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					National Fertilizers Limited
UNIT PROFILE: -

        National Fertilizers Limited was established on 23rd August 1974 for setting up two fertilizer plants
        at Bhatinda (Punjab) and Panipat (Haryana) based on partial oxidation of fuel oil. W hen Govt. of
        India undertook the task of reorganization of fertilizer sector in 1978; the Nangal Unit of Fertilizer
        Corporation of India was merged with National Fertilizers Limited. Later on NFL executed two
        numbers gas-based plant at Vijaipur (Madhya Pradesh) on HBJ gas pipeline. National Fertilizers
        Limited is now operating three fuel oil based plants located at Nangal, Bhatinda and Panipat and
        two gas based plants, at Vijaipur. The capacity of three fuel oil based plants is; 900 Te/day of
        Ammonia, and 2*1350 TPD of gas based plant at Vijaipur. 1000 TPD of urea at Nangal, which has
        been revamped to a capacity of 1448TPD in 2000-01 and 1550 TPD of urea at Bhatinda and
        Panipat. Capacity of gas-based plant at Vijaipur is 4*1100 TPD of urea. Company at present
        occupies the position of the largest producer of Nitrogenous fertilizers in the country.
        National Fertilizers Panipat.
                                               The Government of India approved the Panipat Project on 10th
                                     February 1975 for implementation. Prime consultants for design, engineering
                                     and erection and commissioning of the plants were M/s. Toyo Engineering
                                     Corporation of Japan and M/s. Engineers India Limited. Starting from the zero
                                     date of 30.4.1975, the feed in was achieved on 1.9.78. The unit went in
                                     commercial production from 1.9.1979. In 2001-2002, Panipat unit achieved
                                     Ammonia production of 299280 MT (100.77 % of installed capacity) and
                                     511538 MT of urea (100.01 % capacity utilization). The unit has also produced
                                     3104.775 MT Sulphur as by product during the year. Expansion of Panipat unit
                                     with Naphtha/LNG based plant of 1350 TPD of Ammonia and 2200 TPD of
                                     urea is under consideration by Govt. of India.
ii      Energy Consumption:
        Panipat unit consumes fuel oil, LSHS/HPS as feedstock for producing Ammonia as intermediate
        product and Urea as final products. It also consumes coal and furnace oil in auxiliary boilers for
        producing steam and generating power in captive power plant for meeting own requirement of
        power. In addition to captive power generation, provision for import of electricity from Haryana
        State Electricity Board grid has been made in the original set up of the plant. In 2001-2002, NFL
        Panipat unit consumed 242267 MT of fuel oil/LSHS/HPS as feed stock, 583198.773 MT of coal in
        captive power plant boiler and steam boilers, 38110.100 KL of fuel oil in Captive Power Plant and
        steam boilers and 15780 MW of purchased electricity.
        The unit has made consistent efforts in reducing the consumption by different ways such as
        Increase in Capacity Utilization: The unit has achieved more than 100% capacity utilization for the last 5
        years except last year i.e. 2000-2001. This could be achieved by innovative management techniques, better
        maintenance procedures and improved operational methods. This could be achieved even though the plant is
        23 years old. In spite of various constraints such as breakdowns, maintenance problems faced due to coal
        mills, Boiler and more no of equipments in comparison to the latest generation plants, the unit has been able
        to achieve energy consumption figure of 14.009 Mkcal per tonne of ammonia and 9.174 Mkcal per tonne of
        urea in 2001– 2002, which is excellent.
        NFL, Panipat utilized fuels worth Rs.116.83 crores and purchased power worth Rs.8.82 Crores in the year
        2001-2002
 iii)   Energy conservation commitment, policy and set up:
        National fertilizers Limited, Panipat is wholly committed to conserve energy to the fullest possible
        extent. Unit is giving utmost importance to energy conservation by optimization of plant operation
          and process parameters, regular monitoring of fuel consumption, analyzing the reasons of higher
          consumption and eliminating bottlenecks. Since inception of the plant, unit has strived to improve
          the specific energy consumptions by way of devising and implementing energy conservation
          schemes.
          Company has Energy conservation cell under the Department of Technical Services. E.C.Cell is
          headed by Dy General Manager (Technical Services). This cell consists of one Ch. Mgr (TS), one
          Sr. Manager, and two Sr Asstt. Manager and one Asstt. Mgr who coordinate all matters pertaining
          to energy conservation. Performance of various energy conservation schemes and specific energy
          consumption of main product is evaluated and is discussed in fortnightly coordinating meeting
          where all managers including the General Manager (I/C) are present. The action plan required if
          any is prepared and is implemented.
          The fertilizer sector is one of the most energy intensive units. About 85% of the total cost of urea is
          consumed in energy alone. Even a minor reduction in energy consumption results in increasing the
          profit. Hence, the policy of the organization is to reduce the energy consumption to the minimum.
          The new schemes are being implemented based on the techno-economic viability.
 iv)      Energy conservation achievements:
          NFL, Panipat has implemented various energy conservation schemes successfully during last five
          years. Implementation of these schemes has resulted in improvement in steam consumption rate,
          boiler efficiency, better process control and optimization etc. A substantial amount of energy has
          been saved by proper implementation of the energy conservation projects.
v)        Energy conservation plans and target:
          Company waits with eagerness for all opportunities coming in the way to conserve the energy to
          largest possible extent. The following schemes are under implementation for improving the energy
          performance further.
          Up gradation of critical control loops with micro processor based control system:
          Various control loops, which are very critical from consistent operation point of view, are
          identified and then these control loops are being upgraded to microprocessor based control system.
          An expenditure of about Rs. 25 lakhs is likely to be incurred on these schemes. Implementation of
          this scheme would result in increased on stream days of the plant.
       vi) Environment and Safety:

