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INDUSTRIAL TRAINING PRESENTATION ON

POWER GENERATION
AT
IFFCO,AONLA

PRESENTED BY:
DIVYA PRAKASH SRIVASTAVA
ME-G, IV YEAR

ABOUT IFFCO, AONLA

Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) was entrusted for setting up a
urea fertiliser complex with annual capacity of 8.646 lakh tonnes of urea at
Aonla, Bareilly.

There are two plant namely ANOLA-1 having capacity of 1520 MT per day and
ANOLA-2 having capacity 2620 MT per day.

The implementation of Aonla-I project has been taken as a model for future
fertiliser projects by Government of India.

IFFCO Aonla-I has also bagged two prestigious national awards one for best
project implementation (second prize) from Ministry of Programme
implementation, Govt. of India and other for technical film New Horizons
Aonla project from Fertiliser Association of India (FAI) in the year 1989.

IFFCO In Brief
PHULPUR UNIT

KALOL UNIT
Year of Commissioning
- 1975
Annual Ammonia Capacity - 3.63 Lakh MT
Annual Urea Capacity
- 5.45 Lakh MT
CORPORATE OFFICE
NEW DELHI

Year of Commissioning
1981/1997
Annual Ammonia Capacity - 8.24
Lakh MT
Annual Urea Capacity
- 14.16
Lakh MT

KANDLA UNIT
Year of Commissioning - 1975
Annual NPK/DAP Capacity24.15Lakh MT

AONLA UNIT
PARADEEP UNIT
Year of Acquiring - SEP2005
Annual Capacity -20.00
Lakh MT
(DAP + COMPLEX)

Year of Commissioning
1988/1996
Annual Ammonia Capacity 10.03 Lakh MT
Annual Urea Capacity
17.29 Lakh MT

AMMONIA PLANT
Capacity-1740MTPD
Consultant- M/s Haldor Topsoe, Denmark
Main raw material-natural gas i.e. 1.7
million cube per day(supplied by GAIL)

UREA PLANT
Capacity-1515MTPD
Consultant- M/s Snam Progetti, Italy
Based on- Snamprogetti, ammonia
stripping process.
Main raw material-ammonia and co2

POWER GENERATION
In

order to provide power to the plant IFFCO, Aonla uses two


GAS TURBINE GENERATOR, one Steam Generator (SG)
and two Heat Recovery Steam Generating units (HRSG).

The

GTG, manufactured by M/S Hitachi limited, Japan has a


capacity to generate 25.280 MW at ISO base rating or 18.320
MW power output at the site conditions.

Two

HRSG units each having capacity to generate 80 T/hr at


116 atm and 515 deg C is manufactured by M/s Kawasaki
heavy industries, Japan.

CONTINUED
The

exhaust of GT at about 500 deg C will be used in


HRSG to generate steam at high pressure.

The

SG unit is a water tube double drum, natural


circulation, oil (low sulphur high start, LSHS) or natural
gas fired boiler manufactured by M/s Mitsui Engg. Co.
Japan.

The

capacity of the SG unit is 150 tons/hr of super-heated


steam at pressure of 116 atm and temp 515 deg C.

STEAM GENERATION
The

generated steam have pressure of 116 atm and temperature of about


515 deg C.

The

overall requirement of steam for the plant is about 220 tonne per

day.
The

two Heat Recovery Steam Generator of capacity 80 tonne each


provide 160 tonne of steam required.

The

remaining is generated inside the water tube boiler. Boiler takes the
load of changing requirement of steam inside the plant.

CONTINUED
The

steam generator is designed to fire HSD, LSHS/FO,


and NG with four set of oil and gas combination
burners.

Exhaust

gas from the gas turbine is used in the HRSG to


generate steam.

STEAM GENERATOR(BOILER)
The

steam generator comprises a water cooled furnace, a


convection bank, steam and water drum, headers for
collecting and distributing water and steam, primary and
secondary super heater, framed, casing insulation etc.

It

takes up the load of changing demand of steam in different


operation performed inside the plant.

It

also has a Boiler Feed water system to provide water of


desired quality to the boiler for the generation of steam.

HEAT RECOVERY STEAM GENERATOR


Aheat

recovery steam generatororHRSGis anenergy


recoveryheat exchangerthat recovers heat from a hot gas
stream. It produces steamthat can be used in a further
process.

Two

HSRG generate 160 tonne of steam per hr.

It

recovers heat from the flue gases coming from the gas
turbine.

HRSGs

consist of four major components: the economizer,


evaporator, Superheater and water pre heater.

GAS TUBINE POWER PLANT


The simple gas turbine power plant mainly consists of a gas
turbine coupled to a rotary type air compressor and a combustor
or combustion chamber which is placed between the compressor
and turbine in the fuel circuit. Auxiliaries, such as cooling fan,
water pumps, etc. and the generator itself, are also driven by
the turbine. Other auxiliaries are starting device, lubrication
system, duct system, etc. A modified plant may have in addition
to the above, an inter-cooler, a regenerator and a preheater.

PRINCIPLE OF OPERATION

Intake
- Slow down incoming air

- Remove distortions
Compressor

- Dynamically Compress air


Combustor

- Heat addition through chemical


reaction
Turbine

- Run the compressor


Nozzle/ Free Turbine
- Generation of thrust power/shaft
power

Arrangement of Closed Cycle Gas Turbine


Plant

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