vide S.O. 60(E) dated 27/01/94 has listed a set of
industrial activities in Schedule I of the notification which for setting up new projects or
modernization/ expansion will require environmental clearance and will have to conduct an
Environment Impact Assessment (EIA) study. However, the project activity under
consideration does not require any EIA to be conducted, as the activity is not included in
Schedule I.
Article 12 of the Kyoto Protocol necessitates that a CDM project activity contributes to the
sustainable development of the host country. Assessing the project activitys positive and
negative impacts on the local environment and on society is thus a key element for each CDM
project.
The CDM project activity developed by IFFCO ensures maximum global and local benefits
with respect to certain environmental, social issues and contributes positively towards
sustainable development.
The GHG emission reductions (by reducing the burning of fossil fuels in boilers which leads to
CO2 emissions) from project activity benefit the global environment. The local environment is
benefited by resource conservation, employment generation, water conservation etc.
IFFCO plants being an ISO 14001 organization has specialized environmental management
systems, consistent evaluation of the impacts & key parameters have ensured that the plants
meets the environmental targets .The recipient of many environmental excellence awards for its
best environment management practices, IFFCO implements many environmentally benign
projects. The project activity is one such voluntary measure, which has positive long-term
environmental impact. The nature of the impacts that are evident during the operational phase
are discussed in detail in the table given below. The environmental impact during the
construction phase is regarded as temporary or short term and hence does not affect the
environment significantly.

CDM Executive Board
F.1.
SL. NO.
A
1
Page 40
Documentation on the analysis of the environmental impacts, including transboundary impacts:

ENVIRONMENTAL IMPACTS & BENEFITS
MITIGATION MEASURES / REMARKS
CATEGORY: ENVIRONMENTAL NATURAL RESOURCE CONSERVATION

Fossil fuel conservation:
The project activity reduces consumption of fossil fuels like Coal, Natural gas, The project activity is a step towards fossil fuel conservation.
Naphtha and LSHS used in the boilers. Coal/ Natural gas is a finite natural
resource used as fuel to generate power and for production processes. Since
the project activity reduces Coal, Natural gas, Naphtha & LSHS consumption
it positively contributes towards conservation of Coal, Natural gas, Naphtha
& LSHS and making them available for other important applications.
CATEGORY: ENVIRONMENTAL AIR QUALITY
Reduction in steam consumption through revamping of ammonia plant reduces The project activity reduces emission of CO2 -a global entity.
fossil fuel consumption in the boilers. Hence the project activity reduces CO2
emissions by reducing burning of fossil fuels.

CDM Executive Board
Page 41
SL. NO.
C
1

CATEGORY: ENVIRONMENTAL WATER
Water conservation -The project activity aims to reduce steam consumption and in turn reduces the requirement of demineralised water in the boiler.
There is no possible water pollution arising due to project activity.
CATEGORY: ENVIRONMENTAL LAND
Reduction in coal, Naphtha & LSHS consumption reduces coal mining and The project activity leads to positive impact on Land environment.
oil exploration, which leads to loss of biodiversity, land destruction and
erosions arising from such activities.
Industry has also developed Green Belt in and around the plant premises.
There is no possible soil or land pollution arising due to project activity.
CATEGORY: ENVIRONMENTAL NOISE GENERATION
1
F
The project activity does not contribute to noise pollution.

CATEGORY: SOCIAL-ECONOMIC
The project activity generates employment opportunities to local populace The project is expected to bring positive changes in the life style and
during construction phase
quality of life.
The project activity is within the plant premises and there is no human
displacement. Therefore no rehabilitation programme is needed.
The project activity adopts higher technology which would aid in capacity
building of employees by better exposures
2
3
SL. NO.

CDM Executive Board
CATEGORY: ECOLOGY
There are no endangered species located in and around the plant area.
Page 42

CDM Executive Board
Page 43
Thus the above tables clearly purports that the project activity has excellent environmental benefits in
terms of reduction of carbon emissions, fossil fuel conservation, decreased environmental destruction
and enhanced restoration, improved economical and social prosperity.
F.2.
If environmental impacts are considered significant by the project participants or the host
Party, please provide conclusions and all references to support documentation of an environmental
impact assessment undertaken in accordance with the procedures as required by the host Party:
As discussed above, the project activity would not have any adverse environmental impacts.
The project activity does not fall under the purview of the Environmental Impact Assessment (EIA)
notification of the Ministry of Environment and Forest, Government of India. Hence, not required by the
host party.