          A brief write up on Environment:
          A chemical factory is likely to produce some effluents in the form solid, liquid or gases, which
          may or may not be toxic. These effluents have to be necessarily treated before disposal to
          outside so that the ecological balance is not affected. At Panipat unit, utmost care was taken
          during the design stage of the plant/units to control all the pollutants at the source.
          Panipat unit is basically an Ammonia-Urea fertilizer complex having a capacity of 900 MTPD
          Ammonia & 1550MTPD Urea. There is auxiliary steam generation plant to produce high
          pressure steam to meet the needs of various processes; utilities plant to meet the requirement
          of Power; DM water-Cooling Water, etc and Effluent Treatment Plant to treat the liquid
          effluent.
          Type of effluents generated and procedure for their treatment are summarized below:
A.    Effluent Generation
   1.     Solid Effluents:
          The solid effluents generated in Ammonia plant on account of thermal cracking of heavy oil in
          Gasifier is being recycled back to the system as carbon oil after mixing with heavy oil.
          However, during start up / shutdown and in case of any disturbances in Carbon Recovery
          Plant, the carbon is being dumped to the LDPE lined (ski ten) nearby ponds in the form of
           carbon slurry. The dried carbon from the pond is being sold to the out side parties having
           authorization from Haryana State Pollution Control Board.
           The other solid effluent generated is ash in coal-fired boilers. The ash collected in ESP’s in the
           boiler is being dumped out in the form of ash slurry at Dahar pond @ distance of 7 Kms from
           factory premises. The over flow water from Dahar pond, which meets the MINAS norms, is
           being utilized for irrigation purpose nearby villagers. The ash slurry pond at Dahar is
           thoroughly LDPE lined to prevent leaching of pollutants if present.
    2.     Liquid Effluents:
           The liquid effluent generated from main process plant Ammonia, Urea plants are diverted to
           the Effluent Treatment Plant, waste water generated from DM Water plant during the course
           of regeneration of cat ion and Anion units are also diverted to Effluent Treatment Plant. The
           Sewage generated in the township as well as in factory premises are also diverted to Effluent
           Treatment Plant. The Effluent water containing Ammonia and Urea are treated by biological
           process with the help of other liquid effluent generated in DMW
           Plant and sewage water. The out going treated water from Effluent Treatment Plant, which
           meets MINAS norms, is being used for de-ashing purpose in SGP and CPP Boiler.
    3.     Gaseous Effluent:
        The gaseous effluent from Ammonia Plant
           In Ammonia plant two types of gaseous effluent are generated-one during the start up of the
           plant, which is burnt at 75-meter tall flare stack before release to atmosphere. The other
           gaseous effluent generated during normal operation of the plant is tail gas, off gases&H2S
           bearing Claus gas. The tail gas is being utilized in Steam Super heater to super heat the steam
           produced in Waste Heat Boilers in Ammonia plant, incinerator in Sulphur Recovery plant & in
           CPP Boiler. A little amount of tail gas is being utilized in flare stack to keep the flame on
           continuous basis. The off gases, which contains mostly CO2 & N2 and having no heat value is
           released to atmosphere through the 75-meter tall flare stack. The Claus gas, which is sent to
           Sulphur Recovery Plant, and elemental Sulphur, @ purity of 99.9% is being extracted by
           oxidation –reduction process. The effluent gas from Sulphur Recovery Plant after burning in
           incinerator where heat is being recovered to produce low-pressure steam is vented through a
           50-meter tall chimney. The effluent gases from Sulphur Recovery Plant meets MINAS norm.
           Thus, not only the pollution is controlled but valuable substance i.e. elemental Sulphur is being
           recovered resulting in saving of foreign exchange.
        Flue gas from Boiler Chimney:
           The flue gas from Boiler chimney is vented through 80/90-meter tall chimney from SGP and
           CPP boilers after passing through electrostatic perpetrator having an efficiency of more than
           99%. SPM content in the flue gas in the boiler chimney remains below the MINAS norms.
       Dust recovery from Urea Plant
           Urea dust recovery system has been installed at the tope of Prilling Tower 68 meter high. The
           dust evolved by urea prilling is being scrubbed by spraying water from spray nozzles in a
           header provided around the prilling tower. The remaining dust after scrubbing operation is
           being retained by the foam filters provided at the top. There are four Induced Draft Fans
           provided at the top having a capacity of 1,80,000 Nm3/hr each. The gases effluent so
           discharged contain less than 50 ppm of urea. Automatic washing of the foam filters is done to
           further improvement in the existing system.

