Energy Efficiency Opportunities at IPL

1. Energy Efficiency Opportunities at IPL

2. Company Overview • IPL is a Global Fertiliser and Explosive Manufacturer • Approximately 4500 employees • 20 manufacturing sites worldwide • Australian energy use 24.0PJ in 09-10 (inc feedstock) • 96% of energy use from 2 Sites: Gibson Island (Brisbane), Phosphate Hill (NW QLD) • The Ammonia plant is the major energy user on both sites

3. EEO in the First Cycle • Gibson Island assessment 2007 - 2008 • Phosphate Hill assessment 2008 - 2009 • After initial assessments, subsequent work focused on progressing identified opportunities • Some opportunities require a full plant shutdown in order to implement. This activity only occurs 4 yearly

4. Opportunity Identification Identification • Major opportunity identified in 2007 at Gibson Island workshop was coating of primary reformer with CETEK coating (a fired heater) • The coating is sprayed on to the furnace wall, and improves heat transfer to the tubes • Benefits are site specific • The project had been discussed in the IPL case study as a potential project being evaluated

5. Opportunity Identification • Looking through inspection port into radiant section • Energy is radiated from the flame and wall to the tubes

6. Opportunity Identification Gathering Information • Initial cost benefit analysis showed good payback • Concerns about the benefit of the technology for the specific design of furnace • Site visit by 3 staff to visit a similar plant with the coating in order to validate the claims • This visit revealed coating was working in a similar plant and gave confidence to request Capital for the proposal

7. Additional Opportunity Gathering Information • Review of impact on modification to other aspects of the furnace • Specifically effect on downstream units, and potential to increase energy use in other areas was of concern • A mass and energy balance of the specific area of concern was commissioned • This study revealed that a downstream coil was significantly underperforming (another EEO opportunity)

8. Additional Opportunity Gathering Information • Information from the study on the coil, was used to guide decision making • A number of alternative configurations was investigated to determine optimum scenario • The superheat coil was entirely replaced • Other potential impacts of plant performance (waste steam) reviewed

9. Post Implementation

10. Post Implementation - Outcome Measured Results • Reduced firing pressure in main furnace • No firing in superheat section • Total reduction of 600GJ a day in fuel gas flowrate for two projects combined • 6% reduction in fuel gas to furnace for constant feed

11. Learnings • Business case for opportunity was strengthened by the considerable work put into evaluation stage • Study on downstream impacts revealed further opportunities • Involving site team and knowledge critical • Benefits matched well with that predicted from modelling