CDM Executive Board
Page 44
SECTION G. Stakeholders comments

>>
G.1.
Brief description how comments by local stakeholders have been invited and compiled:
The project activity, which primarily aims at reduction in steam consumption through revamping of
ammonia plant, will result in simultaneous benefits of conservation of natural resources and achieving
energy efficiency of the plants.
Stakeholders have been identified on the basis of their involvement at various project activity stages.
The list of relevant stakeholders includes all governmental and non-governmental organization, which
would be communicated / applied to get necessary clearances.
IFFCO invited local villagers, elected representatives for stakeholders meeting through printed invitation
letter. During the meeting IFFCO officials apprised local villagers, elected representatives about the
various activities carried out by IFFCO in field of energy efficiency and environment. IFFCO informed
about the project activity and its associated benefits.
The stakeholders identified for the project are as under:
Elected body of representatives administering the local area
Ministry of Environment & Forest (MoEF), Government of India
Project Consultants
Equipment Suppliers
G.2. Summary of the comments received:
Stakeholders Involvement
The village Panchayat /local elected body of representatives administering the local area (of IFFCO
plants) is a true representative of the local population in a democracy like India. Hence, their consent /
permission to set up the project is necessary. IFFCO has started taking measures for necessary
consultation for approval of the project.
Local population comprises of the local people in and around the project area (of IFFCO plants). The
project makes way to a source for employment for skilled & unskilled workers during construction
phase. Hence, the local populace is encouraging the project.
The project activity would not result in any displacement of any local population. The project activity
would be set up inside the factory premises (of IFFCO plants). Thus, the project activity would not
cause any adverse social impacts on local population.
Ministry of Environment & Forests (MoEF) would be providing the host country approval for the
project.
Project consultants would be involved in the project to take care of various pre contract and post
contract project activities like preparation of basic and detailed engineering documents, preparation of
tender documents, selection of vendors / suppliers, supervision of project implementation, successful
commissioning and trial runs.
Equipment suppliers would supply the equipments as per the specifications finalized for the project and
successfully erect & commission of the same at the site and for performance.

CDM Executive Board
G.3.
Page 45
Report on how due account was taken of any comments received:
The relevant comments and important clauses mentioned in the project documents were considered while
preparing the CDM Project Design Document.As per UNFCCC requirement the PDD would be
published at the validators web site for public comments.

CDM Executive Board
Page 46
Annex 1
CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY
Organization:
Indian Farmers Fertiliser Cooperative Ltd. (IFFCO)
Street/P.O.Box:
34, Nehru Place,
Building:
IFFCO House
City:
New Delhi
State/Region:
Postfix/ZIP:
110019
Country:
India
Telephone:
91 11 26432507, 26432510
FAX:
91 11 26463833, 26478007
E-Mail:
URL:
www.iffco.nic.in
Represented by:
Title:
Executive Director (Tech.)
Salutation:
Mr.
Last Name:
Chandra
Middle Name:
First Name:
Subhash
Department:
Mobile:
Direct FAX:
Direct tel:
Personal E-Mail:

CDM Executive Board
Organization:
Street/P.O.Box:
Building:
City:
State/Region:
Postfix/ZIP:
Country:
Telephone:
FAX:
E-Mail:
URL:
Represented by:
Title:
Salutation:
Last Name:
Middle Name:
First Name:
Department:
Mobile:
Direct Fax:
Direct Tel:
Personal E-Mail:
Japan Carbon Finance, Ltd.

6th Floor, 1-3, Kudankita 4-Chome,
Chiyoda-ku
Tokyo
102-0073
Japan
+81-3-5212-8870
+81-3-5212-8886
jcf@jcarbon.co.jp
http://www.jcarbon.co.jp
Deal Manager
Mr.
Oya
Shin
Carbon Finance Department
+81-3-5212-8886
+81-3-5212-8878
s-oya@jcarbon.co.jp
Page 47

CDM Executive Board
Page 48
Annex 2
INFORMATION REGARDING PUBLIC FUNDING
No Public Funding is available to the project activity

CDM Executive Board
Page 49
Annex-3
BASELINE INFORMATION
The baseline information has been given in the enclosures 3, 4 and 5 attached.