B     Ecological balance:
           To maintain the ecological balance about 2.5 lakhs trees have been planted in and around
           factory premises, township and CISF colony area. A green belt @ area of 1400 sq meter has
           also been provided around the factory premises as per the environment control board advice.
           Besides it a dear park has also been developed in the township and bird century near the factory
           premises. All these means are very useful to keep the ecological balance
             To keep a close watch on the performance of pollution control on line monitoring equipments
             has been provided in various plants. ISO Kinetic stock samplers are monitoring stack emission
             regularly. This ensures the optimum level of emission at source as well as efficiency of the
             stacks. Some of the stacks are equipped with on line analyzers like smoke density, carbon
             monoxide, oxygen and Sulphur dioxide. Ambient air and stack monitoring is also got done by
             accredited out side agencies from time to time in order to ensure adherence to various
             emission norms.
             For the reference of dispersion of air pollutants, a computerized wind monitoring system has
             been installed at one of the monitoring stations. The system is automatic and computes average
             wind speed and direction after every ten seconds. In addition to this, max-min temperature,
             relative humidity, semi fall measurement is also done and the date is recorded continuously.




           ISO 14001
           NFL Panipat is committed to achieve Pollution free environment and balanced ecology by
           adopting Environmental Management System. The Unit is conducting regular Environmental
           Audits and compliance with the statutory and legal requirements. Based on the environment
           Policy of NFL, Panipat the Unit engaged M/S KPMG Quality Registrar for carrying out audit
           leading to award of ISO 14001-1996 On successful completion of all the audits and statutory
           requirements, our Unit was recommended for this prestigious award and the Certificate was
           received on 1st June 2000.
           “THE AWARD OF ISO 14001-1996 CERTIFICATE TO THE UNIT IS COMMITMENT
           TO POLLUTION FREE ENVIRONMENT IN AND AROUND THE FACTORY AND
           SOCIETY AS A WHOLE.”
           It is a fact that pollution controls having no limits, but our efforts shall never be lacking to
           achieve lowest emissions. Our R&D work group is also well engaged in developing technology
           to improve the present treatment system and to utilize services of experts and best technology
           available in this regard.
           It will be a pleasure for us to record here that due to effective participation of Management in
           the field of environment protection, Panipat Unit has got the following awards;
 Haryana Govt. awarded Ist prize for ENVIRONMENT MANAGEMENT & CONSERVATION on the
  World Environment Day on 5th June 1994.
 International Greenland Society has adjudged our Unit as one of the best Organization in implementing
  pollution control measures and awarded the JAWAHARLAL NEHRU MEMORIAL NATIONAL
  AWARD for the year 1995.

Safety:
             Company has always maintained its consciousness towards safety of the employees. Unit has a
             full-fledged Safety Department, which consists of well-qualified and experienced Safety
             Engineers. This department ensures that the working conditions are safe, safety procedures are
             followed and personal protective equipments are used. A number of schemes, exhibitions,
             bulletins, safety competition and good house keeping contests are conducted by Safety
             Department for inculcating the feeling of safety amongst the employees. Safety committees at
             the plant level are encouraged to give suggestions to improve the safety in operation and at
             work place. On site Emergency Management Plan, has been prepared by the company for
             handling emergencies by making optional use of resources. The unit has achieved a number of
             awards at various times which are listed as under.
1. COMPANY PROFILE
          National Fertilizers Limited, (NFL), a leading producer of
  Nitrogenous Fertilizers in India, was incorporated on 23rd August, 1974
  with two manufacturing Units at Bathinda and Panipat. Subsequently, on
  the reorganization of Fertilizer group of Companies in 1978, the Nangal
  Unit of Fertilizer Corporation of India came under the NFL fold.
  The Company expanded its installed capacity 7.26 lakh Mts. in 1984 by installing
  and commissioning its Vijaipur Gas based Plant in Madhya Pradesh.

        The Vijaipur Plant was a land mark achievement in project
  management in India. The Plant was completed well within time and
  approved project cost, in recognition of which it was awarded the Ist
  price in Excellence in Project Management by Govt. of India.
  Subsequently the plant doubled its capacity to 14.52 lakh MT by
  commissioning Vijaipur Expansion Unit in 1997.

         NFL, a profitable public sector undertaking operates under the
  administrative control of the Deptt. of Fertilizers in the Ministry of
  Chemicals & Fertilizers.

         NFL, a Schedule -A & Mini Ratna Category-I Company, is a
  market leader in the fertlizer industry with a market share of 13.7%(During
  the 2001-02). The Company's strength lies in its sizeable presence,
  professional marketing team and its strong distribution network nationwide

         National Fertilizers Limited is the second largest producer of
  nitrogenous fertilizer in the country and has four operating fertilizer units
  located at Nangal, Bhatinda, Panipat and Vijaipur with a total installed
  capacity of 32.083 lakh tones Urea.

          The Vijaipur unit comprises of two streams-Vijaipur-I and
  Vijaipur-II, which went into commercial production in July, 1988 and
  March, 1997 respectively. Both the streams are based on “Steam
  reforming process” of Haldor Topsoe (Denmark) for Ammonia plants and
  “Ammonia stripping process” of Snam Progetti (Italy) for Urea plants.
  Vijaipur-I was adjudged as the „Best Implemented Project‟ by the Ministry
  of Program Implementation G.O.I. in the year 1989.
          Vijaipur-II Plant is the latest state of art technology and is highly
  energy efficient than Vijaipur-I Plant due to incorporation of energy
  saving schemes in the process at the design stage itself. It is also having
  provision of mixed feed (Natural Gas + Naphtha) thus giving more
  flexibility of operation. Both the plants have consistently achieved high
  levels of capacity utilization logging an annual average of 110%.
            The overall performance of National Fertilizers Limited, Vijaipur
    for the year 2001-2002 was as under.
                 Urea production (MT) :                   1,706,823
               Sales turnover (Rs.Crores):                126,537.07
               Gross profit (Rs. Crores) :                  189.59