CDM Executive Board
Page 50
Annex-4
MONITORING PLAN
The Monitoring and Verification (M&V) procedures define a project-specific standard against which
the projects performance (i.e. GHG reductions) and conformance with all relevant criteria will be
monitored and verified. It includes developing suitable data collection methods and data interpretation
techniques for monitoring and verification of GHG emissions. It also allows scope for review, scrutinize
and benchmark all this information against reports pertaining to M & V Protocols (MVP).
The purpose of these procedures would be to direct and aegis continuous monitoring of project
performance/key project indicators to determine project outcomes, GHG emission reductions. The MVP
provides a range of data measurement, estimation and collection options/techniques consistent with good
practices to allow project managers and operational staff, auditors, and verifiers to apply the most
practical and cost-effective measurement approaches to the project. The aim is to enable this project
have a clear, credible, and accurate set of monitoring, evaluation and verification procedures.
The project profitability is based on direct steam reduction in the boilers feeding steam to revamped
ammonia plants (where energy efficiency measures are implemented). The steam meters are used to
monitor and record the flow of steam used for the system.
The project employs latest state-of-the-art monitoring and control equipment that measure, record, and
control various key parameters. The project performance (reduction in steam consumption) is combined
effect of many energy efficiency schemes. Table in Section D 2.1.1 describes main parameters to be
monitored for estimation of emission reduction based on reduction in Specific Steam Consumption
Ratio (SSCR) in entire Ammonia section. These parameters are directly used in calculations of emission
reduction given in section-E.
Appendix 1 describes the other parameters which are to be monitored to analyse the performance of
individual energy saving scheme and thereby project performance. Appendix 1 provides (remark
column) the link between the characteristics of the individual scheme and its relation with steam
reduction in Ammonia plant. These parameters do not have any direct role to play in estimation of
emission reduction given in section-E.
Main parameters monitored will be as follows.
1.
The monitoring of quantity of steam used in ammonia plant per Tonne of NH3 production using
steam meter.
2.
Monitoring the parameters related with boiler (HRSG, HRU, LSHS/Coal fired boiler, Auxiliary
Boiler) efficiency on direct basis e.g. Steam enthalpy parameters, Fuel Parameters, and heat
balance parameters.
3.
Estimation of boiler efficiency by direct method based on enthalpy balance across boiler. In case of
HRSG and HRU in Aonla plant, the relation between steam generation and fuel consumption is
derived by Gas Turbine Manufacturers charts. This chart is validated by monitoring of heat
balance parameters and conducting heat balance once in a year.
4.
Monitoring of retrofits in the plant for change in baseline and project emissions.
For other set of parameters please refer Appendix 1 .

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The instrumentation system installed for the project is Distributed Control System (DCS) of reputed
make, with shift-wise recording and feedback facility with desired level of accuracy. All instruments
will be calibrated and marked at regular intervals so that the accuracy of measurement can be ensured
all the time.
GHG SOURCES
Direct On-Site Emissions
Direct on-site emissions after implementation of the CDM project arise from net emissions due to use of
steam in process. As discussed above, these emissions are monitored and taken into account while
estimating net emission reductions of project.
Direct Off-Site Emissions
There is no off-site emission due to the project.
Indirect On-Site Emissions
There is no indirect on-site emission due to the project.
Indirect Off-Site Emissions
No indirect off-site emissions could occur due to CDM project.
Project Parameters affecting Emission Reduction
Monitoring Approach
The general monitoring principles are based on:
l Frequency
l Reliability
l Registration and reporting
As the emission reduction units from the project are determined by the reduction in steam quantity, it is
important to discuss the monitoring principles in context of monitoring these parameters.
Frequency of monitoring
The project developer has installed all metering facilities within the plant premises. The measurements
is, monitored and controlled on continual basis and recorded shift-wise (8-hours shift) in a Distributed
Control System (DCS). In case of non-availability of data from DCS due to unforeseen situations, the
desired data shall be logged in log sheets by operator duly authenticated by head of plant
Reliability
The amount of emission reduction units is proportional to the net energy reduction due to project. Thus
the steam meter reading is of crucial value. All measurement devices will be of digital type meters with
on-line DCS (Distributed Control System), having best accuracy and will be procured from reputed
manufacturers. Since the reliability of the monitoring system is governed by the accuracy of the
measurement system and the quality of the equipment for reproducibility, all instruments must be
calibrated once a year for ensuring reliability of the system. All instruments carry