HIGHLIGHTS & ACHIEVEMENTS FOR THE YEAR 2001-2002
   Unit was certified for ISO-14001 by an independent International auditors M/s
    KPMG of Nether land. We are already ISO-9002 certified unit since 1997. The
    M/s KPMG of Netherland did renewal of ISO-9002 and ISO-14001 for the next
    three years.
   Lowest ever Specific Energy Consumption of 5.984 Gcal/MT Urea was achieved
    by the Complex(Vijaipur-I + Vijaipur-II) . Previous lowest Specific Energy
    Consumption for the Complex was 6.002 Gcal/MT Urea (achieved in 1999-2000)
   Vijaipur-II achieved lowest ever annual specific energy consumptions of 7.816
    Gcal/MT ammonia & 5.713 Gcal/MT Urea. Previous lowest annual specific
    energy(achieved in 2000-2001) : 7.825 Gcal/MT for Ammonia & 5.737 Gcal/MT
    for Urea
   During the year, NFL Vijaipur achieved highest ever quarterly & annual
    despatches of 514651.00 MT (July-Sept.'2001) & 1713052.9 MT respectively
    surpassing previoust highest quarterly & annual despatches of 488150.6 MT
    (achieved in July-Sept.'2000) & 1695323.0 MT (achieved in 1998-1999)
   Primary Reformer of Ammonia-II achieved longest ever continuous operation of
    390 days. It continued to run without any interruption from 10.02.2001 to
    07.03.2002 when it was stopped for annual turn-around. Primary Reformer of
    Ammonia-I also achieved continuous operation of 350 days.
   Commendation Certificates from Ministry of Power for "Excellence in Energy
    Conservation " in Fertilizer Sector for the years 1999 & 2000 ,awarded to N.F.L.
    Vijaipur, were received by C.M.D. on 14.12.2001.
        Safety Audit was conducted by M/s PDIL, NOIDA in 2001-2002.
         Recommendations implemented.
        Off-Site Emergency Plan prepared and approved by State Govt. authorities. On-
         site Emergency plan was revised and improved upon.
        A „Comprehensive Environmental Impact Assessment Study‟ is carried out third
         party - M/s CICON Technologies Ltd., Bhopal.
2.       ENERGY CONSUMPTION
                NFL Vijaipur Unit consumes Natural Gas (NG) and Liquid fuel Naphtha
         as raw material/ fuel. Overall Energy Consumption / MT Urea in the year 2001-
         2002 is 5.984 Gcal/MT of Urea which Is lower than the previous year figure of
         6.008 Gcal/MT of Urea.
                In the year 2001-2002, annual electricity cost was Rs.41.20 Crores which
         is higher than previous year value of Rs.37.49 Crores. This was due to increase in
         usage of electric motors. In the year 2001-2002 Naphtha usages was high due to
         Natural Gas Limitation from M/s. GAIL.
                Energy consumption (Cost Of Natural Gas & Naphtha) was 90% of the
         total manufacturing cost.
3.       ENERGY CONSERVATION COMMITMENTS, POLICY AND SET UP
         MANAGEMENT COMMITMENT TOWARDS ENERGY CONSERVATION:
         Being one of the largest producers of Nitrogenous fertilizers in the country, NFL
visualized the importance of energy conservation and consumption in the fertilizer
industry and took the lead in this direction by establishing Energy Conservation Cells at
the Corporate Office and at the Unit levels. The underlying policy is four pronged
         1.     Energy monitoring and control
         2.     New technology absorption and adaptation
         3.     Carry out Energy audits both internal as well as external
         4.     Energy consumption benchmarking with a target to achieve the best.
The basic objectives of this energy cell are:
         -Monitoring daily and monthly energy consumption data from each plant.
         - Evaluation of energy performance by Steam and Material balance of each plant
         - Check list of steam traps, insulation, leakages, vent valve passing .
     -Machine and plant efficiency calculation- heat exchangers etc.
     -Process parameters and catalyst performance evaluation.
     - Inform the plant for remedial measures / actions.
     - Prepare action plans based on energy consumption analysis.
            In addition to the regular monthly energy audit by an in-house technical
     group, energy audit activities are also planned on the basis of energy audit
     conducted at an appropriate interval of time through out side agencies.