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tag plates, which indicate the date of calibration and the date of next calibration. Therefore it ensures
the monitoring system is highly reliable.
Registration and reporting
Registration is done on the basis of shift-wise data logging in computer. Daily, weekly and monthly
reports will be prepared stating the steam reduction.
The following reports will be generated for monitoring and controlling emissions.
The daily report of shift-wise data on steam used in Ammonia plant. The specific steam
consumption per unit of Ammonia produced is worked out. The net reduction in steam
consumption is thus estimated by multiplying difference in specific steam consumption and total
Ammonia produced.
Daily report on Ammonia generated from plant.
Verification
The reduction in steam consumption leads to the CO2 emission reductions. The project control system
comprises sophisticated monitoring system like on-line display meters and Distributed Control Systems
(DCS) which measures, collects the information about various process parameters, monitors and
controls on a continuous basis. Fully functional management information is built, which is generated
through DCS in pre-decided daily reports formats so that accessing and verification of actual data are
possible at any point of time. A computerised MIS can is generated and distributed among decision
makers of the project. The major activities to be verified are as under
Verification of various measurement and monitoring methods
Verification of instrument calibration methods
Verification of data generated through on-line meters and DCS
Verification of measurement accuracy
Periodicity for monitoring of boiler efficiency

Following guidelines are used to decide the periodicity for monitoring and estimation of boiler efficiency
by indirect method.
The ultimate analysis and calorific value analysis of Naphtha, Coal, and LSHS conducted for every
delivery of fuel. In case of Natural Gas (which is supplied by pipeline), these parameters are tested
every day (data supplied by supplier, Gas Authority of India Limited (GAIL)).
During each fuel change like from Naphtha to Natural Gas or vice versa, the efficiency is estimated.
In case of new delivery of Naphtha, Coal & LSHS calorific value and ultimate analysis is conducted.
If there is no change in fuel properties and boiler efficiency parameters remain unaffected during
operation, earlier value of efficiency is taken for estimation of emission reduction.
In case of HRU and HRSGs of Aonla plant, the efficiency factor is not taken into account, but the
Gas Turbine chart has been prepared based on actual run data of GTG/HRSG/HRUs is used to
determine the fuel consumption for steam generation at given electricity consumption. This chart is
validated by monitoring conducting direct efficiency analysis once in six months. Following is the
description of methodology to be used for efficiency determination based on measured parameters in
GTG and HRSG.

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Methodology to calculate direct efficiency of GTG and HRSG system

Parameters measured / required:
Natural gas consumption in GTG ( Nm3 / hr )
Natural gas consumption in HRSG ( Nm3 / hr )
Net Calorific value of Natural gas (kcal / Nm3 )
Power generation by GTG ( MWh)
Power energy factor 860 kcal / kWh
Enthalpy of Feed water (kcal / kg )
Enthalpy of Steam (kcal / kg )
Steam generation by HRSG - ( T / Hr )
Step 1: Calculate net input energy to GTG and HRSG system

Net input energy to GTG and HRSG system (Gcal / hr)
= Input energy to GTG + Input energy to HRSG system
= (Natural gas consumption in GTG ( Nm3 / hr )
X Net Calorific value of Natural gas (kcal / Nm3 ) ) / 1000000
+ (Natural gas consumption in HRSG ( Nm3 / hr )
X Net Calorific value of Natural gas (kcal / Nm3 ) ) / 1000000
Step 2 : Calculate Net output energy from GTG and HRSG system
Net output energy from GTG and HRSG system ( Gcal / hr )
= Output energy from GTG + Output energy from HRSG system
= (Power generation by GTG X 1000 ( MWh)
X Power to energy factor (860 kcal / kWh ) ) / 1000000
+ (Steam generation by HRSG ( T/ hr )
X 1000 X (Enthalpy of steam Enthalpy of feed water) (kcal / kg)) /1000000
Step 3 : Efficiency of GTG and HRSG system
Page 53

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Efficiency of GTG and HRSG system (%)

= Net output energy from GTG and HRSG System
/ Net input energy to GTG and HRSG system
Page 54

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Page 55
Appendix - 1
Other Monitoring Parameters under Monitoring Plan
ID number
Data Variable
Source of
data
Data unit
Measured
Recording
Proportion How will the Comment
(m),
Frequency
of data
data be
calculated
to be
archived?
(c) or
monitored
(electronic/
estimated (e)
paper)
Other Parameters are used to demonstrate that (1) Intended objectives of each scheme are met and ;(2) To demonstrate the contribution of each scheme in emission
reduction)
Kalol plant
D.2.1.1 (b) 1
Carbon
Plant
Percent
Measured & Every Month
Total
Paper
Monoxide (CO)
calculated
and will be monitored Month-wise. The CO slip
slip
ensures the reduction in feed and thereby
subsequent steam consumption in primary reformer.
The data would be archived until 2 years after end
of the crediting period.
D.2.1.1 (b) 2
Temperature
Plant
Deg C
Total
Paper
across new
calculated
Month. This data along with D.2.1.1(b)3 provides
BFW Preheater
the additional heat gain due to CO slip recovery,
which would reduce the steam load on boiler by
same amount. The data would be archived until 2
D.2.1.1 (b) 3
BFW flow
Plant
Tonne / shift
Measured
Every Month
Total
Paper
additional heat gain due to CO slip recovery, which
would reduce the steam load on boiler by same
amount. The data would be archived until 2 years
after end of the crediting period.
D.2.1.1 (b) 4
Process steam
Plant
Tonne / shift
Measured
Every Month
Total
Paper
Measured/calculated in the plant premises to the
flow in primary
best accuracy and will be monitored Month-wise.
This data provides the reduction in steam
reformer
consumption in primary reformer due to CO slip
recovery. The data would be archived until 2 years
Installation of S-50 radial flow synthesis converter and HP /MP Boiler
D.2.1.1 (b) 5
Steam
Plant
Tonne / shift
Measured
Every Month
Total
Paper
consumption in
and will be monitored Month-wise. This data

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ID number
Data Variable
Page 56
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
synthesis gas
turbine
D.2.1.1 (b) 6
D.2.1.1 (b) 7
NH3
concentration
Plant
Steam
Plant
consumption in
synthesis gas
turbine
D.2.1.1 (b) 8
Steam
Plant
consumption in
synthesis gas
turbine
D.2.1.1 (b) 9
Steam
Plant
consumption in
synthesis gas
turbine
D.2.1.1 (b) 10
Pressure drop
across LT shift
Plant
Measured
Every Month
Total
Paper
Synthesis Gas compressor LP & HP case internal replacement

Tonne / shift
Measured
Every Month
Total
Paper
Drying of make-up gas and synthesis loop re-piping

Tonne / shift
Measured
Every Month
Total
Paper
Improvement in outlet systems for HT/LT shift converters

Tonne / shift
Measured
Every Month
Total
Paper
Kg/cm2 (g)
Measured
Every Month
Total
Paper
Comment
indicates the reduction in steam consumption due to

lower load on synthesis compressor. The data would
period.
provides the improved Ammonia Conversion in new
converter and the additional heat of reaction
generating extra steam in MP and HP boiler. The
crediting period.
and will be monitored Month-wise. This data will
indicate the reduction in steam consumption due to
HP and LP case internal replacement of synthesis
gas compressor. The data would be archived until 2
This data is main data to be monitored for the
scheme. The data would be archived until 2 years
The data gives reduction in steam consumption due
to increased suction pressure of synthesis gas
compressor due to lower pressure drop across
LT/HT shift converters. The data would be archived