     CORPORATE POLICY OF UNIT ON ENERGY CONSERVATION:
            Energy conservation as corporate policy caries the highest importance in
     N.F.L. The energy consumption norms have been fixed for each operation and are
     closely monitored on daily, monthly, quarterly and yearly basis.


            Based on the energy audit studies, the following broad strategy was
     formulated for the reduction of energy consumption by NFL.
            -Increase capacity utilization
            -Increase On-stream efficiency and On-stream days
            -Improve operation and maintenance practices and implement other good
            house keeping     measures
            - Implementation of major modifications and retrofits
            - Maximum utilization of waste and by products
            - Training and Motivation on energy conservation.
4.   ENERGY CONSERVATION ACHIEVEMENTS
            Over the years since commissioning of plants, persistent efforts have been
     made to improve energy performances & various energy saving schemes have
     been implemented which have resulted in considerable monetary savings. With
     the commissioning of Vijaipur-II, energy level has further reduced. In the year
     2001-2002 energy consumption was 5.984 Mkcal/Ton of Urea which was lower
     than the value for the year 2000-2001.
            Though normal industry practice is to take major turnaround every year,
     we have improved the reliability of plants and machinery by various past
     modifications and the shut-downs have been reduced to once in two years thereby
     increasing the on-stream days of the plant at optimum loads.
             In the year following energy conservation measures were implemented
     successfully. Brief description is listed below.
             In house study by technical services on Performance of Pumps in the
     Ammonia / Urea / Offsites facilities. On the basis of the study it was found that at
     various points it was possible with slight modifications to stop extra pumps which
     were in line. On the basis of pump report following pumps were stopped.
             Urea-I Plant:    Two     number    pumps(P-6/P-22)     supplying flushing
     condensate at various points were provided in Urea Plants. As per inhouse study
     Medium Pressure Flushing Pump P-6 was stopped by providing interconnection
     between P-6 and P-22 pumps. Similarly two number pumps (P-6/P-13 ) for LP
     Flushing was provided, one for exporting the condensate and another for
     supplying LP condensate at various flushing points of Urea Plant. As per inhouse
     study Medium Pressure Flushing Pump P-10 was stopped by providing
     interconnection between P-13 and P-10 pumps.
             Offsites: Two number service water pumps were required to be run to
     maintain the required pressure in the complex. With the running of both pumps
     capacity was not optimally utilized. With optimisation at consumption points it
     second service pump was stopped and around 22 Kwh power was saved.
5.   ENERGY CONSERVATION PLANS AND TARGETS
             Though the energy conservation is a continuous and everlasting process,
     NFL, Vijaipur has been making all out efforts in the field of energy saving. With
     a view to improving the energy performance further and conserving energy,
     number of energy saving schemes, based on recommendations of energy audit,
     are planned to be implemented. Some of them are given below:
     (i)     Replacement of two numbers back pressure turbine with motors,
     (ii)    Replacement of GRP blades with FRP in Urea-I cooling tower fans.
     (iii)   Replacement of defective steam traps.
       Further a Comprehensive in-house study is being undertaken to reduce
energy consumption of Line-I Plants. Measures, which were being considered for
implementation and are at various stages of approval stage are listed below:
·      Replacement of CO2 Compressor Turbine from 40ata to 105ata.
·      Installation of High Efficiency trays in Urea Reactors.
·      Augmentation of Sweet water cooling system of synthesis section.
·      Revamp of Benfield section.
·      Installation of DCS control system for Line-I Plants.