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ID number
Data Variable
Page 57
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
converter
demonstrates that intended objective of lower

pressure drop across LT/HT shift converters, is
achieved. The data would be archived until 2 years
Revamping of CO2 removal system to 2-stage a-MDEA process
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 11
LP steam
Plant
consumption for
regeneration
D.2.1.1 (b) 12
CO2 slip from

the absorber
Plant
percent
Measured
calculated
& Every Month
Total
Paper
D.2.1.1 (b) 13
Process steam
in primary
reformer
Plant
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 14
D.2.1.1 (b) 15
Steam
Plant
consumption of
the ID fan drive
turbine
CO slip
Comment
Plant
Tonne / shift
Revamp of Induced Draft (ID) Fan drive Turbine

Measured
Every Month
Total
Paper

This data demonstrates the reduction in LP steam
due to implementation of scheme. The data would
period.
ensures that there is no difference in slip of CO2 and
intended purpose of CO2 removal section is being
served. The data would be archived until 2 years
This data demonstrates the effect of scheme on
consumption of steam in primary reformer. The data
crediting period.
The data demonstrates the reduction in MP steam
consumption in ID fan drive turbine, due to
replacement of turbine from back pressure type to
condensing type. The data would be archived until 2
Phulpur Unit I & II

Percent
Total
Paper

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ID number
Data Variable
Page 58
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
calculated
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
D.2.1.1 (b) 16
Temperature
Plant
across new
BFW Preheater
Deg C

calculated
Total
Paper
D.2.1.1 (b) 17
BFW flow
Plant
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 18
Process steam
flow in primary
reformer
Plant
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 19
D.2.1.1 (b)20
Comment

This data provides the reduction in steam
consumption in primary reformer due to CO slip
recovery. The data would be archived until 2 years
Installation of S-50 radial flow synthesis converter and High Pressure (HP) /Medium Pressure (MP) Boiler
Steam
Plant
Tonne / shift
Measured
Every Month
Total
Paper
consumption in
synthesis gas
This data indicates the reduction in steam
consumption due to lower load on synthesis
turbine
compressor. The data would be archived until 2
Plant
%
Measured
Every
Month
Total
Paper
NH3
concentration

CDM Executive Board
ID number
Data Variable
Page 59
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
Comment

crediting period.
D.2.1.1 (b) 21
Steam
Plant
consumption in
synthesis gas
turbine
D.2.1.1 (b) 22
Inlet
temperature of
make up gas of
synthesis
compressor
D.2.1.1 (b) 23
D.2.1.1 (b) 24
Plant
Steam
Plant
consumption in
synthesis gas
compressor
turbine and
refrigeration
turbine.
Steam
Plant
consumption in
synthesis gas
turbine
Pressure drop
Plant
Tonne / shift
Installation of Make-up gas chiller

Measured
Every Month
Total
Paper
Deg C
Measured
Paper
Every Month
Total
Phulpur Unit I
Drying of make-up gas and synthesis loop re-piping
Tonne / shift
Measured
Every Month
Total
Paper
Improvement in outlet systems for HT/LT shift converters

Tonne / shift
Measured
Every Month
Total
Paper
Kg/sqcm(g)
Measured
Every Month
Total
Paper

This data will provide reduction in steam
consumption due to improvement in volumetric
efficiency of compressor. The data would be
period.
Month. This data will provide indication of
improvement
in
volumetric efficiency of
compressor, due to reduction in temperature of inlet
gas. The data would be archived until 2 years after

and will be monitored Month-wise. This data will
provide the reduction in steam consumption due to
reduced power requirement of synthesis gas
compressor turbine and refrigeration turbine. The
crediting period.
The data gives reduction in steam consumption due
to increased suction pressure of synthesis gas
compressor due to lower pressure drop across
LT/HT shift converters. The data would be archived

CDM Executive Board
ID number
Data Variable
D.2.1.1 (b) 25
across LT shift
converter
Page 60
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
Comment