6.         ENVIRONMENTS AND SAFETY


6.1    ENVIRONMENT
       National Fertilizers Limited, Vijaipur is an ISO-14001 unit. This
certification has been given by KPMG Netherlands based on the audit carried out
by them in the year 1998-99. At NFL, Vijaipur, utmost importance is given to
'Environment Protection' in and around the complex. The NFL management
thought of an elaborate system of environment monitoring, treatment and
controlled discharge of effluents right from the planning stage of the Vijaipur-I
project.




CONCEPT OF ZERO EFFLUENT DISCHARGE
       A unique concept of zero effluent discharge was adopted at N.F.L.
Vijaipur due to the inadequate supply of water due to non-availability of large
water sources near the project. The treated wastewater from the factory is
exclusively used for irrigation purposes in the green belts as well as in kitchen
garden with excellent results.


ENVIRONMENT MONITORING CELL
        There is a cell called “Environment Monitoring & Control” which
exclusively looks after environmental aspects.
        National Fertilizers Limited Vijaipur has won various environmental
awards in view of excellent performance in pollution control and environment
protection. It has won Annual State level award 2000 on Environment by Ministry
of Housing and Environment and Jawaharlal Nehru Memorial National Award for
year–2000 for pollution control and energy conservation methods.


AIR POLLUTION CONTROL
        The generation of dust in Urea Prilling Tower is kept well within the
stipulated limits by using a rotary bucket for prilling. Further the prilling towers
are constructed sufficiently tall high (98 meter & 104 Mtr respectively in Line I &
Line II) to facilitate proper disbursement of the dust from the prilling tower
exhaust. The ground level dust concentration is well within the limits.
        Dust extraction systems have also been installed to reduce urea dust in the
vicinity of plant.
        Natural gas or NGL/Naphtha is used as fuel in all the furnaces at NFL,
Vijaipur. Since natural gas contains almost nil (<1ppm) sulfur and sulfur based
compounds, the SO2 and S.P.M. are almost negligible in stack emissions. The
concentration of NOX is also well within stipulated the limits as low NOX
burners have been used in furnaces.


GREEN BELT DEVELOPMENT
        To improve the ecological balance of environment an extensive
programme has been taken up for tree plantation in and around the NFL Complex.
About 2,00,000 trees of 86 different species have been planted so far by NFL
Management covering approx. 206          hectares   of land. In addition to the a
forestation work, horticulture development has been taken up in an area of about
30 hectares. Based on the suggestions given by National Environmental
Engineering Research Institute,(NEERI) Nagpur, the fast growing trees with
thick canopy cover and thick perennial foliage have been planted. This barren
       stretch of land which had no tree to start with has now about 2,00,000 trees and
       the greenery around the complex is testimony to the efforts made by NFL for its
       development.


       6.2     SAFETY
               At National Fertilizers Limited, Vijaipur, there is a constant endeavor to
       improve safety and working conditions. The safety policy of the company aims at
       elimination of Industrial Accidents in order to achieve the same, National
       Fertilizers Limited, Vijaipur has adopted several measures, e.g. integration of
       safety with various departments, provision of safe working conditions,
       familiarization of the employees with the general and special safety practices and
       enforcing them in their work place, deputation of employees in various in house
       as well as external programmes, celebration of safety day. Safety audit is
       conducted every year by external agencies. M/s PDIL, NOIDA, conducted safety
       audit for the year 2001-2002.


National Fertilizers Limited, Vijaipur has won vide acclaims in the field of safety for maintaining high sta
achieving record accident free period. It has won several national and state level awards for safety and accide

   Year of
commissionin            Project description               Actual achievement of energy savings per year basis
     g
                                                         Power lakh kWh      Gas lakh SM³       Total Rs.lakhs

                 Implementation of Energy Saving
  1999-2000     Schemes as per Energy Audit - listed         33.91              144.92             178.83
                       at point 14 above.



               Change of sealing of reciprocating type
  2000-2001    Ammonia Feed Pumps from oil sealing                               12.78              44.86
                         to water sealing.
            Stopping of 3No pumps in Urea(MP
                Condensate Pump P-6 and LP
            Condensate Pump P-10) and offsites
2001-2002                                         7.72   1.23   5.0
            Plant (service water pump) based on
              inhouse study on performance of
                           pumps.