This data demonstrates that intended objective of
lower pressure drop across LT/HT shift converters,
is achieved. The data would be archived until 2
Complete revamping of Co2 removal system to a modern to 2stage GV process
D.2.1.1 (b) 26
LP steam
Plant
consumption for
regeneration
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 27
CO2 slip from

the absorber
Plant
Percent
Measured
calculated
& Every Month
Total
Paper
D.2.1.1 (b) 28
Process steam
in primary
reformer
Plant
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 29
CO slip
Plant
D.2.1.1 (b) 30
Temperature
across new
Plant

period.
crediting period.
Aonla Unit I & II

Percent
Total
Paper
calculated
Deg C
Total
Paper
calculated

CDM Executive Board
ID number
Data Variable
Page 61
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
BFW Preheater
D.2.1.1 (b) 31
BFW flow
Plant
D.2.1.1 (b) 32
Steam
Plant
consumption in
synthesis gas
turbine
D.2.1.1 (b) 33
NH3
concentration
Plant
Tonne / shift
Measured
Every Month
Total
Installation of S-50 radial flow synthesis converter and HP /MP Boiler

Tonne / shift
Measured
Every Month
Total
Paper
Measured
Every Month
Total
Paper
Paper
D.2.1.1 (b) 34
Steam
Plant
consumption in
synthesis gas
turbine
Tonne / shift
Installation of Make-up gas chiller

Measured
Every Month
Total
D.2.1.1 (b) 35
Inlet
temperature of
Deg C
Measured
Plant
Paper
Every Month
Total
Paper
Comment

This data indicates the reduction in steam
consumption due to lower load on synthesis
compressor. The data would be archived until 2
crediting period.
This data will provide reduction in steam
consumption due to improvement in volumetric
efficiency of compressor. The data would be
period.
Month. This data will provide indication of

CDM Executive Board
ID number
Data Variable
Page 62
Source of
data
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
make up gas of
synthesis
compressor
Comment
improvement
in
volumetric efficiency of
compressor, due to reduction in temperature of inlet
gas. The data would be archived until 2 years after
Aonla Unit I
Complete revamping of Co2 removal system to a modern to 2stage GV process
D.2.1.1 (b) 36
LP steam
Plant
consumption for
regeneration
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 37
CO2 slip from

the absorber
Plant
Percent
Measured
calculated
& Every Month
Total
Paper
D.2.1.1 (b) 38
Process steam
in primary
reformer
Plant
Tonne / shift
Measured
Every Month
Total
Paper
D.2.1.1 (b) 39
Outlet
Plant
Temperature of
process
condensate
from
condensate feed
exchanger
Deg C
Aonla Unit II
Installation of additional process Condensate / PC Exchanger
Measured
Every Month
Total
Paper

period.
crediting period.

Month. The data provide the additional quantity of
steam generated and thereby reducing load on fuel
fired boilers. The data would be archived until 2
Modification of HT steam super heat coil in waste heat section of primary reformer

CDM Executive Board
Page 63
ID number
Data Variable
Source of
data
D.2.1.1 (b) 40
Outlet
Plant
Temperature of
HP steam at
super heater
D.2.1.1 (b) 41
Flue gas
temperature
going to stack
Plant
D.2.1.1 (b) 42
LP steam
import from
power plant to
Ammonia I
plant
Plant
Data unit
Measured
Recording
(m),
Frequency
calculated
(c) or
estimated (e)
Measured
Every Month
Proportion
of data
to be
monitored
How will the

data be
archived?
(electronic/
paper)
Paper
Comment

Month (either using instantaneous instrument or
through DCS). This data provides the waste heat
gain in primary reformer to increase superheat of
steam and reduce steam consumption. The data
crediting period.
New Combustion Air Module in Waste Heat Section of Primary Reformer in Ammonia II
Deg C
Measured
Every Month
Total
Paper
Month (either using instantaneous instrument or
through DCS). This data provides the waste heat
gain in primary reformer to increase superheat of
steam and reduce steam consumption. The data
crediting period.
Saving of HP steam in power plant
Tonne / shift
Measured
Every Month
Total
Paper
Deg C
Total

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Page 64
Appendix - 2
LIST OF ABBREVIATIONS
CC
CDM
CER
CO
CO2
CP
Cum
DCS
DOE
DPR
EB
EIA
GHG
GJ
GV
GOI
GoUP
GEB
GWh
HP
HR or hr
HV
IPCC
IFFCO
KP
LP
1 Lakh
MkWh
MU
MT
NG
p.a.
PDD
PFD
PLF
PIN
SSCR
TJ
TPH
UNFCCC
UP
UPPCB
LSHS
HTAS
Climate Change
Clean Development Mechanism
Certified Emission Reductions
Carbon Monoxide
Carbon di-oxide
Credit Period
Cubic Meter
Distributed Control System
Designated Operational Entity
Detailed Project Report
Executive Board
Environmental Impact Assessment
Green House Gas/es
Gega Joules
Giammarco-Vetrcoke
Government of India
Government of Uttar Pradesh
Gujarat Electricity Board
Gega Watt hour
High Pressure
Hour
High Voltage
Intra-governmental Panel for Climate Change
Indian Farmers Fertilizer Cooperative
Kyoto Protocol
Low Pressure
1,00,000
Million Kilo Watt hour
Million units
Metric Ton
Natural Gas
Per annum
Project Design Document
Process Flow Diagram
Plant Load Factor
Project Idea Note
Specific Steam Consumption Ratio
Trillion Joules
Tones Per Hour
United Nations Framework Convention on Climate Change
Uttar Pradesh
Uttar Pradesh Pollution Control Board
Low Sulphur Heavy Stock
Haldor Topsoe

CDM Executive Board
Page 65
Appendix - 3
LIST OF REFERENCES
Sr.No
Particulars of the references

Kyoto Protocol / UNFCCC Related
1.
Kyoto Protocol to the United Nations Framework Convention on Climate Change
2.
Website of United Nations Framework Convention on Climate Change (UNFCCC),

http://unfccc.int
3.
UNFCCC Decision 17/CP.7 : Modalities and procedures for a clean development

mechanism as defined in article 12 of the Kyoto Protocol.
4.
UNFCCC document, Clean Development Mechanism-Project Design Document (CDMPDD) version 01(in effect as of: August 29, 2002)
5.
UNFCCC document : Annex B to attachment 3 Indicative simplified baseline and

monitoring methodologies for selected small scale CDM project activity categories ver
01, January 21, 2003.
6.
Intergovernmental Panel on Climate Change (IPCC) Document on emission factors.

IPCC-1996-Rev.
7.
Steam tables to determine enthalpy of steam
8.
National Document to refer fuel emission factor, if any.

Project Related
9.
Project scheme documents and records from IFFCO records
10. M/s HTAS energy audit/ retrofit study report

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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

CDM Executive Board

CLEAN DEVELOPMENT MECHANISM

General description of project activity

Application of a baseline methodology

Duration of the project activity / Crediting period

Application of a monitoring methodology and plan

Estimation of GHG emissions by sources

Annex 1: Contact information on participants in the project activity

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

SECTION A. General description of project activity

Title of the project activity:

Reduction in Steam Consumption through Revamping of Ammonia Plant of Indian Farmers

Description of the project activity:

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Technical description of the project activity:

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

A.4.1.4.Detail of physical location, including information allowing the unique identification of

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Table 1 - Details of energy efficiency schemes

Installation of Make-up Gas Chiller

Synthesis Gas Compressor LP (Low Pressure) & HP case Internal Replacement

Drying of Make-up Gas and Synthesis Loop Re-piping

Complete revamping of CO2 removal system to a modern two-stage GV process

Installation of additional Process Condensate (PC) / PC Exchanger at Aonla-II

New Combustion Air Module in Waste Heat Section of Primary Reformer

Closing steam balance for Aonla unit I

Closing steam balance for Aonla unit II

Complete revamping of CO2 removal system to a modern 2-stage GV process at Phulpur - I

Revamping of CO2 removal system to 2-stage a-MDEA process at Kalol

Revamp of Induced Draft (ID) Fan Drive Turbine at Kalol

Closing steam balance for Kalol Plant

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Estimated amount of emission reductions over the chosen crediting

Annual estimation of emission

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Total number of crediting years

A.4.5. Public funding of the project activity:

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

SECTION B. Application of a baseline methodology

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Overall IRR of all plants

IRR (%) without CDM fund

IRR (%) with CDM funds

IRR (%) without IRR

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

Primary and Secondary Reformers section

LT and HT Shift Converter section

CO2 removal Section

Synthesis Loop Converter section

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

LSHS Fired Boiler and

CO2 Removal Section

Synthesis Converter Section

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02